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Skytrak
Lifting Systems
6042
Skytrak 6042 Service Manual
418 pages
Manual
Specs
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An Oshkosh Corporation Company
Ser
vic
e Man
ual
Models
6036, 6042, 8042,
10042 & 10054
SN 0160069719 to P
resent
including 016006579
1, 0160065792, 01600657
96,
0160065798, 0
160065824, 0160065
825,
0160065826, 0
160069336, 0160069
359,
0160069383, 0
160069411, 0160069
441,
0160069566, 0160
069567 & 0160069568
31211015
Revised
July 31, 2017
2
Table of Contents
Machine Configuration
4
Contents
5
Safety Practices
9
Do Not Operate Tags
10
Safety Alert System and Signal Words
10
Introduction
10
Personal Hazards
11
Equipment Hazards
11
General Hazards
11
Safety Instructions
11
Operational Hazards
12
Safety Decals
12
General Information and Specifications
13
Replacement Parts and Warranty Information
15
Specifications
16
Travel Speeds
16
Hydraulic Cylinder Performance
16
Electrical System Data
17
Engine Performance Specifications
17
Tires Data
18
Fluid Specifications
19
Fluid and Lubricant Capacities
21
Service and Maintenance Schedules
22
Lubrication Schedules
26
Thread Locking Compound
32
Torque Charts
33
SAE Fastener Torque Chart
33
Metric Fastener Torque Chart
39
Hydraulic Connection Assembly and Torque Specification
43
Tapered Thread Types
43
Straight Thread Types, Tube and Hose Connections
43
Straight Thread Types, Port Connections
44
Flange Connection Types
44
Tightening Methods
44
General Tube Type Fitting Assembly Instructions
44
American Standard Pipe Thread Tapered Connections
45
NPTF Pipe Thread
46
British Standard Pipe Thread Tapered Connections
47
BSPT Pipe Thread
47
Assembly Instructions for 37 Degrees (JIC) Flare Fittins
48
37 Degrees Flare (JIC) Thread - Steel
48
37 Degrees Flare (JIC) Thread - Aluminum Brass
49
Assembly Instructions for 45 Degrees SAE Flare Fittings
50
45 Degrees Flare (SAE)
51
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
52
O-Ring Face Seal (ORFS)
53
Assembly Instructions for DIN 24 Degrees Flare Bite Type Fittings
54
DIN 24 Degrees Cone (MBTL & MBTS)
55
Assembly Instructions for Bulkhead (BH) Fittings
56
Bulkhead Fittings (BH) - INCH
57
Bulkhead Fittings (BH) - Metric
58
Assembly Instructions for O-Ring Boss (ORB) Fittings
60
O-Ring Boss (ORB) Table
61
Assembly Instructions for Adjustable Port End Metric Fittings
68
Metric Flat Face Port (MFF) L Series Table
69
Metric Flat Face Port (MFF) S Series Table
72
Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends
76
Metric Pipe Parallel O-Ring Boss (MPP)
77
Assembly Instructions for Adjustable Port End (BSPP) Fittings
78
British Standard Parallel Pipe Port (BSPP) - L Series Table
79
British Standard Parallel Pipe Port (BSPP) S Series Table
82
Assembly Instructions for Flange Connections (FL61 and FL62)
86
Flange Code (FL61 & FL62) - Inch Fasteners
87
Flange Code (FL61 & FL62) - Metric Fasteners
88
Double Wrench Method
89
FFWR and TFFT Methods
90
Adjustable Stud End Assembly
90
O-Ring Installation (Replacement)
90
Boom
91
Boom System Component Terminology
93
Boom - Safety Information
94
Boom Assembly Maintenance
94
Boom System Operation
94
Boom Removal
94
Third Boom Section Removal
95
Second Boom Section Removal
97
First Boom Section Removal
98
First Boom Section Installation
99
Second Boom Section Installation
101
Third Boom Section Installation
102
Boom Installation
104
Boom System - Four Section (10054)
105
Fourth Boom Section Removal
105
Third Boom Installation
114
Fourth Boom Section Installation
115
Boom Extend and Retract Chains
118
Boom Chain Inspection
118
Chain Edge Wear
119
Chain Elongation
119
Distorted or Battered Link Plates (Chain)
120
Turning or Protruding Pins (Chain)
120
Cracked Plates (Chain)
120
Ultimate Strength Failure (Chain)
120
Expose Chains for Inspection
121
Chain Lubrication
121
Extend Chains
121
Retract Chains
121
Boom Chain Tension Check
122
Boom Chain Tension Adjustment
122
Component/Assembly Verification
123
Outer Boom Chains Tension Adjustment
124
Inner Boom Chain Tension Adjustment
126
Extend Chains Removal and Replacement
128
Retract Chain Removal and Replacement
129
Extend Chains Removal and Replacement (10054)
131
Fourth Boom Section Extend Chains Removal and Replacement
132
Retract Chain Removal and Replacement (10054)
134
Fourth Boom Section Retract Chain Removal and Replacement
135
Boom Wear Pads Inspection
138
Wear Pad Installation and Lubrication
138
Quick Coupler Removal
139
Forks Inspection
139
Quick Coupler Installation
139
Boom Troubleshooting
140
Cab and Covers
143
Operator Cab and Covers Component Terminology
144
Operator Cab
145
Cab Safety
145
Steering Wheel
145
Steering Column and Steering Valve
145
Steering Valve Installation
146
Service Brake Pedal
147
Brake Valve Removal and Installation
147
Service Brake Pedal Removal
147
Service Brake Pedal Installation
147
Throttle Pedal Removal
148
Throttle Pedal Installation
148
Joystick Assembly
148
Auxiliary/Frame Level Lever Assemblies
149
Joystick Assembly Installation
149
Lever Assembly Removal
149
Windshield Wiper Assembly
150
Heater System
150
Lever Assembly Installation
150
Cab Heater Assembly Removal
150
Cab Heater Assembly Installation
151
Under Seat Heater Assembly Removal
152
Under Seat Heater Assembly Installation
152
Heater and A/C System Removal and Installation
153
Cab Removal
155
Cab Installation
156
Axles, Drive Shafts, Wheels and Tires
157
Axle, Drive Shaft and Wheel Component Terminology
158
Axle Assemblies
161
Axle Serial Number Plate
161
Axle Internal Service
161
General Information
161
Axle Maintenance
162
Axle Replacement
162
Axle Removal
162
Axle Installation
163
Outrigger Removal
164
Outrigger Installation
165
Axle Assembly and Drive Shaft Troubleshooting
168
Drive Shaft Inspection and Maintenance
172
Drive Shaft Removal
172
Drive Shaft Installation
172
Wheels and Tires
173
Removing Wheel and Tire Assembly from Machine
173
Brakes
174
Installing Wheel and Tire Assembly Onto Machine
174
Brake Disc Inspection
174
Towing a Disabled Machine
175
Transmission Assembly Component Terminology
177
Transmission Assembly Component Terminology
178
Transmission Serial Number
179
Transmission Replacement
179
Transmission Removal
179
Transmission Inspection and Internal Repair
181
Transmission Installation
181
After Transmission Service or Replacement
182
Transmission Troubleshooting
183
Engine
187
Engine Serial Number
189
Engine Specifications and Maintenance Information
189
Introduction
189
Engine Component Terminology
190
Engine Cooling System
191
Coolant System Pressure Cap
191
Thermostat Replacement
191
Radiator/Oil Cooler and Replacement
192
Radiator/Oil Cooler Removal
192
Radiator/Oil Cooler Installation
192
Engine Electrical System
192
Fuel System
193
Fuel/Hydraulic Oil Tank Removal
193
Fuel/Hydraulic Oil Tank Disassembly
193
After Fuel System Service
194
Fuel/Hydraulic Oil Cleaning and Drying
194
Fuel/Hydraulic Oil Assembly
194
Fuel/Hydraulic Oil Tank Installation
194
Diesel Exhaust Fluid (DEF) Tank
195
DEF Tank Removal
195
DEF Tank Inspection
195
DEF Tank Installation
195
Diesel Exhaust Fluid (DEF) Header
196
DEF Header Removal
196
DEF Header Cleaning
196
Diesel Exhaust Fluid (DEF) Pump Filter Removal
197
DEF Header Filter Replacement
197
DEF Pump Cleaning
197
Diesel Exhaust Fluid (DEF) System Cleaning
198
DEF Pump Filter Installation
198
DEF Tank Cleaning
198
Cummins Diesel Exhaust Fluid (DEF) Tank
199
Cummins Diesel Exhaust Fluid (DEF) Header
200
Cummins Diesel Exhaust Fluid (DEF) System Cleaning
201
DEF Header Installation
201
Diesel Exhaust Fluid (DEF) System - Engine Coolant Strainer Cleaning
202
Engine Exhaust System
203
Exhaust Removal
203
Exhaust System Installation
203
Air Cleaner Assembly Removal
207
Air Cleaner Assembly Installation
207
Engine Replacement
208
Engine Removal
208
Engine Installation
209
Isolation Coupler Removal
210
Isolation Coupler Installation
210
Hydraulic Section
211
Hydraulic Component Terminology
212
Hydraulic Section - Safety Information
214
Hydraulic Circuits
215
Hydraulic Pressure Diagnosis
215
Hydraulic Pressure Checks and Adjustments
215
Hydraulic Pressure Specifications
216
Hydraulic Schematics
234
Hydraulic Oil Reservoir Draining
248
Hydraulic Oil Reservoir Filling
248
Hydraulic Filter Replacement
248
Hydraulic System Pump Replacement
249
Valves and Manifolds
250
Main Control Valve Removal
250
Main Control Valve Disassembly
250
Main Control Valve Parts Cleaning
251
Main Control Valve Parts Inspection
251
Main Control Valve Assembly
251
Main Control Valve Installation
252
Main Control Valve Test
252
Service Brake Valve Removal
253
Service Brake Valve Installation
253
Brake Bleeding
254
Steering Orbitrol Valve
255
Steer Select Valve
255
Brake System Check
255
Steer Select Valve Removal
256
Steer Select Valve Disassembly, Cleaning, Inspection, Assembly
256
Steer Select Valve Installation
256
Secondary Function Manifold
257
Outrigger Valve Removal
258
Outrigger Valve Disassembly, Cleaning, Inspection and Assembly
258
Extend Lockout Valve Removal
259
Outrigger Valve Installation
259
Extend Lockout Valve Disassembly, Cleaning, Inspection, Assembly
260
Extend Lockout Valve Installation
260
Extend Lockout Valve Test
260
Hydraulic Cylinders
261
Cylinder Disassembly
261
Cylinder Cleaning Instructions
262
Cylinder Inspection
262
Cylinder Assembly Instructions
262
Cylinder Installation
262
Cylinder Pressure Checking
263
Steering Cylinders
263
Cylinder Torque Specifications
264
Electrical System
267
Electrical Component Terminology
269
Electrical System - Safety Information
270
Engine Compartment Fuse and Relays
270
Specifications
270
Cab Harness Fuses and Relays
271
Electrical System Schematics
273
Cab Schematic
273
Chassis - Engine Schematics
274
Cab O/R Option Schematic
277
HVAC Option Schematic
279
Road Light Option Schematic
280
Worklights/Beacon Option Schematic
281
Telematics Option Schematics
282
Dielectric Grease Application
283
AMP Seal
283
AMP Mate-N-Lok
284
DIN Connectors
284
Exclusions
284
Engine Control Unit Connectors
285
Sealed Enclosures
285
MIL-C-5015 Spec Connector’s
285
Engine Start Circuit
286
Testing the Starter on the Engine
286
Starter Circuit Checks
286
Starter Removal
286
Battery Inspection
287
Starter Installation
287
Battery Removal and Installation
287
Battery Disconnect/Connect
287
Charging Circuit
288
Alternator Removal
288
Alternator Installation
288
Window Wiper/Washer Windshield Wiper Motor
289
Skylight Wiper Motor Removal
290
Windshield Washer Reservoir
291
Skylight Wiper Motor Inspection, Installation and Testing
291
Cab Heater and Fan
292
Cab Heater Controls Removal
292
Solenoids, Sensors and Senders
293
Cab Heater Controls Installation and Testing
293
Coolant Level Sensor Removal
293
Coolant Level Sensor Installation
293
Transmission Temperature Sender Removal
294
Transmission Solenoid Valves
294
Transmission Temperature Sender Inspection and Replacement
294
Transmission Temperature Sender Installation and Testing
294
Service Brake Switch Removal and Installation
295
Boom Angle Sensor Removal
296
Service Brake Switch Adjustment
296
Boom Extend Interlock Sensor Removal
297
Boom Angle Sensor Installation
297
Outrigger Pressure Switches Removal and Installation
298
Boom Extend Interlock Sensor Installation
298
Display Monitor Removal and Installation
299
Dash Switches
299
Ignition Switch Removal
299
Ignition Switch Inspection and Replacement
300
Ignition Switch Installation
300
Dash Switches Removal, Inspection and Installation
301
Machine Data Access
302
Hand Held Analyzer
302
Mobile Analyzer
303
Analyzer Software Version P1.2
304
Analyzer Software Accessibility
305
Access Level
305
Diagnostics
305
Machine Set-Up
306
Personalities
307
Calibrations
308
Telematics Gateway
309
Telematics-Ready (TCU) Plug
310
Telematics Component Locations
310
Telematics Gateway Harness Breakdown
311
Connector Tables
312
3D Harness View
314
Electrical System Troubleshooting
315
Electrical System Fault Detection
315
Offboard Diagnostics
315
Machine Fault Codes
316
Engine Fault Codes
320
Stabil-TRAK System and Boom Interlock System
369
Stabil-TRAK System Component Terminology
371
Boom Extend Interlock System Component Terminology (10054 Only)
372
Stabil-TRAK Description
373
Stabil-TRAK Operation
374
Free Pivot Mode (Stabili-TRAK)
374
Slow Pivot Mode (Stabili-TRAK)
374
Locked Mode (Stabili-TRAK)
374
Stabil-TRAK Solenoid Valves
375
Logic Wiring Harness
375
Relay Testing
376
Outrigger Pressure Switches Testing
377
Outrigger Pressure Switches Removal
377
Outrigger Pressure Switches Installation
377
Boom Extend Interlock System Description
378
Boom Extend Interlock System Operation (10054 Only)
379
Extend Interlock Mode
379
Outrigger Interlock Mode
379
Stabil-TRAK System Test
380
Stabil-TRAK System Test Procedures
381
Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (6042/8042/10042)
383
Electrical Circuit - Free Pivot Mode
384
Electrical Circuit - Locked Mode
386
Stabil-TRAK™ and Boom Interlock Electrical Circuit Operation and Troubleshooting (10054)
387
Stabil-TRAK Electrical Circuit - Boom Extend Mode
389
Boom/Outrigger Interlock System Test
392
Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting
394
Stabil-TRAK Cylinder Oil Flow
396
Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil out
398
Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil out
399
Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil out
400
Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil out
401
Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil out
402
Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil out
403
Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil out
404
Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil out
405
Hydraulic Circuit Operation - Locked Mode
406
Hydraulic Troubleshooting - Locked Mode, will Not Frame Level Right
407
Hydraulic Circuit Operation - Locked Mode, Frame Level Left
408
Hydraulic Troubleshooting - Locked Mode, will Not Frame Level Left
409
Boom Extend System Hydraulic Circuit Operation and Troubleshooting
410
Hydraulic Circuit Operation - Extend Interlock Mode
412
Hydraulic Troubleshooting - Extend Interlock Mode
412
Hydraulic Circuit Operation - Outrigger Interlock Mode
414
Hydraulic Troubleshooting - Outrigger Interlock Mod
414
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Skytrak 6042 Specifications
General
Brand
Skytrak
Model
6042
Category
Lifting Systems
Language
English
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