Skytrak 6042 Service Manual User Manual Page 243
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8.11
Model 6042 Legacy Origin 7/02
Hydraulic System
Engine Information
Idle. . . . . . . . . . . . . . . . . . . . . .1,050 ±50 rpm
Full Speed . . . . . . . . . . . . . . .2,750 ±100 rpm
Hydraulic Oil Information
Oil Type - 10W, meet ISO Grade 46
Capacity - Reservoir . . . . 32.2 gal. (122 liter)
Capacity - System . . . . . . . . 57 gal. (216 liter)
Note: To adjust relief settings, pressure reducing
settings or standby pressure, turn the
adjustment screw clockwise to increase
pressure or counterclockwise to decrease
pressure.
The hydraulic oil temperature for the pump flow
test should be between 100-120° F (38-49° C)
(tank hot to the touch) during testing.
Equipment Needed to Perform Tests
from Hydraulic Diagnostic Test Kit
Circuit Gauge Fittings
4,000 psi gauge
(280 bar gauge)
Unit equipped with fittings from factory.
1,000 psi gauge
(70 bar gauge)
Unit equipped with fittings from factory.
300 psi gauge
(21 bar gauge)
Requires a #4 o-ring Boss Fitting with
Diagnostic Nipple.
TEST
LOCATION
Hydraulic Pump Flow Test
To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of 6,000
psi (413,4 bar) will be required (not included with Hydraulic Diagnostic Test Kit).
2,000 psi (137,8 bar) load @ Engine Speed of 2,500 ±25 rpm — Flow rate should be 34-40 GPM (2,1-2,5 liter/sec).
TEST
LOCATION
Valve
Port
ADJUST.
LOCATION
COMPONENT
DESCRIPTION
PRESSURE
READINGS
PRESSURE TEST PROCEDURES
VG Unloader Valve
Main System Relief
3,000 ±100 psi
(207 ±7 bar)
With engine at high idle, use the boom control lever to fully retract the boom.
Hold over relief and check pressure. If pressure is incorrect, adjust or replace
cartridge.
Auxiliary
Hydraulics
3,000 ±100 psi
(207 ±7 bar)
With engine at high idle, move auxiliary control lever left or right. Hold auxiliary
control lever over relief and check pressure. If pressure is incorrect, check
unloader pressure per . If is ok, check port reliefs on the aux section of
main control valve (consult factory).
VG
N/A
Attachment Tilt
Relief/
FORWARD
or REARWARD
3,000 ±100 psi
(207 ±7 bar)
CONSULT FACTORY
VG Unloader Valve
See
Standby Pressure
250-300 psi
(17-21 bar)
Note: DO NOT touch any functions while the pressure gauge is connected.
You will damage the pressure gauge.
With engine at idle and no functions operated, check standby pressure. If
pressure is incorrect, adjust or replace the differential pressure sense
cartridge on the unloader valve.
LSG
N/A
Unloader Valve
Load Sense
0-3,000 psi
(0-207 bar)
With engine at idle, load sense is 0 psi.
With engine at FULL throttle, use the boom control lever to fully retract the
boom. Hold over relief. Pressure should be 2,750-3,000 psi (190-207 bar).
PSG
Secondary
Function
Manifold
Steering Relief
2,500 ±100 psi
(172 ±7 bar)
With engine at FULL throttle, turn the steering wheel all the way in one
direction and hold while checking pressure. If pressure is incorrect, adjust or
replace the pressure-reducing cartridge.
PBG
N/A
Secondary
Function
Manifold
See
Park Brake
400 psi (28 bar)
minimum
500-600 psi
(34-41 bar)
maximum
With engine at idle, park brake released and no functions operated, pressure
should be 400 psi (28 bar) minimum.
With engine at idle, park brake released and steering held over relief,
pressure should be 500-600 psi (34-41 bar) maximum.
After releasing the steering wheel, the pressure MUST NOT
drop more than
50 psi in one minute. If pressure drop is incorrect, refer to brake system
information in the service manual.
If pressure is incorrect, adjust per test .
PPG
Secondary
Function
Manifold
See
500-600 psi
(34-41 bar)
With engine at idle, park brake released and steering held over relief while
checking pressure. If pressure is incorrect, adjust or replace the pressure
reducing valve in the secondary function manifold.
N/A
Brake Valve
(Manual Brake
Pressure)
See
400 psi
(28 bar)
minimum
With engine OFF, pump brake pedal twice. DO NOT overstroke the brake
pedal. If pressure is incorrect, check for external leaks. If no leaks are found,
refer to brake system information in the service manual.
N/A
Brake Valve
(Service Brake
Pressure)
See
550 psi
(38 bar)
minimum
With engine at idle, depress and hold brake pedal. DO NOT
turn steering
wheel. DO NOT overstroke the brake pedal. Check pressure. If pressure is
incorrect, refer to brake system information in the service manual.
G1
Stabilizer
Cylinder
See
75-150 psi
(5,2-10,3 bar)
With the engine at idle, check the pressure on the cylinder.
2 54
6 7 83
9
CAUTION:
GAUGE DAMAGE may occur. Malfunctioning hydraulic system circuits
may have excessive pressure and can cause hydraulic pressure spikes. Test circuit with
the highest reading pressure gauge first. If this gauge cannot record an accurate
pressure reading, use the next lower pressure gauge.
1
2
2
2
2
2 2
2
3
3
4
5 5
6
7
7
7
8
8
9
9
- 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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