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Skytrak 6042 - Service Manual

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An Oshkosh Corporation Company
Service Manual
Models
6036, 6042, 8042,
10042 & 10054
SN 0160069719 to Present
including 0160065791, 0160065792, 0160065796,
0160065798, 0160065824, 0160065825,
0160065826, 0160069336, 0160069359,
0160069383, 0160069411, 0160069441,
0160069566, 0160069567 & 0160069568
31211015
Revised
July 31, 2017

Table of Contents

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Summary

Section 1 Safety Practices

1.5.1 Safety Alert System and Signal Words

Explains the use of DANGER, WARNING, and CAUTION signal words.

1.6.1 Personal Hazards

Emphasizes the use of personal safety gear and safe lifting practices.

1.6.2 Equipment Hazards

Covers safety precautions for lifting equipment and using hand tools.

1.6.4 Operational Hazards

Details hazards related to engine, fluids, surfaces, temperature, and tires.

Section 2 General Information and Specifications

2.3 Fluid Specifications

Lists required fluids and their classifications for various compartments and ambient temperatures.

2.4 Fluid and Lubricant Capacities

Details capacities for engine oil, fuel, coolant, hydraulic, transmission, and axle systems.

2.5 Service and Maintenance Schedules

Outlines maintenance tasks required at specific hour intervals.

2.6 Lubrication Schedules

Provides lubrication intervals for 50, 250, and 1000 hours.

2.8.1 SAE Fastener Torque Chart

Lists torque values for Grade 5 Bolts & Grade 2 Nuts and Grade 8 Bolts & Grade 8 Nuts.

2.8.2 Metric Fastener Torque Chart

Provides torque values for Class 8.8 and Class 10.9 metric fasteners.

2.9 Hydraulic Connection Assembly and Torque Specification

Defines and provides assembly instructions and torque specs for various hydraulic fittings.

2.9.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections

Provides instructions for NPTF pipe thread assembly, including thread sealant and tightening.

2.9.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections

Details assembly procedures for BSPT pipe thread connections, including sealant and turns.

2.9.4 Assembly Instructions for 37° (JIC) Flare Fittings

Explains how to inspect, align, and torque 37° flare fittings for steel and aluminum/brass.

2.9.5 Assembly Instructions for 45° SAE Flare Fittings

Provides instructions for assembling 45° SAE flare fittings for steel and aluminum/brass materials.

2.9.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings

Details the procedure for ORFS fittings, including o-ring installation and torque.

2.9.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)

Outlines assembly steps for DIN 24° cone flareless bite type fittings.

2.9.8 Assembly Instructions for Bulkhead (BH) Fittings

Provides instructions for assembling bulkhead fittings, including thread preparation and torque.

2.9.9 Assembly Instructions for O-Ring Boss (ORB) Fittings

Details assembly procedures for O-ring boss fittings, including torque specifications.

2.9.10 Assembly Instructions for Adjustable Port End Metric Fittings

Provides instructions for assembling adjustable port end metric fittings.

2.9.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends

Outlines assembly procedures for Metric ISO 6149 port assembly stud ends.

2.9.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings

Details assembly steps for adjustable port end BSPP fittings.

2.9.13 Assembly Instructions for Flange Connections (FL61 and FL62)

Provides instructions for assembling FL61 and FL62 flange connections.

Section 3 Boom

3.2 Safety Information

General safety precautions for boom service and maintenance.

3.4 Boom Assembly Maintenance

Provides sequential instructions for removing and installing boom sections.

3.4.1 Boom Removal

Details steps for removing the entire boom assembly from the machine.

3.4.2 Third Boom Section Removal

Step-by-step guide for removing the third boom section.

3.4.3 Second Boom Section Removal

Instructions for removing the second boom section from the first.

3.4.4 First Boom Section Removal

Detailed steps for removing the first boom section from the machine.

3.4.5 First Boom Section Installation

Procedure for installing the first boom section, including cylinder and hose connections.

3.4.6 Second Boom Section Installation

Steps for installing the second boom section into the first boom section.

3.4.7 Third Boom Section Installation

Instructions for installing the third boom section into the second boom section.

3.4.8 Boom Installation

Procedure for installing the complete boom assembly onto the machine frame.

3.6 Boom Assembly Maintenance

Provides sequential instructions for removing and installing boom sections for four-section booms.

3.6.1 Fourth Boom Section Removal

Step-by-step guide for removing the fourth boom section.

3.6.2 Third Boom Section Removal

Instructions for removing the third boom section from the second.

3.6.3 Second Boom Section Removal

Steps for removing the second boom section from the first.

3.6.4 First Boom Section Removal

Detailed steps for removing the first boom section.

3.6.5 First Boom Section Installation

Procedure for installing the first boom section.

3.6.6 Second Boom Section Installation

Instructions for installing the second boom section into the first.

3.6.7 Third Boom Section Installation

Steps for installing the third boom section into the second boom section.

3.6.8 Fourth Boom Section Installation

Procedure for installing the fourth boom section into the third.

3.7 Boom Extend and Retract Chains

Details inspection, lubrication, and adjustment procedures for boom chains.

3.7.1 Boom Chain Inspection

Provides guidelines for inspecting boom chains for wear, cracks, and contamination.

3.7.2 Inspection Guidelines

Explains how to check for edge wear and elongation on boom chains.

3.7.5 Boom Chain Tension Check

Details how to check the sag and tension of boom chains.

3.7.6 Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042)

Explains how to adjust the tension of boom extend chains for specific models.

3.7.7 Boom Chain Tension Adjustment (10054)

Provides instructions for adjusting boom chain tension for Model 10054.

3.7.8 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042)

Step-by-step guide for removing and replacing extend chains on specific models.

3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042)

Instructions for removing and replacing retract chains on specific models.

3.7.10 Extend Chains Removal and Replacement (10054)

Steps for removing and replacing extend chains on Model 10054.

3.7.11 Retract Chain Removal and Replacement (10054)

Procedure for removing and replacing retract chains on Model 10054.

3.8.1 Wear Pad Inspection

Instructions for inspecting wear pads for visibility and proper clearance.

3.9 Quick Coupler

Provides procedures for removing and installing the quick coupler assembly.

3.9.1 Quick Coupler Removal

Steps to remove the quick coupler, including detaching attachments and pins.

3.9.2 Quick Coupler Installation

Instructions for installing the quick coupler onto the boom head.

3.11 Troubleshooting

Provides a guide for common boom operation problems and their solutions.

Section 4 Cab and Covers

4.2.1 Cab Safety

Highlights safety concerns related to ROPS/FOPS and cab modifications.

4.3.1 Steering Wheel

Provides instructions for removing and installing the steering wheel.

4.3.2 Steering Column and Steering Valve

Covers removal, installation, and testing procedures for the steering column and valve.

4.3.3 Service Brake Pedal

Details removal and installation procedures for the service brake pedal.

4.3.4 Throttle Pedal

Explains the removal and installation process for the throttle pedal.

4.3.5 Joystick Assembly

Provides instructions for removing and installing the hydraulic joystick assembly.

4.3.6 Auxiliary;Frame Level Lever Assemblies

Covers removal, installation, and testing of frame level and auxiliary hydraulic joysticks.

4.4 CAB REMOVAL

Step-by-step instructions for safely removing the cab from the machine.

4.5 CAB INSTALLATION

Procedure for installing the cab onto the machine frame, including alignment and connections.

Section 5 Axles, Drive Shafts, Wheels and Tires

5.3.4 Axle Maintenance

Covers cleaning, drying, periodic operation, and submersion procedures for axles.

5.3.5 Axle Replacement (6036 & 6042)

Provides step-by-step instructions for removing and installing axles on 6036 & 6042 models.

5.3.6 Axle Replacement (8042, 10042 & 10054)

Details axle removal and installation procedures for 8042, 10042, & 10054 models.

5.4 Axle Assembly and Drive Shaft Troubleshooting

Lists common problems with axles and drive shafts and their solutions.

5.5.1 Drive Shaft Inspection and Maintenance

Instructions for inspecting drive shafts for wear, damage, and proper alignment.

5.5.2 Drive Shaft Removal

Step-by-step procedure for removing the drive shaft assemblies.

5.5.3 Drive Shaft Installation

Provides instructions for installing drive shaft assemblies, including alignment and torque.

5.6.1 Removing Wheel and Tire Assembly from Machine

Details steps for removing the wheel and tire assembly from the machine.

5.6.2 Installing Wheel and Tire Assembly onto Machine

Provides instructions for installing the wheel and tire assembly onto the machine.

5.7.1 Brake Disc Inspection

Explains how to check brake discs for wear and condition.

5.8 Towing a Disabled Machine

Provides instructions and precautions for towing a disabled machine.

Section 6 Transmission

6.4 Transmission Replacement

Details procedures for removing, inspecting, installing, and servicing the transmission.

6.4.1 Transmission Removal

Step-by-step guide for removing the transmission from the machine.

6.4.2 Transmission Inspection and Internal Repair

Covers inspection and internal repair procedures for the transmission.

6.4.3 Transmission Installation

Provides instructions for installing the transmission, including mounting and torque.

6.5 Transmission Troubleshooting

Covers common problems and remedies for transmission operation.

Section 7 Engine

7.6 Fuel System

Covers diesel fuel specifications and fuel/hydraulic oil tank procedures.

7.6.4 Diesel Exhaust Fluid (DEF) Tank

Provides removal, inspection, and installation procedures for the DEF tank.

7.6.5 Diesel Exhaust Fluid (DEF) Header

Details removal, cleaning, and installation procedures for the DEF header.

7.6.6 Diesel Exhaust Fluid (DEF) Pump Filter

Covers removal and cleaning procedures for the DEF pump filter.

7.6.7 Cummins Diesel Exhaust Fluid (DEF) System Cleaning

Provides instructions for cleaning the DEF system, including tank and header.

7.6.8 Cummins Diesel Exhaust Fluid (DEF) Tank

Details DEF tank removal, inspection, and installation for specific serial number ranges.

7.6.9 Cummins Diesel Exhaust Fluid (DEF) Header

Covers DEF header filter replacement and installation procedures.

7.6.10 Diesel Exhaust Fluid (DEF) Pump Filter

Refers to Section 7.6.6 for DEF pump filter information.

7.6.11 Cummins Diesel Exhaust Fluid (DEF) System Cleaning

Provides procedures for cleaning the DEF system, including tank and header.

7.6.12 Diesel Exhaust Fluid (DEF) System - Engine Coolant Strainer Cleaning

Details the procedure for cleaning the engine coolant strainer.

Section 8 Hydraulic Section

Section 9 Electrical System

Section 10 Stabil-TRAK System and Boom Interlock System

Skytrak 6042 Specifications

General IconGeneral
BrandSkytrak
Model6042
CategoryLifting Systems
LanguageEnglish

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