Skytrak 6042 Service Manual User Manual Page 372
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- Table of contents
- TROUBLESHOOTING
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Electrical System
9.2
Model 6042 Legacy Origin 7/02
9.7.20 Windshield Washer Circuit and Troubleshooting (Option). . . . . . . . . . . . . 9.42
9.7.21 Heater Circuit and Troubleshooting (Option). . . . . . . . . . . . . . . . . . . . . . . 9.44
9.7.22 Roadlights High Beam Circuit and Troubleshooting (Option) . . . . . . . . . . 9.46
9.7.23 Roadlights Hazard Lights Circuit and Troubleshooting (Option) . . . . . . . . 9.48
9.7.24 Roadlights Turn Signals Circuit and Troubleshooting (Option) . . . . . . . . . 9.50
9.7.25 Roadlights Position Lights & Low Beam Lights Circuit and Troubleshooting
(Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52
9.7.26 Roadlights Brake Lights Circuit and Troubleshooting (Option) . . . . . . . . . 9.54
9.7.27 Roadlights Worklights Circuit and Troubleshooting (Option) . . . . . . . . . . . 9.56
9.7.28 Worklight (Without Roadlights) Circuit and Troubleshooting (Option) . . . . 9.58
9.8 Transmission Gear Selection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 9.60
9.8.1 Transmission, Forward First Gear Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 9.61
9.8.2 Transmission, Forward Second Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . 9.62
9.8.3 Transmission, Forward Third Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 9.63
9.8.4 Transmission, Forward Fourth Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . . 9.64
9.8.5 Transmission, Reverse First Gear Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
9.8.6 Transmission, Reverse Second Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . 9.66
9.8.7 Transmission, Reverse Third Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 9.67
9.9 Dash Panel Warning Indicator Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 9.68
9.9.1 Engine Alternator Charging Warning Indicator Troubleshooting . . . . . . . . 9.69
9.9.2 Engine Coolant Temperature Warning Indicator Troubleshooting . . . . . . . 9.70
9.9.3 Transmission Temperature Warning Indicator Troubleshooting. . . . . . . . . 9.71
9.9.4 Hydraulic Oil Temperature Warning Indicator Troubleshooting . . . . . . . . . 9.72
9.9.5 Park Brake Warning Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . 9.73
9.9.6 Engine Oil Pressure Warning Indicator Troubleshooting. . . . . . . . . . . . . . 9.74
9.9.7 Fuel Level Indicator Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.75
9.9.8 Hourmeter Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.76
9.9.9 Stabil-TRAK™ Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 9.77
9.9.10 Roadlights High-Beam Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . 9.78
9.9.11 Roadlights Hazard Signals Indicator Troubleshooting. . . . . . . . . . . . . . . . 9.79
9.10 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.80
9.10.1 Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.80
9.10.2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.80
9.11 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.82
9.11.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.84
9.11.2 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.85
9.12 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.89
9.12.1 Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.89
9.12.2 Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.90
9.12.3 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.91
9.13 Window Wiper/Washer (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95
9.13.1 Windshield Wiper Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95
9.13.2 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.96
9.13.3 Roof Wiper Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.98
9.13.4 Roof Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.99
9.13.5 Windshield/Roof Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.100
9.13.6 Windshield/Roof Washer Reservoir and Pump. . . . . . . . . . . . . . . . . . . . . 9.101
9.14 Cab Heater and Fan (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.102
9.14.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.102
- 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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