Skytrak 6042 Service Manual User Manual Page 151
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- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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4.31
Model 6042 Legacy Origin 7/02
Cab and Covers
Figure 4-51 Install the Upper and Lower Transmission
Covers
Note: Steps 17-19 apply to vehicles equipped with
optional heater (enclosed cab models only). If your vehicle
does not have the optional heater, proceed to Step 20.
17. Working under the cab, connect the coolant hoses
(Fig. 4-52, 1 and 2) to the heater hoses. Secure with
two hose clamps (3 and 4).
18. Connect the heater control cable (Fig. 4-52, 5) to the
heater control valve (6). Tighten the hose clamp
screw (7).
Figure 4-52 Connect Heater Hoses
19. Fill the cooling system completely with a 50/50 mixture
of ethylene glycol and water, allowing time for the
coolant to fill the engine block. The cooling system
capacity is listed in “Specifications,” Section 2.
20. Connect the battery negative (-) cable.
21. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any
faulty conditions.
22. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
IMPORTANT: When the engine is initially started, run it
briefly at low idle and check the vehicle for any visual
sign of fluid leakage. STOP the engine immediately if
any leakage is noted, and make any necessary repairs
before continuing.
23. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
MA8620
3
~
~
2
1
3
MA8780
7
3
5
6
1
4
2
WARNING: Hydraulic oil leaking under
pressure can penetrate the skin and cause
severe personal injury. DO NOT use your hand
or any part of your body to check for hydraulic
leaks. When checking for hydraulic leaks, wear
safety glasses and gloves to help provide
protection from spraying hydraulic oil. Use a
piece of cardboard or paper to search for leaks.
WARNING: The cooling system is under
pressure, and escaping coolant can cause
severe burns and eye injury. To prevent
personal injury, NEVER remove the radiator
cap while the cooling system is hot. Wear
safety glasses. Turn the radiator cap to the first
stop and allow pressure to escape before
removing the cap completely.
- 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
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