Skytrak 6042 Service Manual User Manual

Safety Practices1.4 Model 6042 Legacy Origin 7/021.4.2 Hazard StatementsSignal words and messages are used in conjunction with the safety alert symbol

Boom3.54 Model 6042 Legacy Origin 7/023.4.2 Chain LubricationAfter inspection and before being returned to service, chains must be lubricated with a q

3.55Model 6042 Legacy Origin 7/02Boom3.4.4 Boom Chain Tension AdjustmentNote: Always perform Section 3.4.3, Boom Chain Ten-sion Check before adjustin

Boom3.56 Model 6042 Legacy Origin 7/024. Recheck chain tension. (Refer to Section 3.4.3, “Boom Chain Tension Check.”)5. Further chain adjustment can b

3.57Model 6042 Legacy Origin 7/02BoomFigure 3-124 Rear Cover on Outer Booma. Component/Assembly VerificationThe inner to intermediate boom separation

Boom3.58 Model 6042 Legacy Origin 7/023. To increase the separation distance: Loosen the retract chain locknut (Fig. 3-127, 1) on the bottom of the ou

3.59Model 6042 Legacy Origin 7/02Boom4. At the rear of the boom, locate the extend chain elastic locknuts (Fig. 3-130, 1). Record the amount of thread

Boom3.60 Model 6042 Legacy Origin 7/0211. Lay the new extend chain (Fig. 3-133, 1) on top of the outer boom (2) with the threaded clevis (3) toward th

3.61Model 6042 Legacy Origin 7/02BoomFigure 3-136 Assembly of Rear Cover to Outer Boomb. Retract Chain Removal and Replacement1. Park the vehicle on

Boom3.62 Model 6042 Legacy Origin 7/02Note: Record the location of the shoulder bolt (Fig. 3-139, 4) to ensure correct installation.9. At the rear of

3.63Model 6042 Legacy Origin 7/02Boom19. The person at the front of the boom should guide the threaded end of the clevis (Fig. 3-141, 1) through the h

1.5Model 6042 Legacy Origin 7/02Safety Practices1.6 SAFETY INSTRUCTIONSFollowing are general safety statements to consider before performing maintenan

Boom3.64 Model 6042 Legacy Origin 7/0226. Adjust retract chain tension. (Refer to Section 3.4.4, a. “Component/Assembly Verification.”)27. After adjus

3.65Model 6042 Legacy Origin 7/02Boom3.5 BOOM WEAR PADSFlat rectangular wear pads with metal inserts are used. The inserts are special metal hardware

Boom3.66 Model 6042 Legacy Origin 7/02b. Intermediate BoomThe inner boom must be removed from the vehicle to allow removal of the rear wear pads on th

3.67Model 6042 Legacy Origin 7/02Boomc. Outer BoomAll outer boom pads (Fig. 3-150, 1) are mounted on the front of the outer boom. Remove the top wear

Boom3.68 Model 6042 Legacy Origin 7/023.6 QUICK ATTACH ASSEMBLYThis vehicle is equipped with a quick attach system for easy attachment changes.3.6.1 D

3.69Model 6042 Legacy Origin 7/02Boom3.6.3 Quick Attach Removal1. Remove the elastic locknut (Fig. 3-153, 1) and capscrew (2) holding the attachment t

Boom3.70 Model 6042 Legacy Origin 7/023.6.4 Quick Attach Installation 1. Assemble the quick attach to the gooseneck. Line up the quick attach (Fig. 3-

3.71Model 6042 Legacy Origin 7/02Boom3.7 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur dur

Boom3.72 Model 6042 Legacy Origin 7/023. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes and/or connection leaks.2. Lift/lower hydrau

3.73Model 6042 Legacy Origin 7/02Boom10. Excessive chain wear. 1. Improper chain adjustment.2. Chain sheave(s) not properly lubricated.3. Chain sheave

Safety Practices1.6 Model 6042 Legacy Origin 7/021.6.3 General HazardsSOLVENTS: Only use approved solvents, and solvents that are known to be safe for

Boom3.74 Model 6042 Legacy Origin 7/02This Page Intentionally Left Blank

4.1Model 6042 Legacy Origin 7/02Section 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator’s Cab and Covers Component Terminology . . . . . . .

Cab and Covers4.2 Model 6042 Legacy Origin 7/024.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance

4.3Model 6042 Legacy Origin 7/02Cab and Covers4.2 OPERATOR’S CAB4.2.1 Operator’s Cab Description The welded metal cab features a modular design, allow

Cab and Covers4.4 Model 6042 Legacy Origin 7/024.3 OPEN CAB COMPONENTS4.3.1 Seat/Seat Belta. Seat Removal1. Park the vehicle on a firm, level surface.

4.5Model 6042 Legacy Origin 7/02Cab and Covers4.3.2 Steering Wheel, Column and ShifterThe steering wheel and transmission travel and gear select lever

Cab and Covers4.6 Model 6042 Legacy Origin 7/026. Working through the right dash panel opening, disconnect the transmission travel and gear select lev

4.7Model 6042 Legacy Origin 7/02Cab and Covers3. Unlock and open the rear door. Allow the engine and hydraulic fluid to cool.4. Disconnect the battery

Cab and Covers4.8 Model 6042 Legacy Origin 7/029. Working through the left dash panel opening, label, disconnect and plug the load sense hose (Fig. 4-

4.9Model 6042 Legacy Origin 7/02Cab and CoversNote: ALWAYS use new o-rings when servicing the vehicle.5. Install new o-rings into the fittings. Lubri

1.7Model 6042 Legacy Origin 7/02Safety Practices1.8 HAZARD/EMERGENCY INFORMATION DECALSLocations of vehicle hazard and other emergency information dec

Cab and Covers4.10 Model 6042 Legacy Origin 7/024.3.4 Brake Pedal and Valvea. Brake Valve RemovalRefer to Section 8.12.4, a. “Service Brake Valve Remo

4.11Model 6042 Legacy Origin 7/02Cab and Covers4.3.5 Throttle Pedal Replacementa. Throttle Pedal Removal1. Park the vehicle on a firm, level surface.

Cab and Covers4.12 Model 6042 Legacy Origin 7/024.3.6 Joystick Assembly Replacementa. Joystick Assembly Removal1. Park the vehicle on a firm, level su

4.13Model 6042 Legacy Origin 7/02Cab and Coversb. Joystick Assembly Installation1. Install the boom lift/lower, extend/retract joystick assembly (Fig.

Cab and Covers4.14 Model 6042 Legacy Origin 7/024.3.7 Control Cable Replacement a. Control Cable Removal1. Park the vehicle on a firm, level surface.

4.15Model 6042 Legacy Origin 7/02Cab and Covers9. Disconnect the frame sway control cable (Fig. 4-23, 2):a. Remove the spring pin (Fig. 4-23, 3) and a

Cab and Covers4.16 Model 6042 Legacy Origin 7/024. Connect the boom lift/lower control cable to the main control valve assembly:a. Install the cable i

4.17Model 6042 Legacy Origin 7/02Cab and Coversb. Loosen and remove the inner jam nut (Fig. 4-26, 3), and remove the auxiliary hydraulics control cabl

Cab and Covers4.18 Model 6042 Legacy Origin 7/023. Connect the auxiliary hydraulics control cable to the main control valve:a. Slide the inner jam nut

4.19Model 6042 Legacy Origin 7/02Cab and Covers4.3.10 Miscellaneous Cab ComponentsFigure 4-32 Miscellaneous Cab ComponentsMA8810231. Mirror Assembly2

Safety Practices1.8 Model 6042 Legacy Origin 7/02This Page Intentionally Left Blank

Cab and Covers4.20 Model 6042 Legacy Origin 7/024.4 ENCLOSED CAB (OPTIONAL) COMPONENTS4.4.1 Windshield Wiper AssemblyRefer to Section 9.13.2, “Windshi

4.21Model 6042 Legacy Origin 7/02Cab and CoversNote: The button-head screw (Fig. 4-35, 1) at the lower rear position on each side of the heater will

Cab and Covers4.22 Model 6042 Legacy Origin 7/023. Pull the hoses (Fig. 4-37, 1 and 2) through the grommets, and connect to the heater. Secure with tw

4.23Model 6042 Legacy Origin 7/02Cab and Coversc. Heater/Defroster System ComponentsFigure 4-38 Heater/Defroster System ComponentsMA8740211. Heater H

Cab and Covers4.24 Model 6042 Legacy Origin 7/024.4.5 Door and Latches1. Open and securely support the door assembly (Fig. 4-39, 1).2. Remove the stra

4.25Model 6042 Legacy Origin 7/02Cab and Covers4.4.6 WindowsNote: The slider window assembly (Fig. 4-40, 1), skylight glass (2) and left side rear gl

Cab and Covers4.26 Model 6042 Legacy Origin 7/024.5 CAB REMOVALIMPORTANT: To help ensure safety and optimum performance, replace the cab if it is dam

4.27Model 6042 Legacy Origin 7/02Cab and Covers5. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open t

Cab and Covers4.28 Model 6042 Legacy Origin 7/02Note: Record the location, and label all cables to ensure correct installation.11. Disconnect the con

4.29Model 6042 Legacy Origin 7/02Cab and Covers19. Remove the mirrors and all other cab components, as needed, if not previously removed.20. Carefully

2.1Model 6042 Legacy Origin 7/02Section 2General Information and SpecificationsContentsPARAGRAPH TITLE PAGE2.1 6042 Component Terminology . . . . . .

Cab and Covers4.30 Model 6042 Legacy Origin 7/026. Route the throttle cable through the hole in the bulkhead plate (Fig. 4-48, 1) under the cab.7. Con

4.31Model 6042 Legacy Origin 7/02Cab and CoversFigure 4-51 Install the Upper and Lower Transmission CoversNote: Steps 17-19 apply to vehicles equipp

Cab and Covers4.32 Model 6042 Legacy Origin 7/024.7 ACCESS PANELS AND COVERS4.7.1 Access Panel and Cover ReplacementNote: Refer to Model 6042 Legacy

5.1Model 6042 Legacy Origin 7/02Section 5Axles, Drive Shafts, Wheels and TiresContentsPARAGRAPH TITLE PAGE5.1 Axle, Drive Shaft and Wheel Component Te

Axles, Drive Shafts, Wheels and Tires5.2 Model 6042 Legacy Origin 7/025.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGYTo understand the safety, o

5.3Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires5.2 GENERAL INFORMATIONIMPORTANT: To help ensure optimum performance, the drive

Axles, Drive Shafts, Wheels and Tires5.4 Model 6042 Legacy Origin 7/025.3.3 Axle Serial Number PlateThe front axle serial number plate (Fig. 5-1, 1) i

5.5Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and TiresCLEANING: Clean parts with machined or ground surfaces (such as gears, bearings a

Axles, Drive Shafts, Wheels and Tires5.6 Model 6042 Legacy Origin 7/025. If the axle will be disassembled after removal, place a suitable receptacle u

5.7Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and TiresFigure 5-4 Axle to Frame Mounting ConfigurationMA9200105234718121196139998714534

General Information and Specifications2.2 Model 6042 Legacy Origin 7/022.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . .

Axles, Drive Shafts, Wheels and Tires5.8 Model 6042 Legacy Origin 7/02b. Axle Inspection, Internal Service and RepairNote: Detailed axle service inst

5.9Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and TiresFigure 5-6 Axle to Frame Mounting ConfigurationMA9200914101131341572555436128815

Axles, Drive Shafts, Wheels and Tires5.10 Model 6042 Legacy Origin 7/02Note: ALWAYS use new o-rings when servicing the vehicle.13. Install new o-ring

5.11Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires5.3.7 Axle Service and TroubleshootingThis section provides an easy reference gu

Axles, Drive Shafts, Wheels and Tires5.12 Model 6042 Legacy Origin 7/024. Oil leaking from axle (differential housing and/or axle housings).1. Drain a

5.13Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires7. Axle overheating. 1. Oil level too high.2. Axle and/or wheel end housings fil

Axles, Drive Shafts, Wheels and Tires5.14 Model 6042 Legacy Origin 7/025.3.9 Axle Internal Component TroubleshootingNote: The following conditions ma

5.15Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires5.4 DRIVE SHAFTS5.4.1 Drive Shaft Inspection and ServiceWhenever servicing the v

Axles, Drive Shafts, Wheels and Tires5.16 Model 6042 Legacy Origin 7/025.4.2 Drive Shaft MaintenanceRefer to the Model 6042 Legacy Owners/Operators Ma

5.17Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires4. Disconnect the battery negative (-) cable at the battery negative (-) termina

2.3Model 6042 Legacy Origin 7/02General Information and Specifications2.1 6042 COMPONENT TERMINOLOGYTo understand the safety, operation and maintenanc

Axles, Drive Shafts, Wheels and Tires5.18 Model 6042 Legacy Origin 7/024. Use a soft, round drive pin with a flat face approximately 1/32" (0,8 m

5.19Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires5.4.6 Drive Shaft Assembly1. Install the dust cap (Fig. 5-13, 7), split retainin

Axles, Drive Shafts, Wheels and Tires5.20 Model 6042 Legacy Origin 7/025. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, tra

5.21Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires5.5 WHEELS AND TIRESThe standard Model 6042 uses a welded 13.00-24 steel wheel.

Axles, Drive Shafts, Wheels and Tires5.22 Model 6042 Legacy Origin 7/025.5.1 Removing Wheel and Tire Assembly from Vehicle1. Park the vehicle on a fir

5.23Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tires5.5.2 Wheel CleaningRemove all rust, corrosion, dirt and other foreign material

Axles, Drive Shafts, Wheels and Tires5.24 Model 6042 Legacy Origin 7/021. Position wheel onto studs on wheel end of axle.2. Install wheel lug nuts. Be

5.25Model 6042 Legacy Origin 7/02Axles, Drive Shafts, Wheels and Tiresc. Tire and Wheel LubricationPrior to mounting the tire onto the rim, apply a su

Axles, Drive Shafts, Wheels and Tires5.26 Model 6042 Legacy Origin 7/02e. Tire Speed and Road Surface LimitationsThe tires on this vehicle are designe

6.1Model 6042 Legacy Origin 7/02Section 6Transmission: ZF 4 WG-98 TCContentsPARAGRAPH TITLE PAGE6.1 Transmission Assembly Component Terminology . . .

General Information and Specifications2.4 Model 6042 Legacy Origin 7/022.2 INTRODUCTION2.2.1 Service MethodsAppropriate service methods and proper rep

Transmission: ZF 4 WG-98 TC6.2 Model 6042 Legacy Origin 7/026.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and mai

6.3Model 6042 Legacy Origin 7/02Transmission: ZF 4 WG-98 TC6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifi

Transmission: ZF 4 WG-98 TC6.4 Model 6042 Legacy Origin 7/026.5 TRANSMISSION SPECIFICATIONS6.5.1 Transmission General SpecificationsGeneral transmissi

6.5Model 6042 Legacy Origin 7/02Transmission: ZF 4 WG-98 TCFigure 6-2 The Lubrication and Maintenance Chart Decals6.6.2 Transmission Maintenance Sche

Transmission: ZF 4 WG-98 TC6.6 Model 6042 Legacy Origin 7/026.7 TRANSMISSION REPLACEMENTNote: Contact the OmniQuip Service Department at 1-800-439-89

6.7Model 6042 Legacy Origin 7/02Transmission: ZF 4 WG-98 TC9. Place a suitable receptacle under the transmission drain plug (Fig. 6-6, 1). Remove the

Transmission: ZF 4 WG-98 TC6.8 Model 6042 Legacy Origin 7/0217. Label, disconnect and cap the transmission oil cooler inlet (Fig. 6-8, 1) and outlet (

6.9Model 6042 Legacy Origin 7/02Transmission: ZF 4 WG-98 TCFigure 6-9 Remove Transmission from FrameMA92201895133144332256791011111412

Transmission: ZF 4 WG-98 TC6.10 Model 6042 Legacy Origin 7/0228. Remove any external transmission components as required, including the transmission t

6.11Model 6042 Legacy Origin 7/02Transmission: ZF 4 WG-98 TCFigure 6-11 Transmission InstallationMA92206781341291012121111131415823315

2.5Model 6042 Legacy Origin 7/02General Information and SpecificationsThe vehicle serial number plate (Fig. 2-1, 1) is located at the front of the veh

Transmission: ZF 4 WG-98 TC6.12 Model 6042 Legacy Origin 7/027. Connect the transmission temperature switch connector (Fig. 6-12, 1) and shift solenoi

6.13Model 6042 Legacy Origin 7/02Transmission: ZF 4 WG-98 TC6.7.4 After Transmission Service or ReplacementRefer to the ZF 4 WG-98 TC Transmission Rep

Transmission: ZF 4 WG-98 TC6.14 Model 6042 Legacy Origin 7/026.9 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common

6.15Model 6042 Legacy Origin 7/02Transmission: ZF 4 WG-98 TC3. Low clutch pressure. 1. Incorrect oil level.2. Main pressure valve stuck open.3. Broken

Transmission: ZF 4 WG-98 TC6.16 Model 6042 Legacy Origin 7/026. Grinding or “clunking” noise from transmission.1. Oil level too low.2. Transmission fi

7.1Model 6042 Legacy Origin 7/02Section 7Engine: Cummins 4BT3.9ContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . . . . . . . . . . . . .

Engine: Cummins 4BT3.97.2 Model 6042 Legacy Origin 7/027.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions are written for worldwide use. In

7.3Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9MA9150RadiatorRadiatorShroudEngine IsolatorLower Rear Engine Mounting BracketOil CoolerCoolant O

Engine: Cummins 4BT3.97.4 Model 6042 Legacy Origin 7/027.2 SAFETY INFORMATIONGeneral Vehicle OperationPreparationEngine OperationCleaningEngine Coolan

7.5Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9Rotating Parts and Fan BladesBatteryEngine OilDiesel FuelEngine RepairPartsWARNING: Keep away f

General Information and Specifications2.6 Model 6042 Legacy Origin 7/022.3 TORQUES2.3.1 FastenersAll fasteners (nuts, bolts, washers, etc.) are equal

Engine: Cummins 4BT3.97.6 Model 6042 Legacy Origin 7/027.3 ENGINE SERIAL NUMBERThe Cummins 4BT3.9 serial number (Fig. 7-1, 1) is stamped on the right

7.7Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.97.6 ENGINE COOLING SYSTEMThe engine cooling system is a closed, pressurized system that consists

Engine: Cummins 4BT3.97.8 Model 6042 Legacy Origin 7/02Note: Drain approximately two quarts (2 liters) of coolant.4. Slowly turn the radiator cap (no

7.9Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.99. Remove the three capscrews (Fig. 7-6, 1) securing the thermostat housing (2) to the engine.Fi

Engine: Cummins 4BT3.97.10 Model 6042 Legacy Origin 7/027.6.3 Radiator/Oil Cooler and Coolant Heater ReplacementBefore considering radiator or oil coo

7.11Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.99. Loosen clamps (Fig. 7-9, 1 and 2) on the radiator return (lower) hose (3). Work the hose off

Engine: Cummins 4BT3.97.12 Model 6042 Legacy Origin 7/02b. Radiator and Oil Cooler Installation1. If replacing the radiator, install the right (Fig. 7

7.13Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.914. Install the battery (Fig. 7-13, 2) and battery hold-down (5). Figure 7-13 Battery and Cabl

Engine: Cummins 4BT3.97.14 Model 6042 Legacy Origin 7/024. Place a suitable container beneath the radiator petcock (Fig. 7-15, 1). Slowly turn the rad

7.15Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.97.8 FUEL SYSTEMThe fuel system includes a fuel tank (Fig. 7-17, 1), fuel level sender with gask

2.7Model 6042 Legacy Origin 7/02General Information and Specifications4. Using a permanent type ink marker, make a mark (Fig. 2-2, 2) on one of the fl

Engine: Cummins 4BT3.97.16 Model 6042 Legacy Origin 7/027.8.1 Diesel FuelFuel represents a major portion of vehicle operating costs and therefore must

7.17Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9Figure 7-18 Fuel/Hydraulic Oil Tank ComponentsMA91102151567141312112018171916341098

Engine: Cummins 4BT3.97.18 Model 6042 Legacy Origin 7/0213. Disconnect the lower hydraulic oil strainer hose from the strainer connection (Fig. 7-19,

7.19Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.96. Install the inlet (Fig. 7-19, 12) and outlet (11) hoses to the fuel tank. Secure with clamps

Engine: Cummins 4BT3.97.20 Model 6042 Legacy Origin 7/027.8.3 Fuel Level Sender and GaugeThe fuel level sender and gauge assembly is described in Sect

7.21Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9a. Locating Faulty Fuel InjectorsA faulty fuel injector can cause:•Misfiring•Knocking•Overheati

Engine: Cummins 4BT3.97.22 Model 6042 Legacy Origin 7/021. Use a 16-mm wrench to prevent the injector body (Fig. 7-23, 1) from turning. Loosen the hol

7.23Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.97.9 ENGINE EXHAUST SYSTEMThe exhaust system is supported by the engine and the vehicle frame to

Engine: Cummins 4BT3.97.24 Model 6042 Legacy Origin 7/027.9.2 Exhaust System Installation1. Install the muffler bracket (Fig. 7-26, 11) to the engine,

7.25Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.97.10.2 Air Cleaner Assembly InstallationNote: Apply Loctite® 242 threadlock to the hex-head ca

General Information and Specifications2.8 Model 6042 Legacy Origin 7/02c. Adjustable (Angle) O-Ring Boss Fittings To O-Ring Boss PortsImproper assembl

Engine: Cummins 4BT3.97.26 Model 6042 Legacy Origin 7/028. Disconnect the back-up alarm harness connector (Fig. 7-30, 4) from alarm (5). Disconnect an

7.27Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9Note: The engine harness is routed and attached to the engine at various places using hold-dow

Engine: Cummins 4BT3.97.28 Model 6042 Legacy Origin 7/0224. Remove the right side exhaust pipe mount bracket (Fig. 7-37, 1) and hex-head capscrews (23

7.29Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9Figure 7-37 Engine Component LocationMA9100112347856139101411151721619182221202423

Engine: Cummins 4BT3.97.30 Model 6042 Legacy Origin 7/027.11.2 Engine Disassembly, Inspection and ServiceEngine disassembly, internal inspection, serv

7.31Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9 Figure 7-38 Engine Component LocationMA9100112347856139101411151721619182221202324

Engine: Cummins 4BT3.97.32 Model 6042 Legacy Origin 7/0213. Uncap the lines and install the transmission oil input (Fig. 7-39, 1) and output (2) hoses

7.33Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.9Figure 7-42 Fuel/Hydraulic Oil Tank Components22. Install the inlet (Fig. 7-42, 12) and outlet

Engine: Cummins 4BT3.97.34 Model 6042 Legacy Origin 7/0229. Connect the engine coolant temperature switch lead (Fig. 7-43, 1) and oil pressure switch

7.35Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.935. Install the front (Fig. 7-46, 9) and rear (10) band clamps around the muffler (4), and inst

2.9Model 6042 Legacy Origin 7/02General Information and Specifications2.3.4 SAE Flat Face O-Ring Seal Hydraulic Fittingsa. Assembly ProcedureImproper

Engine: Cummins 4BT3.97.36 Model 6042 Legacy Origin 7/0245. Connect the negative (-) grounding cable (Fig. 7-49, 1) to the vehicle frame.Figure 7-49

7.37Model 6042 Legacy Origin 7/02Engine: Cummins 4BT3.97.12 ENGINE STORAGEIf the engine is properly protected and stored according to the following re

Engine: Cummins 4BT3.97.38 Model 6042 Legacy Origin 7/027.13 TROUBLESHOOTINGProblem Possible Causes (see key, below)Low Cranking PowerWill Not StartDi

8.1Model 6042 Legacy Origin 7/02Section 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . .

Hydraulic System8.2 Model 6042 Legacy Origin 7/028.9 Four-Wheel Steer Indexing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3Model 6042 Legacy Origin 7/02Hydraulic System8.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information present

Hydraulic System8.4 Model 6042 Legacy Origin 7/028.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this vehicle. The temperature of h

8.5Model 6042 Legacy Origin 7/02Hydraulic System8.3 SPECIFICATIONSRefer to Section 2.5, Specifications for hydraulic system specifications.8.4 HYDRAUL

Hydraulic System8.6 Model 6042 Legacy Origin 7/028.5 HOSES, TUBE LINES, FITTINGS, ETC. There are numerous hydraulic hoses, tubes, fittings, etc. used

8.7Model 6042 Legacy Origin 7/02Hydraulic System8.6 HYDRAULIC PRESSURE DIAGNOSISOmniQuip Textron Parts Worldwide has two kits available to use for hyd

General Information and Specifications2.10 Model 6042 Legacy Origin 7/02c. Adjustable (Angle) O-Ring Boss Fittings To O-Ring Boss PortsImproper assemb

Hydraulic System8.8 Model 6042 Legacy Origin 7/028.6.1 Pressure Checks and AdjustmentsWhen diagnosing trouble in the hydraulic system, use the hydraul

8.9Model 6042 Legacy Origin 7/02Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.10 Model 6042 Legacy Origin 7/028.7 HYDRAULIC SYSTEM TESTING8.7.1 6042 Hydraulic TestingFigure 8-3 6042 Hydraulics TestingMA9240

8.11Model 6042 Legacy Origin 7/02Hydraulic SystemEngine InformationIdle. . . . . . . . . . . . . . . . . . . . . .1,050 ±50 rpmFull Speed . . . . . .

Hydraulic System8.12 Model 6042 Legacy Origin 7/02This Page Intentionally Left Blank

8.13Model 6042 Legacy Origin 7/02Hydraulic System8.8 HYDRAULIC CIRCUITS AND TROUBLESHOOTINGThis section covers the hydraulic circuits and includes a c

Hydraulic System8.14 Model 6042 Legacy Origin 7/028.8.1 Brake Circuit and Troubleshooting(Refer to Section 8.8.19, “Brake Circuit Description” for a m

8.15Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKNotOKNotOKNotOKNotOKCheck pressure at front axle.If service brakes are not holding, check t

Hydraulic System8.16 Model 6042 Legacy Origin 7/028.8.2 Boom Extend Circuit and Troubleshooting(Refer to Section 8.8.20, “Boom Extend/Retract Circuit

8.17Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

2.11Model 6042 Legacy Origin 7/02General Information and SpecificationsThis Page Intentionally Left Blank

Hydraulic System8.18 Model 6042 Legacy Origin 7/028.8.3 Boom Retract Circuit and Troubleshooting(Refer to Section 8.8.20, “Boom Extend/Retract Circuit

8.19Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

Hydraulic System8.20 Model 6042 Legacy Origin 7/028.8.4 Boom Lift Circuit and Troubleshooting(Refer to Section 8.8.21, “Boom Lift/Lower Circuit Descri

8.21Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

Hydraulic System8.22 Model 6042 Legacy Origin 7/028.8.5 Boom Lower Circuit and Troubleshooting(Refer to Section 8.8.21, “Boom Lift/Lower Circuit Descr

8.23Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

Hydraulic System8.24 Model 6042 Legacy Origin 7/028.8.6 Frame Sway (Left) and Stabilizer Circuit and Troubleshooting(Refer to Section 8.8.22, “Frame S

8.25Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

Hydraulic System8.26 Model 6042 Legacy Origin 7/028.8.7 Frame Sway (Right) and Stabilizer Circuit and Troubleshooting(Refer to Section 8.8.22, “Frame

8.27Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

General Information and Specifications2.12 Model 6042 Legacy Origin 7/022.4 METRIC CONVERSION FACTORS2.4.1 Approximate American to Metric ConversionsW

Hydraulic System8.28 Model 6042 Legacy Origin 7/028.8.8 Attachment Tilt (Down) and Slave Cylinder Circuit and Troubleshooting(Refer to Section 8.8.23,

8.29Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

Hydraulic System8.30 Model 6042 Legacy Origin 7/028.8.9 Attachment Tilt (Up) and Slave Cylinder Circuit and Troubleshooting(Refer to Section 8.8.23, “

8.31Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

Hydraulic System8.32 Model 6042 Legacy Origin 7/028.8.10 Pump, Unloader Valve and Cooling Circuit and Troubleshooting(Refer to Section 8.8.24, “Pump,

8.33Model 6042 Legacy Origin 7/02Hydraulic SystemNOTE:When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correc

Hydraulic System8.34 Model 6042 Legacy Origin 7/028.8.11 Auxiliary Hydraulics Circuit and Troubleshooting (Male Coupler Pressurized)(Refer to Section

8.35Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKIf there are no auxiliary hydraulic functions, check cable connections at main control valv

Hydraulic System8.36 Model 6042 Legacy Origin 7/028.8.12 Auxiliary Hydraulics Circuit and Troubleshooting (Female Coupler Pressurized)(Refer to Sectio

8.37Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKIf there are no auxiliary hydraulic functions, check cable connections at main control valv

2.13Model 6042 Legacy Origin 7/02General Information and Specifications2.4.2 Approximate Metric to American ConversionsWhen this is known Multiply by

Hydraulic System8.38 Model 6042 Legacy Origin 7/028.8.13 Front-Wheel Steering Circuit (Left Turn) and Troubleshooting(Refer to Section 8.8.26, “Steeri

8.39Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKNotOKNotOKNotOKNotOKIf there is no front-wheel steering, check the pressure at the “PSG” po

Hydraulic System8.40 Model 6042 Legacy Origin 7/028.8.14 Front-Wheel Steering Circuit (Right Turn) and Troubleshooting(Refer to Section 8.8.26, “Steer

8.41Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKNotOKNotOKNotOKNotOKIf there is no front-wheel steering, check the pressure at the “PSG” po

Hydraulic System8.42 Model 6042 Legacy Origin 7/028.8.15 Four-Wheel Steering Circuit (Left Turn) and Troubleshooting(Refer to Section 8.8.26, “Steerin

8.43Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace th

Hydraulic System8.44 Model 6042 Legacy Origin 7/028.8.16 Four-Wheel Steering Circuit (Right Turn) and Troubleshooting(Refer to Section 8.8.26, “Steeri

8.45Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace th

Hydraulic System8.46 Model 6042 Legacy Origin 7/028.8.17 Crab Steering Circuit (Left) and Troubleshooting(Refer to Section 8.8.26, “Steering Circuit D

8.47Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace th

General Information and Specifications2.14 Model 6042 Legacy Origin 7/022.5 SPECIFICATIONS2.5.1 Vehicle Dimensions (With Standard 12-ply 13.00-24 Tire

Hydraulic System8.48 Model 6042 Legacy Origin 7/028.8.18 Crab Steering Circuit (Right) and Troubleshooting(Refer to Section 8.8.26, “Steering Circuit

8.49Model 6042 Legacy Origin 7/02Hydraulic SystemNotOKNotOKIf there is no four-wheel or crab steering, check the steer select valve.Inspect/replace th

Hydraulic System8.50 Model 6042 Legacy Origin 7/028.8.19 Brake Circuit DescriptionThe brake system circuit (Fig. 8-4) includes the park brake and the

8.51Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-22 Cross-Section of Service Brake Valve4. Pressure in both the front and rear axle brake li

Hydraulic System8.52 Model 6042 Legacy Origin 7/028. Controlling the force applied to the service brake pedal determines the amount of braking power.9

8.53Model 6042 Legacy Origin 7/02Hydraulic Systema. Boom Lift Circuit (Fig. 8-7)With the joystick in the boom lift position, pressure shifts the lift/

Hydraulic System8.54 Model 6042 Legacy Origin 7/028.8.23 Attachment Tilt and Slave Circuit DescriptionSystem pressure is applied in the attachment til

8.55Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-23 Front-Wheel Steering Mode8.8.26 Steering Circuit DescriptionsVehicle steering includes f

Hydraulic System8.56 Model 6042 Legacy Origin 7/02Figure 8-24 Four-Wheel Steering Modeb. Four-Wheel SteeringWhen the steer select switch (Fig. 8-24,

8.57Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-25 Crab Steering Modec. Crab SteeringWhen the steer select switch (Fig. 8-25, 1) is in the

2.15Model 6042 Legacy Origin 7/02General Information and SpecificationsFigure 2-6 Vehicle Dimensions with Standard TiresSUNJMI0.0OLKVFRCQDAT24.0"

Hydraulic System8.58 Model 6042 Legacy Origin 7/028.9 FOUR-WHEEL STEER INDEXING PROCEDUREIf the vehicle does not drive “straight,” the steering could

8.59Model 6042 Legacy Origin 7/02Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.60 Model 6042 Legacy Origin 7/028.10 HYDRAULIC RESERVOIRThe hydraulic reservoir (Fig. 8-26, 1) and the fuel tank (2) are one unit. T

8.61Model 6042 Legacy Origin 7/02Hydraulic SystemOccasionally, fluid may seep, leak or be more forcefully expelled from the filter head (Fig. 8-26, 11

Hydraulic System8.62 Model 6042 Legacy Origin 7/028.11.2 Pump Replacementa. Pump Removal1. Park the vehicle on a firm, level surface, fully retract th

8.63Model 6042 Legacy Origin 7/02Hydraulic System2. A special steel sleeve made from 1-1/2" (38,1 mm) diameter round steel bar stock, 4-5/8"

Hydraulic System8.64 Model 6042 Legacy Origin 7/02Figure 8-31 Hydraulic System Pumpd. Pump Disassembly 1. Secure the pump (Fig. 8-31, 1) with the pum

8.65Model 6042 Legacy Origin 7/02Hydraulic Systemf. Pump Inspection1. Inspect internal pump components for wear, damage, etc. If inner surfaces of the

Hydraulic System8.66 Model 6042 Legacy Origin 7/02Figure 8-32 Hydraulic System Pump11. Install the remaining thrust plate (Fig. 8-32, 11) with channe

8.67Model 6042 Legacy Origin 7/02Hydraulic Systemh. Pump Installation1. Place the pump (Fig. 8-33, 1) and a new oiled o-ring (2) into position on the

SECTION CONTENTSModel 6042 Legacy Origin 7/02iã 2002 OmniQuip Textron Inc.Section Subject PageSection 1Safety Practices . . . . . . . . . . . . . .

General Information and Specifications2.16 Model 6042 Legacy Origin 7/022.5.2 Vehicle WeightsCurb Weight w/48" Carriage (Open Cab) 23,520 lb (10.

Hydraulic System8.68 Model 6042 Legacy Origin 7/028.12 VALVES AND MANIFOLDSValves are devices that open or close passageways. Manifolds contain circui

8.69Model 6042 Legacy Origin 7/02Hydraulic Systemb. Unloader Valve Disassembly, Inspection and Assembly1. Safely secure the unloader valve (Fig. 8-36,

Hydraulic System8.70 Model 6042 Legacy Origin 7/028.12.2 Main Control ValveThe main control valve (Fig. 8-37, 1) is mounted on the frame under the low

8.71Model 6042 Legacy Origin 7/02Hydraulic Systema. Main Control Valve Removal1. Park the vehicle on a firm, level surface, fully retract the boom, ra

Hydraulic System8.72 Model 6042 Legacy Origin 7/02Figure 8-40 Main Control Valve - Auxiliary/Frame Sway/Attachment Tilt/Load Sense Outlet SectionsMA9

8.73Model 6042 Legacy Origin 7/02Hydraulic Systemb. Main Control Valve DisassemblyThis section covers disassembly of one half (Fig. 8-41, 1) of the ma

Hydraulic System8.74 Model 6042 Legacy Origin 7/02Figure 8-42 Main Control Valve - Auxiliary Hydraulics/Frame Sway/Attachment Tilt/Load Sense Section

8.75Model 6042 Legacy Origin 7/02Hydraulic SystemDisassemble the Frame Sway Section1. Carefully separate the frame sway section (Fig. 8-42, 11) from t

Hydraulic System8.76 Model 6042 Legacy Origin 7/02Figure 8-43 Main Control Valve - Mid-Inlet/Outlet, Extend/Retract, Lift/Lower and Outlet SectionsMA

8.77Model 6042 Legacy Origin 7/02Hydraulic Systemc. Main Control Valve Disassembly This section covers the disassembly of the other half (Fig. 8-44, 1

2.17Model 6042 Legacy Origin 7/02General Information and Specifications2.5.3 Attachment Weights2.5.4 Performance SpecificationsNote: Performance crit

Hydraulic System8.78 Model 6042 Legacy Origin 7/02Figure 8-45 Main Control Valve - Mid-Inlet/Outlet, Extend/Retract, Lift/Lower and Outlet SectionsMA

8.79Model 6042 Legacy Origin 7/02Hydraulic SystemDisassemble the Extend/Retract Section1. Carefully separate the extend/retract section (Fig. 8-43, 32

Hydraulic System8.80 Model 6042 Legacy Origin 7/02Figure 8-46 Main Control Valve - Auxiliary Hydraulics/Frame Sway/Attachment Tilt/Load Sense Section

8.81Model 6042 Legacy Origin 7/02Hydraulic Systemf. Main Control Valve Assembly This section covers the assembly of the load sense outlet, attachment

Hydraulic System8.82 Model 6042 Legacy Origin 7/02Figure 8-47 Main Control Valve - Mid-Inlet/Outlet, Extend/Retract, Lift/Lower and Outlet SectionsMA

8.83Model 6042 Legacy Origin 7/02Hydraulic Systemg. Main Control Valve Assembly This section covers assembly of the outlet, lift/lower, extend/retract

Hydraulic System8.84 Model 6042 Legacy Origin 7/02h. Main Control Valve Installation1. Insert the carriage bolts (Fig. 8-48, 2 and 3) from the bottom

8.85Model 6042 Legacy Origin 7/02Hydraulic System8.12.3 Secondary Function ManifoldThe secondary function manifold (Fig. 8-49, 1) is a directional con

Hydraulic System8.86 Model 6042 Legacy Origin 7/02b. Secondary Function Manifold Disassembly, Cleaning, Inspection and Assembly1. Secure the secondary

8.87Model 6042 Legacy Origin 7/02Hydraulic Systemc. Secondary Function Manifold Installation1. Align the secondary function manifold with its mount ho

General Information and Specifications2.18 Model 6042 Legacy Origin 7/022.5.5 Hydraulic Cylinder Performance SpecificationsNote: Vehicle with no load

Hydraulic System8.88 Model 6042 Legacy Origin 7/023. Unlock and open the rear door. Allow the hydraulic fluid to cool.4. To remove the service brake v

8.89Model 6042 Legacy Origin 7/02Hydraulic Systemb. Service Brake Valve Installation1. Install the service brake valve (Fig. 8-53, 3) with the four lo

Hydraulic System8.90 Model 6042 Legacy Origin 7/02Figure 8-54 Brake Bleeder Locationsc. Brake TestCarefully bleed the brake lines as soon as the brak

8.91Model 6042 Legacy Origin 7/02Hydraulic System8.12.5 Shuttle ValveThe shuttle valve (Fig. 8-55, 1) is attached to the brake valve (2) with a tee fi

Hydraulic System8.92 Model 6042 Legacy Origin 7/02c. Shuttle Valve InstallationNote: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to

8.93Model 6042 Legacy Origin 7/02Hydraulic Systema. Power Steering Valve Removal1. Park the vehicle on a firm, level surface, fully retract all hydrau

Hydraulic System8.94 Model 6042 Legacy Origin 7/028.12.7 Steer Select ValveThe vehicle can be used in the front-wheel, four-wheel or crab steering mod

8.95Model 6042 Legacy Origin 7/02Hydraulic System5. Label or otherwise mark the hydraulic hoses (Fig. 8-61, 1) in relation to the steer select manifol

Hydraulic System8.96 Model 6042 Legacy Origin 7/02c. Steer Select Manifold and Valve Installation1. Attach the steer select manifold (Fig. 8-63, 2) an

8.97Model 6042 Legacy Origin 7/02Hydraulic SystemThis Page Intentionally Left Blank

2.19Model 6042 Legacy Origin 7/02General Information and Specifications2.5.6 Electrical SystemBattery:Type, Rating 12V DC, Negative (-) Ground, Mainte

Hydraulic System8.98 Model 6042 Legacy Origin 7/028.13 HYDRAULIC CYLINDERSThis section covers servicing the attachment tilt (Fig. 8-64, 1), slave (2),

8.99Model 6042 Legacy Origin 7/02Hydraulic System4. ALWAYS use new oiled o-rings, seals, gaskets, etc. DO NOT over-stretch seals, wipers and o-rings.

Hydraulic System8.100 Model 6042 Legacy Origin 7/02 Figure 8-66 Attachment Tilt Cylinder Componentsb. Attachment Tilt Cylinder DisassemblyNote: An a

8.101Model 6042 Legacy Origin 7/02Hydraulic System9. Remove the two setscrews (Fig. 8-66, 9) from the piston (8). Pry or drill out the setscrews as re

Hydraulic System8.102 Model 6042 Legacy Origin 7/02Figure 8-67 Attachment Tilt Cylinder Components4. Install both precision wearbands (Fig. 8-67, 19)

8.103Model 6042 Legacy Origin 7/02Hydraulic Systemf. Attachment Tilt Cylinder Installation1. Attach a suitable sling to an overhead crane or other sui

Hydraulic System8.104 Model 6042 Legacy Origin 7/02Figure 8-69 Slave Cylinder Components4. Label or otherwise mark the hydraulic hoses in relation to

8.105Model 6042 Legacy Origin 7/02Hydraulic System6. Fasten the rod end in a soft-jawed vise and put a padded support below and near the threaded end

Hydraulic System8.106 Model 6042 Legacy Origin 7/02Figure 8-70 Slave Cylinder Components5. Carefully install the head gland (Fig. 8-70, 4) onto the r

8.107Model 6042 Legacy Origin 7/02Hydraulic System3. Use new oiled o-rings and reattach and secure the hydraulic hoses to the slave cylinder fittings.

General Information and Specifications2.20 Model 6042 Legacy Origin 7/022.5.7 Engine Performance SpecificationsNote: Engine manufacturer's maxim

Hydraulic System8.108 Model 6042 Legacy Origin 7/02Figure 8-72 Extend/Retract Cylinder Components 6. Attach a suitable sling to an overhead crane or

8.109Model 6042 Legacy Origin 7/02Hydraulic System5. Using a pin spanner wrench, unscrew the head gland (Fig. 8-72, 7) from the tube (2). The head gla

Hydraulic System8.110 Model 6042 Legacy Origin 7/02Figure 8-73 Extend/Retract Cylinder Components e. Extend/Retract Cylinder AssemblyNote: Follow Se

8.111Model 6042 Legacy Origin 7/02Hydraulic System13. Lubricate the inside of the tube (Fig. 8-73, 2) and outside of the piston (8) and head gland (7)

Hydraulic System8.112 Model 6042 Legacy Origin 7/028.13.7 Lift/Lower CylinderThe lift/lower cylinders (Fig. 8-74, 1) are anchored to the underside of

8.113Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-75 Lift/Lower Cylinder ComponentsIMPORTANT: When sliding the rod and piston assembly into

Hydraulic System8.114 Model 6042 Legacy Origin 7/02Figure 8-76 Lift/Lower Cylinder Components11. Remove the small o-ring (Fig. 8-76, 12) from within

8.115Model 6042 Legacy Origin 7/02Hydraulic Systeme. Lift/Lower Cylinder AssemblyNote: Follow Section 8.13.3, “General Cylinder Assembly Instructions

Hydraulic System8.116 Model 6042 Legacy Origin 7/024. Connect all hoses according to the labels or other marks used to identify their locations during

8.117Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-78 Frame Sway Cylinder Components5. Disconnect and cap all hoses and fittings, etc.6. Use

2.21Model 6042 Legacy Origin 7/02General Information and Specifications2.5.8 Fluid and Lubricant CapacitiesEngine Crankcase Oil:Capacity with Filter C

Hydraulic System8.118 Model 6042 Legacy Origin 7/02Figure 8-79 Frame Sway Cylinder ComponentsIMPORTANT: When sliding the rod and piston assembly int

8.119Model 6042 Legacy Origin 7/02Hydraulic Systemd. Frame Sway Cylinder Inspection and Repair1. Inspect all parts for wear, damage, etc. If inner sur

Hydraulic System8.120 Model 6042 Legacy Origin 7/02f. Frame Sway Cylinder Installation1. Lubricate the cylinder pins with multi-purpose, lithium-based

8.121Model 6042 Legacy Origin 7/02Hydraulic System8.13.9 Stabilizer CylinderThe stabilizer cylinder (Fig. 8-80, 1) is attached to the left side of the

Hydraulic System8.122 Model 6042 Legacy Origin 7/02Figure 8-81 Stabilizer Cylinder Componentsb. Stabilizer Cylinder DisassemblyNote: An additional o

8.123Model 6042 Legacy Origin 7/02Hydraulic System5. Use a pin spanner wrench to unthread the head gland (Fig. 8-81, 9) from the tube (2). The head gl

Hydraulic System8.124 Model 6042 Legacy Origin 7/02Figure 8-82 Stabilizer Cylinder Components4. Install new oiled o-ring (Fig. 8-82, 16), back-up rin

8.125Model 6042 Legacy Origin 7/02Hydraulic SystemIMPORTANT: Use a suitable installation tool or compression sleeve to help prevent twisting or damag

Hydraulic System8.126 Model 6042 Legacy Origin 7/025. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating

8.127Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-86 Swing Carriage Cylinder Components (Optional)b. Swing Carriage Cylinder DisassemblyNote

General Information and Specifications2.22 Model 6042 Legacy Origin 7/022.5.9 Hydraulic System2.5.10 Tires2.5.11 Miscellaneous SpecificationsValve Rel

Hydraulic System8.128 Model 6042 Legacy Origin 7/029. Remove the two setscrews (Fig. 8-87, 8), with locking inserts (9), from the piston (7). Pry or d

8.129Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-87 Swing Carriage Cylinder Components (Optional)7. Install a new piston square seal (Fig.

Hydraulic System8.130 Model 6042 Legacy Origin 7/02f. Swing Carriage Cylinder Installation1. Install the swing carriage cylinder(s) (Fig. 8-88, 1) on

8.131Model 6042 Legacy Origin 7/02Hydraulic SystemThis Page Intentionally Left Blank

Hydraulic System8.132 Model 6042 Legacy Origin 7/028.13.11 Side Tilt Carriage Cylinder (Optional)The optional side tilt carriage cylinder (Fig. 8-89)

8.133Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-90 Side Tilt Carriage (Optional)MT1950124643547

Hydraulic System8.134 Model 6042 Legacy Origin 7/02Figure 8-91 Side Tilt Carriage Cylinder Componentsb. Side Tilt Carriage Cylinder DisassemblyNote:

8.135Model 6042 Legacy Origin 7/02Hydraulic System11. Remove the locking inserts (Fig. 8-91, 9) from their holes in the head gland threads. Pry or dri

Hydraulic System8.136 Model 6042 Legacy Origin 7/02Figure 8-92 Side Tilt Carriage Cylinder Components7. Install the capped T-seal (Fig. 8-92, 14) and

8.137Model 6042 Legacy Origin 7/02Hydraulic SystemFigure 8-93 Side Tilt Carriage (Optional)f. Side Tilt Carriage Cylinder Installation1. Install the

2.23Model 6042 Legacy Origin 7/02General Information and Specifications2.5.12 Tamper ProofingA tamper-proof means is in place on the following adjusta

Hydraulic System8.138 Model 6042 Legacy Origin 7/02g. Side Tilt Carriage Cylinder Pressure Checking and Circuit Bleeding1. Attach a 4,000 psi (276 bar

9.1Model 6042 Legacy Origin 7/02Section 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology . . . . . . . . . . . . . .

Electrical System9.2 Model 6042 Legacy Origin 7/029.7.20 Windshield Washer Circuit and Troubleshooting (Option). . . . . . . . . . . . . 9.429.7.21 He

9.3Model 6042 Legacy Origin 7/02Electrical System9.15 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System9.4 Model 6042 Legacy Origin 7/029.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information pre

9.5Model 6042 Legacy Origin 7/02Electrical System9.1.2 General Overview (Engine Harness)Lower Trans.ConnectorDiodesPressureReducingValveConn.HornConne

Electrical System9.6 Model 6042 Legacy Origin 7/029.2 SERVICE WARNINGS9.2.1 General9.2.2 BatteryAlways disconnect the negative (–) (Fig. 9-1, 1) or po

9.7Model 6042 Legacy Origin 7/02Electrical System9.4 EFFECTIVE GROUND CONNECTIONS1. Effective ground connections are essential to the efficient operat

Electrical System9.8 Model 6042 Legacy Origin 7/029.5.3 Cleaning and DryingClean a wire harness with a natural bristle brush and the same detergent us

9.9Model 6042 Legacy Origin 7/02Electrical System9.6 FUSES AND RELAYSFuses and relays help to protect the electrical system. In general, a blown fuse

General Information and Specifications2.24 Model 6042 Legacy Origin 7/022.6.2 Axle Wheel Endsa. Axle Wheel-End LubricantsIn general, use a Universal T

Electrical System9.10 Model 6042 Legacy Origin 7/02Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To

9.11Model 6042 Legacy Origin 7/02Electrical System9.7 ELECTRICAL SYSTEM TROUBLESHOOTING9.7.1 IntroductionThe electrical system produces, stores and di

Electrical System9.12 Model 6042 Legacy Origin 7/029.7.3 Probing Electrical Connectorsa. Front ProbeDisconnect the connector and probe the terminals f

9.13Model 6042 Legacy Origin 7/02Electrical SystemTesting for ContinuityThe following procedures verify good continuity in a circuit.With a DMM1. Set

Electrical System9.14 Model 6042 Legacy Origin 7/022. The neutral start relay (Fig. 9-11, 1) is located at the fuse block and is mounted behind the ri

9.15Model 6042 Legacy Origin 7/02Electrical System9.7.4 Electrical Symbols DirectoryThe following directory (Fig. 9-14) shows the most common electric

Electrical System9.16 Model 6042 Legacy Origin 7/029.7.5 Electrical Schematic Legend (Console/Stabilizer and Engine Harnesses) Wire No. Gauge Color Fr

9.17Model 6042 Legacy Origin 7/02Electrical System12C 16 DK BLU Splice 27 to Roadlights Connector (Option) (Hazards)15 1818LT BL ULT BL UInstrument Pa

Electrical System9.18 Model 6042 Legacy Origin 7/0242 18 TAN Instrument Panel Fuse to Park Brake Switch Connector (Pin 2)Park Brake Switch Connector J

9.19Model 6042 Legacy Origin 7/02Electrical System150A 16 VIO Splice 150 to Diode Pack (Pin A)150B 18 VIO Splice 150 to Lower Transmission Connector (

2.25Model 6042 Legacy Origin 7/02General Information and Specifications2.6.5 Hydraulic Systema. Hydraulic FluidsThe hydraulic system is factory-filled

Electrical System9.20 Model 6042 Legacy Origin 7/029.7.6 Electrical Schematic (Console/Stabilizer and Engine Harnesses)101102B40.0WASHER& WIPERS32

9.21Model 6042 Legacy Origin 7/02Electrical SystemLOWERTRANSMISSIONCONNECTORS1051011502H150B101B105B105150101Y4Y5Y665477123UPPERTRANSMISSIONCONNECTORS

Electrical System9.22 Model 6042 Legacy Origin 7/029.7.7 Electrical Schematic Legend (Wiper/Washer and Heater Harnesses)Wire No. Gauge Color From - Fu

9.23Model 6042 Legacy Origin 7/02Electrical System9.7.8 Electrical Schematic (Wiper/Washer and Heater Harnesses)(-) (-)52143HEATERBLOWER MOTORLOWMEDHI

Electrical System9.24 Model 6042 Legacy Origin 7/029.7.9 Electrical Schematic Legend (Roadlight Harness)Wire No. Gauge Color From - Function - To1 12

9.25Model 6042 Legacy Origin 7/02Electrical System9.7.10 Electrical Schematic (Roadlight Harness)MA9370HEADLIGHTSWITCHRELAY87A 87863085FLASHERLXP2KK27

Electrical System9.26 Model 6042 Legacy Origin 7/029.7.11 Electrical Schematic Legend (Worklights Harness)Wire No. Gauge Color From - Function - To1 1

9.27Model 6042 Legacy Origin 7/02Electrical System9.7.12 Electrical Schematic (Worklight Harness)MA9360TOIGNITIONSWITCH(RUN)RIGHTFRONTWORKLIGHTLEFTF

Electrical System9.28 Model 6042 Legacy Origin 7/029.7.13 Engine Start Circuit and TroubleshootingFigure 9-15 Engine Start CircuitFUELSHUTOFFSOLENOID

9.29Model 6042 Legacy Origin 7/02Electrical SystemCheck 40-amp main fuse.Check that transmission gear select lever is in (N) NEUTRAL.Engine will not c

Section Subject Pageii Model 6042 Legacy Origin 7/02Section 5Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information and Specifications2.26 Model 6042 Legacy Origin 7/022.6.7 Drive Shaft SplinesIMPORTANT: DO NOT disassemble any of the drive shaft

Electrical System9.30 Model 6042 Legacy Origin 7/029.7.14 Charging Circuit and TroubleshootingFigure 9-16 Charging CircuitFUELSHUTOFFSOLENOIDCBABLKWH

9.31Model 6042 Legacy Origin 7/02Electrical SystemDash panel charge indicator ON continuously.Replace instrument cluster.Check alternator at terminal

Electrical System9.32 Model 6042 Legacy Origin 7/029.7.15 Front Steer Circuit and TroubleshootingFigure 9-17 Front Steer CircuitENGINEHARNESSFEMALECO

9.33Model 6042 Legacy Origin 7/02Electrical SystemNotOKCheck wire 9 (GRY/BLK) for battery voltage at steer select solenoid. Shouldread “0” volts.With

Electrical System9.34 Model 6042 Legacy Origin 7/029.7.16 Four-Wheel Steer Circuit and TroubleshootingFigure 9-18 Four-Wheel Steer CircuitENGINEHARNE

9.35Model 6042 Legacy Origin 7/02Electrical SystemIf OKNotOKCheck for battery voltage at wire 9 (GRY/BLK) at steer select valve solenoid. Check wire 2

Electrical System9.36 Model 6042 Legacy Origin 7/029.7.17 Crab Steer Circuit and TroubleshootingFigure 9-19 Crab Steer CircuitENGINEHARNESSFEMALECONN

9.37Model 6042 Legacy Origin 7/02Electrical SystemIf OKNotOKCheck for battery voltage at wire 8 (LT GRN/WHT) at steer select valve. Checkwire 2C (BLK)

Electrical System9.38 Model 6042 Legacy Origin 7/029.7.18 Front Windshield Wiper Circuit and Troubleshooting (Option)Figure 9-20 Front Windshield Wip

9.39Model 6042 Legacy Origin 7/02Electrical SystemBefore troubleshooting any electrical circuit, ALWAYS begin by checking the following:1. Fuses.2. Al

2.27Model 6042 Legacy Origin 7/02General Information and Specifications2.6.10 PaintUnless otherwise specified, paint components as indicated in the fo

Electrical System9.40 Model 6042 Legacy Origin 7/029.7.19 Roof Windshield Wiper Circuit and Troubleshooting (Option)Figure 9-21 Roof Windshield Wiper

9.41Model 6042 Legacy Origin 7/02Electrical SystemIf OKNotOKCheck for battery voltage at wire 32 (GRY/WHT) and wire 6B (RED/WHT) at cab/wiper harness

Electrical System9.42 Model 6042 Legacy Origin 7/029.7.20 Windshield Washer Circuit and Troubleshooting (Option)Figure 9-22 Windshield Washer Circuit

9.43Model 6042 Legacy Origin 7/02Electrical SystemIf OKNotOKCheck for battery voltage at wire 6D (RED/WHT) and wire 6E (RED/WHT) at cab/washer harness

Electrical System9.44 Model 6042 Legacy Origin 7/029.7.21 Heater Circuit and Troubleshooting (Option)Figure 9-23 Heater Circuit32FUSE BLOCK BUS BAR10

9.45Model 6042 Legacy Origin 7/02Electrical SystemIf OKNotOKCheck for battery voltage at wire 2 (RED/WHT) at heater switch. Check wire 5 (BLK) ground

Electrical System9.46 Model 6042 Legacy Origin 7/029.7.22 Roadlights High Beam Circuit and Troubleshooting (Option)Figure 9-24 Roadlight CircuitHEADL

9.47Model 6042 Legacy Origin 7/02Electrical SystemWith the ignition ON and the lighting control rotated to 2nd position (Position Parking Lights &

Electrical System9.48 Model 6042 Legacy Origin 7/029.7.23 Roadlights Hazard Lights Circuit and Troubleshooting (Option)Figure 9-25 Roadlight CircuitH

9.49Model 6042 Legacy Origin 7/02Electrical SystemWith ignition switch OFF, hazard indicator and all hazard lights remain OFF with the 4 way hazard sw

General Information and Specifications2.28 Model 6042 Legacy Origin 7/022.8 REPLACEMENTALWAYS use the correct tool when removing or replacing any part

Electrical System9.50 Model 6042 Legacy Origin 7/029.7.24 Roadlights Turn Signals Circuit and Troubleshooting (Option)Figure 9-26 Roadlight CircuitHE

9.51Model 6042 Legacy Origin 7/02Electrical SystemWith the ignition ON and the lighting control pushed up for left turn signal or down for right turn

Electrical System9.52 Model 6042 Legacy Origin 7/029.7.25 Roadlights Position Lights & Low Beam Lights Circuit and Troubleshooting (Option)Figure

9.53Model 6042 Legacy Origin 7/02Electrical SystemNotOKReplace roadlight harness.Replace lighting control.Not OKIf OKDisconnect three position plug at

Electrical System9.54 Model 6042 Legacy Origin 7/029.7.26 Roadlights Brake Lights Circuit and Troubleshooting (Option)Figure 9-28 Roadlight CircuitHE

9.55Model 6042 Legacy Origin 7/02Electrical SystemReplace roadlight harness.Not OKIf OKReplace brake switch.Before troubleshooting any electrical circ

Electrical System9.56 Model 6042 Legacy Origin 7/029.7.27 Roadlights Worklights Circuit and Troubleshooting (Option)Figure 9-29 Roadlight CircuitHEAD

9.57Model 6042 Legacy Origin 7/02Electrical SystemNotOKReplace roadlight harness.Replace worklight switch.Not OKIf OKFor boom worklight, check battery

Electrical System9.58 Model 6042 Legacy Origin 7/029.7.28 Worklight (Without Roadlights) Circuit and Troubleshooting (Option)Figure 9-30 Worklight Ci

9.59Model 6042 Legacy Origin 7/02Electrical SystemNotOKReplace worklight harness.Replace worklight switch.Not OKIf OKNotOKReplace worklight harness.Re

2.29Model 6042 Legacy Origin 7/02General Information and Specifications2.10.3 Bearing Installation1. Always install bearings carefully to help avoid d

Electrical System9.60 Model 6042 Legacy Origin 7/029.8 TRANSMISSION GEAR SELECTION TROUBLESHOOTINGThe following seven electrical circuit schematics ad

9.61Model 6042 Legacy Origin 7/02Electrical System9.8.1 Transmission, Forward First Gear CircuitFigure 9-31 Transmission, Forward First Gear CircuitM

Electrical System9.62 Model 6042 Legacy Origin 7/029.8.2 Transmission, Forward Second Gear CircuitFigure 9-32 Transmission, Forward Second Gear Circu

9.63Model 6042 Legacy Origin 7/02Electrical System9.8.3 Transmission, Forward Third Gear CircuitFigure 9-33 Transmission, Forward Third Gear CircuitM

Electrical System9.64 Model 6042 Legacy Origin 7/029.8.4 Transmission, Forward Fourth Gear CircuitFigure 9-34 Transmission, Forward Fourth Gear Circu

9.65Model 6042 Legacy Origin 7/02Electrical System9.8.5 Transmission, Reverse First Gear CircuitFigure 9-35 Transmission, Reverse First Gear CircuitM

Electrical System9.66 Model 6042 Legacy Origin 7/029.8.6 Transmission, Reverse Second Gear CircuitFigure 9-36 Transmission, Reverse Second Gear Circu

9.67Model 6042 Legacy Origin 7/02Electrical System9.8.7 Transmission, Reverse Third Gear CircuitFigure 9-37 Transmission, Reverse Third Gear CircuitM

Electrical System9.68 Model 6042 Legacy Origin 7/029.9 DASH PANEL WARNING INDICATOR TROUBLESHOOTINGThe following troubleshooting flow charts discuss e

9.69Model 6042 Legacy Origin 7/02Electrical System9.9.1 Engine Alternator Charging Warning Indicator Troubleshooting0000 00PEngine alternator charging

General Information and Specifications2.30 Model 6042 Legacy Origin 7/022.12.3 After Hydraulic Component Service1. Check the torque of fasteners on re

Electrical System9.70 Model 6042 Legacy Origin 7/029.9.2 Engine Coolant Temperature Warning Indicator Troubleshooting0000 00PCheck radiator coolant le

9.71Model 6042 Legacy Origin 7/02Electrical System9.9.3 Transmission Temperature Warning Indicator Troubleshooting0000 00PCheck transmission fluid lev

Electrical System9.72 Model 6042 Legacy Origin 7/029.9.4 Hydraulic Oil Temperature Warning Indicator Troubleshooting0000 00PCheck hydraulic fluid leve

9.73Model 6042 Legacy Origin 7/02Electrical System9.9.5 Park Brake Warning Indicator Troubleshooting0000 00PPark brake warning indicator stays ONwith

Electrical System9.74 Model 6042 Legacy Origin 7/029.9.6 Engine Oil Pressure Warning Indicator TroubleshootingRepair engine component.Disconnect wire

9.75Model 6042 Legacy Origin 7/02Electrical System9.9.7 Fuel Level Indicator Troubleshooting0000 00PVerify fuel quantitylevel in tank.Fuel level indic

Electrical System9.76 Model 6042 Legacy Origin 7/029.9.8 Hourmeter Indicator Troubleshooting0000 00PWith the park brake ON and the engine running, che

9.77Model 6042 Legacy Origin 7/02Electrical System9.9.9 Stabil-TRAK™ Indicator TroubleshootingReplace fuse and troubleshoot harness.Replace boom senso

Electrical System9.78 Model 6042 Legacy Origin 7/029.9.10 Roadlights High-Beam Indicator Troubleshooting0000 00PMA9320Roadlights High-Beam IndicatorBe

9.79Model 6042 Legacy Origin 7/02Electrical System9.9.11 Roadlights Hazard Signals Indicator Troubleshooting0000 00PHazard lights indicator does not w

2.31Model 6042 Legacy Origin 7/02General Information and Specifications2.12.7 After Tire and Wheel Service1. Check air pressure. Maintain proper air p

Electrical System9.80 Model 6042 Legacy Origin 7/029.10 ENGINE START CIRCUITThe purpose of the engine start circuit is to energize the starter solenoi

9.81Model 6042 Legacy Origin 7/02Electrical Systema. Testing the Starter on the EngineIf the starter does not engage when the ignition key switch is t

Electrical System9.82 Model 6042 Legacy Origin 7/02f. Starter Installation1. Position the starter (Fig. 9-41, 1) in its mounting opening on the flywhe

9.83Model 6042 Legacy Origin 7/02Electrical SystemFigure 9-43 The Alternator Charging Warning Indicator is Located on theOperator’s Instrument Cluste

Electrical System9.84 Model 6042 Legacy Origin 7/029.11.1 Alternatora. Alternator Removal1. Disconnect the negative (–) battery cable at the negative

9.85Model 6042 Legacy Origin 7/02Electrical Systemb. Alternator Installation1. Position the alternator and align with the upper alternator mount (Fig.

Electrical System9.86 Model 6042 Legacy Origin 7/02c. Battery Load Test1. Disconnect both the negative (–) battery cable (first), and the positive (+)

9.87Model 6042 Legacy Origin 7/02Electrical SystemWhen charging a battery, keep this point in mind:• Battery charging consists of a charge current in

Electrical System9.88 Model 6042 Legacy Origin 7/02g. Battery Removal1. Disconnect the negative (–) battery cable (Fig. 9-49, 1), from the battery (2)

9.89Model 6042 Legacy Origin 7/02Electrical System9.12 ELECTRICAL SYSTEM COMPONENTSElectrical components include warning devices such as the indicator

General Information and Specifications2.32 Model 6042 Legacy Origin 7/02This Page Intentionally Left Blank

Electrical System9.90 Model 6042 Legacy Origin 7/02d. Transmission Temperature Warning IndicatorThis indicator (Fig. 9-51, 1) illuminates when the tra

9.91Model 6042 Legacy Origin 7/02Electrical SystemThe back-up alarm is energized via current from the transmission shift control switch, part of the t

Electrical System9.92 Model 6042 Legacy Origin 7/02a. Power-Up LightsWhen the ignition key switch is turned to power up the vehicle, all lights in the

9.93Model 6042 Legacy Origin 7/02Electrical Systemd. Operator’s Instrument Cluster Removal1. Disconnect the negative (–) battery cable at its battery

Electrical System9.94 Model 6042 Legacy Origin 7/02Figure 9-60 Instrument Cluster Bulb Replacement3. Rotate the suspect bulb assembly (Fig. 9-60) 1/4

9.95Model 6042 Legacy Origin 7/02Electrical SystemOperator’s Display Panel TestCheck the following, as the key switch (Fig. 9-64, 1) is placed in the

Electrical System9.96 Model 6042 Legacy Origin 7/029.13.2 Windshield Wiper MotorFigure 9-66 Windshield Wiper Motor Locationa. RemovalNote: It may be

9.97Model 6042 Legacy Origin 7/02Electrical SystemFigure 9-68 Front Wiper Motor and Spacer Plate1. Install all required hardware to the motor assembl

Electrical System9.98 Model 6042 Legacy Origin 7/029.13.3 Roof Wiper Switch Figure 9-70 Roof Wiper Switch LocationThe roof wiper switch (Fig. 9-70, 1

9.99Model 6042 Legacy Origin 7/02Electrical System9.13.4 Roof Wiper MotorFigure 9-72 Roof Wiper Motor Locationa. Removal1. Disconnect the negative (–

3.1Model 6042 Legacy Origin 7/02Section 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . .

Electrical System9.100 Model 6042 Legacy Origin 7/029.13.5 Windshield/Roof Washer SwitchFigure 9-73 Windshield/Roof Washer Switch LocationThe windshi

9.101Model 6042 Legacy Origin 7/02Electrical System9.13.6 Windshield/Roof Washer Reservoir and PumpThe windshield washer motor and reservoir is a unit

Electrical System9.102 Model 6042 Legacy Origin 7/029.14 CAB HEATER AND FAN (OPTION)9.14.1 Cab Heater ControlsNote: If the suspect component is found

9.103Model 6042 Legacy Origin 7/02Electrical System2. Remove the setscrew (Fig. 9-76, 4) from the variable speed fan control knob (2) or temperature c

Electrical System9.104 Model 6042 Legacy Origin 7/029.15 SWITCHES AND SOLENOIDSNote: For information on the front windshield wiper, roof wiper and wi

9.105Model 6042 Legacy Origin 7/02Electrical System2. Remove lower access panel (Fig. 9-80, 1).Figure 9-80 Ignition Key Switch Location3. Remove the

Electrical System9.106 Model 6042 Legacy Origin 7/02d. Ignition Switch Installation1. Connect the ignition key switch to the cab harness connectors.2.

9.107Model 6042 Legacy Origin 7/02Electrical Systeme. Transmission Neutral Start FeatureThe transmission neutral start feature is a safety feature des

Electrical System9.108 Model 6042 Legacy Origin 7/02b. Fuel Shut-off Solenoid DisassemblyDO NOT disassemble a fuel shut-off solenoid. Replace a defect

9.109Model 6042 Legacy Origin 7/02Electrical SystemExamine the fluid in the hydraulic oil sight glass (Fig. 9-89, 1) to check whether there is a suffi

Boom3.2 Model 6042 Legacy Origin 7/023.1 BOOM SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in

Electrical System9.110 Model 6042 Legacy Origin 7/029.15.4 Park Brake SwitchThe park brake switch (Fig. 9-90, 1) is located on the dash to the left of

9.111Model 6042 Legacy Origin 7/02Electrical Systema. Park Brake Switch Removal1. Disconnect the negative (–) battery cable at the negative battery te

Electrical System9.112 Model 6042 Legacy Origin 7/029.15.5 Transmission Shift Control Switcha. Travel Select LeverThe transmission shift control switc

9.113Model 6042 Legacy Origin 7/02Electrical System9.15.6 Transmission Solenoid Valves The transmission is shifted via six solenoids. Three solenoid v

Electrical System9.114 Model 6042 Legacy Origin 7/02a. Travel Select Lever and Wiring Harness TestingNote: An assistant will be required to operate t

9.115Model 6042 Legacy Origin 7/02Electrical SystemNote: The following chart shows which solenoids are active with any given selection of the transmi

Electrical System9.116 Model 6042 Legacy Origin 7/02c. Transmission Upper Valve Body Solenoid RemovalNote: Before removing the valve body protective

9.117Model 6042 Legacy Origin 7/02Electrical Systemd. Transmission Upper Valve Body Solenoid InstallationNote: When installing the solenoid valve int

Electrical System9.118 Model 6042 Legacy Origin 7/026. Remove the nine lower valve body protective cover screws (Fig. 9-104, 1), lockwashers (2) prote

9.119Model 6042 Legacy Origin 7/02Electrical System6. Connect the negative (–) battery cable to the negative battery terminal (Fig. 9-105, 1).Figure 9

3.3Model 6042 Legacy Origin 7/02Boom3.2 BOOM SYSTEM3.2.1 Boom System DescriptionThe boom operates via an interchange among the hydraulic and mechanica

Electrical System9.120 Model 6042 Legacy Origin 7/029.15.7 SteeringCertain steering functions are dependent upon electrical operations as described be

9.121Model 6042 Legacy Origin 7/02Electrical SystemFront-Wheel Steer ModeWith the steer select switch in the center position (Fig. 9-106, 3), the foll

Electrical System9.122 Model 6042 Legacy Origin 7/029.15.8 Steer Select SwitchesFor additional information, refer to Section 9.7.15, “Front Steer Circ

9.123Model 6042 Legacy Origin 7/02Electrical System9.15.9 Steer Select ValveThe steer select valve (Fig. 9-112, 1), is secured to the steer select man

Electrical System9.124 Model 6042 Legacy Origin 7/029.15.10 Engine Low Oil Pressure SwitchThe engine low oil pressure switch (Fig. 9-115, 1) is locate

9.125Model 6042 Legacy Origin 7/02Electrical System9.15.11 Engine Coolant High Temperature SwitchThe engine coolant high temperature switch (Fig. 9-11

Electrical System9.126 Model 6042 Legacy Origin 7/029.15.12 Transmission Temperature SwitchThe transmission temperature switch (Fig. 9-120, 1) is thre

9.127Model 6042 Legacy Origin 7/02Electrical System2. Unplug the switch connector (Fig. 9-120, 1) from the cab harness connector.3. The switch (Fig. 9

Electrical System9.128 Model 6042 Legacy Origin 7/02a. Engine Block Heater Removal1. Level the vehicle, ground the attachment, place the travel select

9.129Model 6042 Legacy Origin 7/02Electrical SystemFigure 9-126 Engine Block Heaterb. Engine Block Heater DisassemblyDO NOT disassemble the heater el

Section Subject PageiiiModel 6042 Legacy Origin 7/02Section 9Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.4 Model 6042 Legacy Origin 7/023.3.1 Inner Boom Removal1. Remove any attachment from the quick attach assembly. (Refer to Section 3.6.1, “Discon

Electrical System9.130 Model 6042 Legacy Origin 7/029.15.14 Fuel Level Indicator and Fuel Level SenderThe fuel level indicator (Fig. 9-127, 1) can be

9.131Model 6042 Legacy Origin 7/02Electrical SystemFigure 9-129 Ignition Key Switch RUN Position4. Turn the ignition key switch to the OFF (Fig. 9-12

Electrical System9.132 Model 6042 Legacy Origin 7/029.15.15 HourmeterThe hourmeter (Fig. 9-130, 1) is a non-repairable instrument that records hours o

9.133Model 6042 Legacy Origin 7/02Electrical System2. Disconnect the boom lift sensor electrical connector (Fig. 9-132, 2) from the engine harness con

Electrical System9.134 Model 6042 Legacy Origin 7/029.15.17 Service Brake SwitchThe service brake switch works in conjunction with the Stabil-TRAK™ sy

9.135Model 6042 Legacy Origin 7/02Electrical Systemc. Service Brake Switch AdjustmentNote: The service brake switch adjustment will require two peopl

Electrical System9.136 Model 6042 Legacy Origin 7/02This Page Intentionally Left Blank

10.1Model 6042 Legacy Origin 7/02Section 10Stabil-TRAK™ SystemContentsPARAGRAPH TITLE PAGE10.1 Stabil-TRAK™ System Component Terminology. . . . . . .

Stabil-TRAK™ System10.2 Model 6042 Legacy Origin 7/0210.1 STABIL-TRAK™ SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenanc

10.3Model 6042 Legacy Origin 7/02 Stabil-TRAK™ System10.2 STABIL-TRAK™ DESCRIPTIONThe patented rear axle lock or Stabil-TRAK™ system works to stabiliz

3.5Model 6042 Legacy Origin 7/02Boom5. Remove the elastic locknut (Fig. 3-4, 1) and shoulder bolt (2) holding the two yoke plates (3) to the mount at

Stabil-TRAK™ System10.4 Model 6042 Legacy Origin 7/02The Stabil-TRAK™ lock system will be activated when the boom angle is greater than 40° and/or on

10.5Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-5 Stabil-TRAK™The following describes the three basic modes of the patented Stabil-TRA

Stabil-TRAK™ System10.6 Model 6042 Legacy Origin 7/02c. Final Positioning Mode (Fig. 10-8)With the boom above 40°, the Stabil-TRAK™ system is now in

10.7Model 6042 Legacy Origin 7/02 Stabil-TRAK™ System10.3.3 Relay TestingIf after checking the electrical system, a relay is suspect, test the relay a

Stabil-TRAK™ System10.8 Model 6042 Legacy Origin 7/0210.4 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTINGDefinitions:PB = Park BrakeSB

10.9Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-14 Electrical Circuit, Free Pivot ModeStabil-TRAK™ Electrical CircuitFree Pivot ModeFR

Stabil-TRAK™ System10.10 Model 6042 Legacy Origin 7/02Figure 10-15 Electrical Circuit, Final Positioning ModeFINAL POSITIONING MODE 1.Ignition “ON”4

10.11Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-16 Electrical Circuit, Locked ModeStabil-TRAK™ Electrical CircuitLocked ModeLOCKED MO

Stabil-TRAK™ System10.12 Model 6042 Legacy Origin 7/0210.5 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTINGThe function of the Stabil-TRA

10.13Model 6042 Legacy Origin 7/02 Stabil-TRAK™ System10.5.2 Stabilizer Cylinder Oil FlowIn the FREE PIVOT and FINAL POSITIONING MODES, oil flow from

Boom3.6 Model 6042 Legacy Origin 7/0214. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the veh

Stabil-TRAK™ System10.14 Model 6042 Legacy Origin 7/0210.5.3 Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil OutFigure 10-18 FREE PIVOT MODE

10.15Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-19 Stabilizer Cylinder Solenoids, Check Valves and Pressure Reducing Cartridge10.5.4

Stabil-TRAK™ System10.16 Model 6042 Legacy Origin 7/0210.5.5 Hydraulic Circuit Operation - Free Pivot Mode, Base Oil OutFigure 10-20 FREE PIVOT MODE

10.17Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-21 Stabilizer Cylinder Solenoids, Check Valves and Pressure Reducing Cartridge10.5.6

Stabil-TRAK™ System10.18 Model 6042 Legacy Origin 7/0210.5.7 Hydraulic Circuit Operation - Final Positioning Mode, Rod Oil OutFigure 10-22 FINAL POS

10.19Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-23 Stabilizer Cylinder Solenoids, Check Valves and Pressure Reducing Cartridge10.5.8

Stabil-TRAK™ System10.20 Model 6042 Legacy Origin 7/0210.5.9 Hydraulic Circuit Operation - Final Positioning Mode, Base Oil OutFigure 10-24 FINAL PO

10.21Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-25 Stabilizer Cylinder Solenoids, Check Valves and Pressure Reducing Cartridge10.5.10

Stabil-TRAK™ System10.22 Model 6042 Legacy Origin 7/0210.5.11 Hydraulic Circuit Operation - Locked Modea. Conditions:• Boom angle is above 40°• Park

10.23Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-26 LOCKED MODE Hydraulic Circuit (Frame Sway Right)Figure 10-27 Stabilizer Cylinder

3.7Model 6042 Legacy Origin 7/02BoomFigure 3-9 Clamp Support Bracket Inside Inner Boom22. Pull the free ends of the attachment tilt hoses (Fig. 3-10,

Stabil-TRAK™ System10.24 Model 6042 Legacy Origin 7/0210.5.13 Hydraulic Circuit Operation - Locked Mode, Frame Sway Lefta. Conditions• Boom angle is

10.25Model 6042 Legacy Origin 7/02 Stabil-TRAK™ SystemFigure 10-28 LOCKED MODE Hydraulic Circuit (Frame Sway Left)Figure 10-29 Stabilizer Cylinder S

Stabil-TRAK™ System10.26 Model 6042 Legacy Origin 7/0210.5.14 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Right10.5.15 Hydraulic Tro

10.27Model 6042 Legacy Origin 7/02 Stabil-TRAK™ System10.6 STABIL-TRAK™ SYSTEM TESTIMPORTANT: The operator must know that the Stabil-TRAK™ system is

Stabil-TRAK™ System10.28 Model 6042 Legacy Origin 7/02Step 4:a. Use your left foot to depress the service brake pedal.b. Move the travel select lever

10.1Model 6042 Legacy Origin 7/02Section 11IndexAAccess Panels and CoversAccess Panel and Cover Replacement...4.32Accident Prev

10.2 Model 6042 Legacy Origin 7/02IndexTransmission Gear Selection Troubleshooting ...9.60Warning Devices...9.89

10.3Model 6042 Legacy Origin 7/02IndexAuxiliary Hydraulics Circuit Description ... 8.54Boom Extend Circuit... 8

10.4 Model 6042 Legacy Origin 7/02IndexFinal Positioning Mode, Base Oil Out ...10.20Final Positioning Mode, Rod Oil Out ...

10.5Model 6042 Legacy Origin 7/02IndexInspection and Repair ... 9.8Installation ... 9.8Removal and Replace

Boom3.8 Model 6042 Legacy Origin 7/02Note: If replacing the inner boom assembly with a new inner boom, the quick attach assembly and the attachment t

10.6 Model 6042 Legacy Origin 7/02Index

Accident Prevention TagsOS21808990403 Origin 5/00Accident Prevention Tags

Accident Prevention TagsOS21808990403 Origin 5/00

3.9Model 6042 Legacy Origin 7/02Boom33. Lower the attachment tilt cylinder (Fig. 3-15, 4) with the hoist and remove from the backside of the gooseneck

Boom3.10 Model 6042 Legacy Origin 7/023.3.2 Intermediate Boom Removal1. Remove the inner boom as described in Section 3.3.1, “Inner Boom Removal.”2. A

3.11Model 6042 Legacy Origin 7/02Boom6. Remove the retract chain sheave pin (Fig. 3-22, 3) from the mount and the retract chain sheave (4). Remove the

Boom3.12 Model 6042 Legacy Origin 7/0210. Pull the hose reel with hoses out the back of the intermediate boom. Allow the hose reel assembly to slide d

3.13Model 6042 Legacy Origin 7/02BoomFigure 3-27 Extend/Retract Cylinder Rod End PinNote: Use a hoist with a lifting capacity of 5,000 lbs (2268 kg)

Section Subject Pageiv Model 6042 Legacy Origin 7/02This Page Intentionally Left Blank

Boom3.14 Model 6042 Legacy Origin 7/02b. Remove the capscrews (Fig. 3-30, 1), lockwashers (2) and flat washers (3) holding the bottom wear pad (4) and

3.15Model 6042 Legacy Origin 7/02Boom3.3.3 Outer Boom Removal1. Remove both the inner boom and intermediate boom as described in Section 3.3.1, “Inner

Boom3.16 Model 6042 Legacy Origin 7/027. At the rear left side of the outer boom, label and remove the (outer) auxiliary hose for the female coupler (

3.17Model 6042 Legacy Origin 7/02Boom16. Label the attachment tilt tube assemblies (Fig. 3-38, 2) located under the boom. Remove the stacking bolts (6

Boom3.18 Model 6042 Legacy Origin 7/0222. On the right side boom pivot mounting plate, locate the boom sensor (Fig. 3-41, 1). Remove the hex nut (2) o

3.19Model 6042 Legacy Origin 7/02Boom27. Use the hoist to remove the outer boom from the frame. Position the outer boom on a hard, flat surface. Block

Boom3.20 Model 6042 Legacy Origin 7/0235. If replacing the outer boom assembly, on the left side of the outer boom, remove the locknut (Fig. 3-47, 1),

3.21Model 6042 Legacy Origin 7/02Boom3.3.4 Outer Boom InstallationIMPORTANT: Light lubrication of the boom wear surfaces with a rust inhibitor/lubric

Boom3.22 Model 6042 Legacy Origin 7/024. Install new or saved lift/lower cylinder bearings (Fig. 3-52, 1) into the lift/lower cylinder mounts (2) on e

3.23Model 6042 Legacy Origin 7/02BoomFigure 3-54 Rubber BumperNote: Use a hoist capable of lifting 5,000 lbs (2268 kg) and two slings to install the

1.1Model 6042 Legacy Origin 7/02Section 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.24 Model 6042 Legacy Origin 7/0215. Align the rod end of one of the lift/lower cylinders (Fig. 3-57, 1) with the self-aligning bearing on the ou

3.25Model 6042 Legacy Origin 7/02Boom24. Insert the boom sensor (Fig. 3-59, 1) through the hole in the right side mounting plate (2). Install the jam

Boom3.26 Model 6042 Legacy Origin 7/0229. Assemble the inside boom extend hose (Fig. 3-61, 1), coming from the frame bulkhead plate, to the boom exten

3.27Model 6042 Legacy Origin 7/02Boom39. Place the lower clamp halves (Fig. 3-63, 5) on each side of the auxiliary hydraulic (lower) tubes (6). Loosel

Boom3.28 Model 6042 Legacy Origin 7/0245. Make sure the retract chain has been inspected before installing it in the outer boom. Refer to Section 3.4.

3.29Model 6042 Legacy Origin 7/02Boom49. Install the intermediate boom, retract chain and attaching hardware. (Refer to Section 3.3.5, “Intermediate B

Boom3.30 Model 6042 Legacy Origin 7/023.3.5 Intermediate Boom Installation IMPORTANT: Light lubrication of the boom wear surfaces with a rust inhibit

3.31Model 6042 Legacy Origin 7/02Boomc. Place the wear pad inserts (Fig. 3-69, 5), saved, into the cavities in the wear pad (6). Be sure the inserts a

Boom3.32 Model 6042 Legacy Origin 7/02Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear

3.33Model 6042 Legacy Origin 7/02Boom10. Remove the slings and the hoist from the intermediate boom.11. Install the side wear pads to the outer boom:a

Safety Practices1.2 Model 6042 Legacy Origin 7/021.1 INTRODUCTIONOmniQuip Textron Inc. (hereafter, OmniQuip) products meet all applicable industry saf

Boom3.34 Model 6042 Legacy Origin 7/0213. Use a hoist and sling to lift the rod end of the extend/retract cylinder (Fig. 3-75, 1). Align the rod end o

3.35Model 6042 Legacy Origin 7/02Boom3.3.6 Inner Boom InstallationIMPORTANT: Light lubrication of the boom wear surfaces with a rust inhibitor/lubric

Boom3.36 Model 6042 Legacy Origin 7/025. Keep the four hoses in line (left to right) as they come out of the rear of the inner boom. Place a 5/16"

3.37Model 6042 Legacy Origin 7/02Boom12. Assemble the remaining wear pads to the rear of the inner boom. The upper left wear pad has already been asse

Boom3.38 Model 6042 Legacy Origin 7/0213. Make sure that both extend chains have been inspected before installing them on the inner boom. Refer to Sec

3.39Model 6042 Legacy Origin 7/02Boomc. Torque all wear pad mounting capscrews to 31 ±3 lb-ft (42 ±4 Nm).d. Fill all wear pad cavities with a good gra

Boom3.40 Model 6042 Legacy Origin 7/0222. Tie the strings (positioned inside the outer boom) to the male end of each of the attachment tilt hoses and

3.41Model 6042 Legacy Origin 7/02BoomFigure 3-87 Attachment Tilt and Auxiliary Hydraulic Hoses and Tubes26. Place the retract chain (Fig. 3-88, 1) up

Boom3.42 Model 6042 Legacy Origin 7/0230. Assemble the two extend chains to the outer boom mount if the yoke plates were removed from the extend chain

3.43Model 6042 Legacy Origin 7/02BoomFigure 3-92 Quick Attach36. If the inner boom has been replaced with a new boom, the auxiliary hydraulic fitting

1.3Model 6042 Legacy Origin 7/02Safety Practices1.3 TRAINING MECHANICS AS OPERATORSBecause it is necessary to move the vehicle to service or maintain

Boom3.44 Model 6042 Legacy Origin 7/0237. Use a hoist and slings to position the attachment tilt cylinder (Fig. 3-95, 1) inside the gooseneck (2). Be

3.45Model 6042 Legacy Origin 7/02Boom42. Assemble the right side hose (Fig. 3-97, 3) labeled as “Extend” to the extend port (lower) fitting (4) on the

Boom3.46 Model 6042 Legacy Origin 7/023.4 BOOM CHAINSThis vehicle uses double extend chains to extend the boom and a single retract chain to retract t

3.47Model 6042 Legacy Origin 7/02Booma. Inspection GuidelinesExpose the extend and retract chains (refer to Section 3.4.1, b. “Expose Extend Chain for

Boom3.48 Model 6042 Legacy Origin 7/02Turning or Protruding PinsHighly loaded chain, operating with inadequate lubrication, can generate abnormal fric

3.49Model 6042 Legacy Origin 7/02BoomOther Modes of Failure• Ultimate Strength Failure - These types of failures are caused by overloads far in excess

Boom3.50 Model 6042 Legacy Origin 7/02c. Expose Retract Chain for InspectionThe retract chain must be removed from the boom in order to be visually in

3.51Model 6042 Legacy Origin 7/02Boom6. If the chain clevis has a threaded hole on the end (Fig. 3-108, 1), a string or wire can be attached to the re

Boom3.52 Model 6042 Legacy Origin 7/0211. Measure the chain elongation. Measure across 17 pins (Fig. 3-110, 1), somewhere between the chain sheave and

3.53Model 6042 Legacy Origin 7/02BoomIf no string or wire was installed to the end of the clevis:18. From the rear of the boom, one person should push