Skytrak 6042 Service Manual User Manual Page 536
- Page / 544
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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10.2
Model 6042 Legacy Origin 7/02
Index
Transmission Gear Selection
Troubleshooting .....................9.60
Warning Devices.......................9.89
Window Wiper/Washer .............9.95
Wiring Harnesses .......................9.7
Electrical System Troubleshooting
Charging Circuit........................9.30
Crab Steer Circuit .....................9.36
Electrical Schematic Legend-
Console/Stabilizer & Engine
Harnesses..............................9.16
Electrical Schematic Legend-
Roadlights Harness................9.24
Electrical Schematic Legend-
Wiper/Washer & Heater
Harnesses..............................9.22
Electrical Schematic Legend-
Worklights Harness................9.26
Electrical Schematic-
Console/Stabilizer & Engine
Harnesses.................... 9.20–9.21
Electrical Schematic-
Roadlights Harness................9.25
Electrical Schematic-
Wiper/Washer & Heater
Harnesses..............................9.23
Electrical Schematic-
Worklights Harness................9.27
Electrical Symbols
Directory ................................9.15
Engine Start Circuit...................9.28
Four Wheel Steer Circuit ..........9.34
Front Steer Circuit.....................9.32
Front Windshield
Wiper Circuit ..........................9.38
Heater Circuit............................9.44
Introduction...............................9.11
Probing Electrical
Connectors ............................9.12
Roadlight Brake Lights Circuit ..9.54
Roadlight Hazard Lights Circuit 9.48
Roadlight Position Lights & Low
Beam Lights Circuit................9.52
Roadlight Turn Signals Circuit ..9.50
Roadlight Worklights Circuit......9.56
Roadlights High Beam Circuit...9.46
Roof Windshield Wiper
Circuit.....................................9.40
Troubleshooting with a
Digital Multimeter (DMM) .......9.11
Windshield Washer Circuit........9.42
Worklight (Without Roadlights)
Circuit.....................................9.58
Emergency Exit Rear Window ........1.6
Enclosed Cab (Optional)
Components ...............................4.20
Enclosed Cab Components
Door and Latches......................4.24
Heater/Defroster System...........4.20
Roof Wiper Assembly................4.20
Windows....................................4.25
Windshield Wiper Assembly......4.20
Windshield/Skylight
Washer Assembly ..................4.20
Engine Cooling System
Radiator Pressure Cap................7.7
Radiator/Oil Cooler and
Coolant Heater
Replacement ..........................7.10
Thermostat Replacement............7.7
Engine Exhaust System
Installation.................................7.24
Removal....................................7.23
Engine Replacement
Disassembly, Inspection
and Service ............................7.30
Installation.................................7.30
Removal....................................7.25
Engine Start Circuit
Starter .......................................9.80
Starting Circuit...........................9.80
Engine: Cummins 4BT3.9
Air Cleaner Assembly................7.24
Cooling System...........................7.7
Electrical System.......................7.14
Exhaust System ........................7.23
Fuel System..............................7.15
Introduction .................................7.2
Replacement .............................7.25
Safety Information.......................7.4
Serial Number .............................7.6
Specifications and Maintenance
Information ...............................7.6
Standard Practices......................7.6
Storage......................................7.37
Troubleshooting ........................7.38
F
Fluids, Lubricants and Capacities
Axles (Differential Housings).....2.23
Drive Shaft Splines....................2.26
Electrical....................................2.26
Engine.......................................2.25
General Anti-Corrosion .............2.26
Hydraulic System ......................2.25
Lubrication Points (Grease
Fittings) ..................................2.24
Paint..........................................2.27
Thread Locking Compound.......2.27
Transmission.............................2.24
Wheel Ends...............................2.24
Four-Wheel Steer Indexing
Procedure....................................8.58
Fuel System
After Fuel System Service........ 7.22
Diesel Fuel ............................... 7.16
Fuel Filter ................................. 7.20
Fuel Injectors............................ 7.20
Fuel Level Sender and
Gauge.................................... 7.20
Fuel Lift Pump Inspection......... 7.20
Fuel Lift Pump Testing ............. 7.20
Fuel/Hydraulic Oil Tank............ 7.16
Venting Air from the Fuel
System................................... 7.20
Fuses and Relays
Circuit Protection - Fuses ........... 9.9
Fuse and Relay
Replacement ......................... 9.10
G
General Information and Specifications
After Service Startup and
Checks................................... 2.29
Bearings ................................... 2.28
Cleaning ................................... 2.27
Component Terminology ............ 2.3
Fluids, Lubricants and
Capacities.............................. 2.23
Hoses and Tubes ..................... 2.28
Introduction................................. 2.4
Metric Conversion Factors........ 2.12
Pressure Testing and
Adjustment............................. 2.29
Replacement ............................ 2.28
Specifications ...........................2.14
Torques ...................................... 2.6
H
Hazard/Emergency Information
Decals........................................... 1.7
Hoses and Tubes
Inspection ................................. 2.28
Installation ................................ 2.28
Hoses, Tube Lines, Fittings, Etc.
Replacement .............................. 8.6
Replacement Considerations ..... 8.6
Hydraulic Circuits and Troubleshooting
Attachment Tilt (Down) and
Slave Cylinder Circuit ............ 8.28
Attachment Tilt (Up) and
Slave Cylinder Circuit ............ 8.30
Attachment Tilt and Slave
Circuit Description ................. 8.54
Auxiliary Hydraulics Circuit
(Female) ................................ 8.36
Auxiliary Hydraulics Circuit
(Male) .................................... 8.34
- 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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