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Skytrak 6042 Service Manual User Manual Page 540
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10.6
Model
6042
Legacy
Origin
7/02
Index
1
2
...
535
536
537
538
539
540
541
542
543
544
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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