Skytrak 6042 Service Manual User Manual Page 387
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9.17
Model 6042 Legacy Origin 7/02
Electrical System
12C 16 DK BLU Splice 27 to Roadlights Connector (Option) (Hazards)
15 18
18
LT BL U
LT BL U
Instrument Panel Connector (Pin J6) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Water Temperature Switch (Engine Harness)
16 18
18
BRN
BRN
Instrument Panel Connector (Pin J9) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Oil Pressure Switch (Engine Harness)
17 18
16
GRY
GRY
Instrument Panel Connector (Pin J4) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Fuel Level Sender (Engine Harness)
18 18
18
GRN
GRN
Instrument Panel Connector (Pin J12) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Transmission Temperature Switch (Engine Harness)
20 12 BLK Cab/Chassis Connector to Cab Ground
21C 16 RED Headlight Switch Relay (Pin 86) to Roadlights Connector (Option) (High Beam)
22 16 WHT Instrument Panel Fuse to Diode to Instrument Panel Connector (Pin J1)
23 16
16
GRN
ORG/GRN
Headlight Switch Relay (Pin 87) to Roadlights Connector (Option) (High Beam)
(Console/Stabilizer Harness)
Not Used (Engine Harness)
24 14 ORG/GRN Horn/Heater Fuse to Back-Up Alarm Relay (Pin 30)
24A 14
16
ORG/GRN
ORG/BLK
Back-Up Alarm Relay (Pin 30) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Horn Connector (+) (Engine Harness)
26 10 RED Main Fuse to Ignition Switch 3-Way Connector (Pin A)
26A 10 RED Main Fuse to Ignition Switch 5-Way Connector (Pin A)
27 10
10
RED
RED
Main Fuse to Splice 100 (Console/Stabilizer Harness)
Splice 27 to Starter (Pin 30) (Engine Harness)
27A 12 RED Optional Lights Fuse (Lights 1) to Splice 27 to Headlight Switch Relay (Pin 30)
27B 12 RED Optional Lights Fuse (Lights 1) Fuse to Splice 100
27C 12
12
RED
RED
Splice 100 to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Splice 27 (Engine Harness)
27D 12
12
RED
RED
Splice 100 to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Splice 27 (Engine Harness)
27F 12 RED Optional Road/Worklights Fuse (Lights 2) Fuse to Splice 100
28 16
16
PUR/WHT
PUR/WHT
Boom Switch Relay (Pin 87) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Splice 28 (Engine Harness)
28A 16 PUR/WHT Splice 28 to Stabil-TRAK™ Cylinder (SOL 12A)
28B 16 PUR/WHT Splice 28 to Stabil-TRAK™ Cylinder (SOL 12B)
29 12 RED Optional Lights Fuse (Lights 2) to Light Switch Relay (Pin 30)
31 16
16
ORG/RED
ORG/RED
Back-up Alarm Relay (Pin 87) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Back-up Alarm (+) (Engine Harness)
32 14 GRY/WHT Option Fuse to Wiper/Washer Connector (Option)
34 16
16
RED/BLK
RED/BLK
Ignition Switch 5-Way Connector (Pin C) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Fuel Shut-off Solenoid Connector (Pin A) (Engine Harness)
35 16
16
BRN/GRN
BRN/WHT
Jumper Wire 157 to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Boom Sensor Connector (Pin A) (Engine Harness)
38 16
16
ORG
ORG
Instrument Panel Connector (Pin J3) to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Alternator (“D+” Terminal) (Engine Harness)
39 16 RED/GRY Stabilizer Fuse to Boom Switch Relay (Pin 30)
40 16
16
BRN/BLK
BRN/BLK
Splice 40 to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Stabil-TRAK™ Cylinder (SOL 3) (Engine Harness)
40A 16 BRN/BLK Instrument Panel Connector (Pin J11) to Splice 40
40B 16 BRN/BLK Stabilizer Lock Relay (Pin 87) to Splice 40
41 16
16
DK BLU/WHT
BLU/WHT
Park Brake Switch Connector (Pin 1) to Splice 41 to Cab/Chassis Connector (Console/Stabilizer Harness)
Cab/Chassis Connector to Splice 41 (Engine Harness)
41A 16 BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB A)
41B 16 BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB B)
Wire No. Gauge Color From - Function - To
- 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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