Skytrak 8042 - Page 67

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General Information and Specifications

2-55

6036, 6042, 8042, 10042, 10054 31211015

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Main Page

Machine Configuration4
Contents5
Safety Practices9
Do Not Operate Tags10
Safety Alert System and Signal Words10
Introduction10
Personal Hazards11
Equipment Hazards11
General Hazards11
Safety Instructions11
Operational Hazards12
Safety Decals12
General Information and Specifications13
Replacement Parts and Warranty Information15
Specifications16
Travel Speeds16
Hydraulic Cylinder Performance16
Electrical System Data17
Engine Performance Specifications17
Tires Data18
Fluid Specifications19
Fluid and Lubricant Capacities21
Service and Maintenance Schedules22
Lubrication Schedules26
Thread Locking Compound32
Torque Charts33
SAE Fastener Torque Chart33
Metric Fastener Torque Chart39
Hydraulic Connection Assembly and Torque Specification43
Tapered Thread Types43
Straight Thread Types, Tube and Hose Connections43
Straight Thread Types, Port Connections44
Flange Connection Types44
Tightening Methods44
General Tube Type Fitting Assembly Instructions44
American Standard Pipe Thread Tapered Connections45
NPTF Pipe Thread46
British Standard Pipe Thread Tapered Connections47
BSPT Pipe Thread47
Assembly Instructions for 37 Degrees (JIC) Flare Fittins48
37 Degrees Flare (JIC) Thread - Steel48
37 Degrees Flare (JIC) Thread - Aluminum Brass49
Assembly Instructions for 45 Degrees SAE Flare Fittings50
45 Degrees Flare (SAE)51
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings52
O-Ring Face Seal (ORFS)53
Assembly Instructions for DIN 24 Degrees Flare Bite Type Fittings54
DIN 24 Degrees Cone (MBTL & MBTS)55
Assembly Instructions for Bulkhead (BH) Fittings56
Bulkhead Fittings (BH) - INCH57
Bulkhead Fittings (BH) - Metric58
Assembly Instructions for O-Ring Boss (ORB) Fittings60
O-Ring Boss (ORB) Table61
Assembly Instructions for Adjustable Port End Metric Fittings68
Metric Flat Face Port (MFF) L Series Table69
Metric Flat Face Port (MFF) S Series Table72
Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends76
Metric Pipe Parallel O-Ring Boss (MPP)77
Assembly Instructions for Adjustable Port End (BSPP) Fittings78
British Standard Parallel Pipe Port (BSPP) - L Series Table79
British Standard Parallel Pipe Port (BSPP) S Series Table82
Assembly Instructions for Flange Connections (FL61 and FL62)86
Flange Code (FL61 & FL62) - Inch Fasteners87
Flange Code (FL61 & FL62) - Metric Fasteners88
Double Wrench Method89
FFWR and TFFT Methods90
Adjustable Stud End Assembly90
O-Ring Installation (Replacement)90
Boom91
Boom System Component Terminology93
Boom - Safety Information94
Boom Assembly Maintenance94
Boom System Operation94
Boom Removal94
Third Boom Section Removal95
Second Boom Section Removal97
First Boom Section Removal98
First Boom Section Installation99
Second Boom Section Installation101
Third Boom Section Installation102
Boom Installation104
Boom System - Four Section (10054)105
Fourth Boom Section Removal105
Third Boom Installation114
Fourth Boom Section Installation115
Boom Extend and Retract Chains118
Boom Chain Inspection118
Chain Edge Wear119
Chain Elongation119
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 Inspection121
Chain Lubrication121
Extend Chains121
Retract Chains121
Boom Chain Tension Check122
Boom Chain Tension Adjustment122
Component/Assembly Verification123
Outer Boom Chains Tension Adjustment124
Inner Boom Chain Tension Adjustment126
Extend Chains Removal and Replacement128
Retract Chain Removal and Replacement129
Extend Chains Removal and Replacement (10054)131
Fourth Boom Section Extend Chains Removal and Replacement132
Retract Chain Removal and Replacement (10054)134
Fourth Boom Section Retract Chain Removal and Replacement135
Boom Wear Pads Inspection138
Wear Pad Installation and Lubrication138
Quick Coupler Removal139
Forks Inspection139
Quick Coupler Installation139
Boom Troubleshooting140
Cab and Covers143
Operator Cab and Covers Component Terminology144
Operator Cab145
Cab Safety145
Steering Wheel145
Steering Column and Steering Valve145
Steering Valve Installation146
Service Brake Pedal147
Brake Valve Removal and Installation147
Service Brake Pedal Removal147
Service Brake Pedal Installation147
Throttle Pedal Removal148
Throttle Pedal Installation148
Joystick Assembly148
Auxiliary/Frame Level Lever Assemblies149
Joystick Assembly Installation149
Lever Assembly Removal149
Windshield Wiper Assembly150
Heater System150
Lever Assembly Installation150
Cab Heater Assembly Removal150
Cab Heater Assembly Installation151
Under Seat Heater Assembly Removal152
Under Seat Heater Assembly Installation152
Heater and A/C System Removal and Installation153
Cab Removal155
Cab Installation156
Axles, Drive Shafts, Wheels and Tires157
Axle, Drive Shaft and Wheel Component Terminology158
Axle Assemblies161
Axle Serial Number Plate161
Axle Internal Service161
General Information161
Axle Maintenance162
Axle Replacement162
Axle Removal162
Axle Installation163
Outrigger Removal164
Outrigger Installation165
Axle Assembly and Drive Shaft Troubleshooting168
Drive Shaft Inspection and Maintenance172
Drive Shaft Removal172
Drive Shaft Installation172
Wheels and Tires173
Removing Wheel and Tire Assembly from Machine173
Brakes174
Installing Wheel and Tire Assembly Onto Machine174
Brake Disc Inspection174
Towing a Disabled Machine175
Transmission Assembly Component Terminology177
Transmission Assembly Component Terminology178
Transmission Serial Number179
Transmission Replacement179
Transmission Removal179
Transmission Inspection and Internal Repair181
Transmission Installation181
After Transmission Service or Replacement182
Transmission Troubleshooting183
Engine187
Engine Serial Number189
Engine Specifications and Maintenance Information189
Introduction189
Engine Component Terminology190
Engine Cooling System191
Coolant System Pressure Cap191
Thermostat Replacement191
Radiator/Oil Cooler and Replacement192
Radiator/Oil Cooler Removal192
Radiator/Oil Cooler Installation192
Engine Electrical System192
Fuel System193
Fuel/Hydraulic Oil Tank Removal193
Fuel/Hydraulic Oil Tank Disassembly193
After Fuel System Service194
Fuel/Hydraulic Oil Cleaning and Drying194
Fuel/Hydraulic Oil Assembly194
Fuel/Hydraulic Oil Tank Installation194
Diesel Exhaust Fluid (DEF) Tank195
DEF Tank Removal195
DEF Tank Inspection195
DEF Tank Installation195
Diesel Exhaust Fluid (DEF) Header196
DEF Header Removal196
DEF Header Cleaning196
Diesel Exhaust Fluid (DEF) Pump Filter Removal197
DEF Header Filter Replacement197
DEF Pump Cleaning197
Diesel Exhaust Fluid (DEF) System Cleaning198
DEF Pump Filter Installation198
DEF Tank Cleaning198
Cummins Diesel Exhaust Fluid (DEF) Tank199
Cummins Diesel Exhaust Fluid (DEF) Header200
Cummins Diesel Exhaust Fluid (DEF) System Cleaning201
DEF Header Installation201
Diesel Exhaust Fluid (DEF) System - Engine Coolant Strainer Cleaning202
Engine Exhaust System203
Exhaust Removal203
Exhaust System Installation203
Air Cleaner Assembly Removal207
Air Cleaner Assembly Installation207
Engine Replacement208
Engine Removal208
Engine Installation209
Isolation Coupler Removal210
Isolation Coupler Installation210
Hydraulic Section211
Hydraulic Component Terminology212
Hydraulic Section - Safety Information214
Hydraulic Circuits215
Hydraulic Pressure Diagnosis215
Hydraulic Pressure Checks and Adjustments215
Hydraulic Pressure Specifications216
Hydraulic Schematics234
Hydraulic Oil Reservoir Draining248
Hydraulic Oil Reservoir Filling248
Hydraulic Filter Replacement248
Hydraulic System Pump Replacement249
Valves and Manifolds250
Main Control Valve Removal250
Main Control Valve Disassembly250
Main Control Valve Parts Cleaning251
Main Control Valve Parts Inspection251
Main Control Valve Assembly251
Main Control Valve Installation252
Main Control Valve Test252
Service Brake Valve Removal253
Service Brake Valve Installation253
Brake Bleeding254
Steering Orbitrol Valve255
Steer Select Valve255
Brake System Check255
Steer Select Valve Removal256
Steer Select Valve Disassembly, Cleaning, Inspection, Assembly256
Steer Select Valve Installation256
Secondary Function Manifold257
Outrigger Valve Removal258
Outrigger Valve Disassembly, Cleaning, Inspection and Assembly258
Extend Lockout Valve Removal259
Outrigger Valve Installation259
Extend Lockout Valve Disassembly, Cleaning, Inspection, Assembly260
Extend Lockout Valve Installation260
Extend Lockout Valve Test260
Hydraulic Cylinders261
Cylinder Disassembly261
Cylinder Cleaning Instructions262
Cylinder Inspection262
Cylinder Assembly Instructions262
Cylinder Installation262
Cylinder Pressure Checking263
Steering Cylinders263
Cylinder Torque Specifications264
Electrical System267
Electrical Component Terminology269
Electrical System - Safety Information270
Engine Compartment Fuse and Relays270
Specifications270
Cab Harness Fuses and Relays271
Electrical System Schematics273
Cab Schematic273
Chassis - Engine Schematics274
Cab O/R Option Schematic277
HVAC Option Schematic279
Road Light Option Schematic280
Worklights/Beacon Option Schematic281
Telematics Option Schematics282
Dielectric Grease Application283
AMP Seal283
AMP Mate-N-Lok284
DIN Connectors284
Exclusions284
Engine Control Unit Connectors285
Sealed Enclosures285
MIL-C-5015 Spec Connector’s285
Engine Start Circuit286
Testing the Starter on the Engine286
Starter Circuit Checks286
Starter Removal286
Battery Inspection287
Starter Installation287
Battery Removal and Installation287
Battery Disconnect/Connect287
Charging Circuit288
Alternator Removal288
Alternator Installation288
Window Wiper/Washer Windshield Wiper Motor289
Skylight Wiper Motor Removal290
Windshield Washer Reservoir291
Skylight Wiper Motor Inspection, Installation and Testing291
Cab Heater and Fan292
Cab Heater Controls Removal292
Solenoids, Sensors and Senders293
Cab Heater Controls Installation and Testing293
Coolant Level Sensor Removal293
Coolant Level Sensor Installation293
Transmission Temperature Sender Removal294
Transmission Solenoid Valves294
Transmission Temperature Sender Inspection and Replacement294
Transmission Temperature Sender Installation and Testing294
Service Brake Switch Removal and Installation295
Boom Angle Sensor Removal296
Service Brake Switch Adjustment296
Boom Extend Interlock Sensor Removal297
Boom Angle Sensor Installation297
Outrigger Pressure Switches Removal and Installation298
Boom Extend Interlock Sensor Installation298
Display Monitor Removal and Installation299
Dash Switches299
Ignition Switch Removal299
Ignition Switch Inspection and Replacement300
Ignition Switch Installation300
Dash Switches Removal, Inspection and Installation301
Machine Data Access302
Hand Held Analyzer302
Mobile Analyzer303
Analyzer Software Version P1.2304
Analyzer Software Accessibility305
Access Level305
Diagnostics305
Machine Set-Up306
Personalities307
Calibrations308
Telematics Gateway309
Telematics-Ready (TCU) Plug310
Telematics Component Locations310
Telematics Gateway Harness Breakdown311
Connector Tables312
3D Harness View314
Electrical System Troubleshooting315
Electrical System Fault Detection315
Offboard Diagnostics315
Machine Fault Codes316
Engine Fault Codes320
Stabil-TRAK System and Boom Interlock System369
Stabil-TRAK System Component Terminology371
Boom Extend Interlock System Component Terminology (10054 Only)372
Stabil-TRAK Description373
Stabil-TRAK Operation374
Free Pivot Mode (Stabili-TRAK)374
Slow Pivot Mode (Stabili-TRAK)374
Locked Mode (Stabili-TRAK)374
Stabil-TRAK Solenoid Valves375
Logic Wiring Harness375
Relay Testing376
Outrigger Pressure Switches Testing377
Outrigger Pressure Switches Removal377
Outrigger Pressure Switches Installation377
Boom Extend Interlock System Description378
Boom Extend Interlock System Operation (10054 Only)379
Extend Interlock Mode379
Outrigger Interlock Mode379
Stabil-TRAK System Test380
Stabil-TRAK System Test Procedures381
Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (6042/8042/10042)383
Electrical Circuit - Free Pivot Mode384
Electrical Circuit - Locked Mode386
Stabil-TRAK™ and Boom Interlock Electrical Circuit Operation and Troubleshooting (10054)387
Stabil-TRAK Electrical Circuit - Boom Extend Mode389
Boom/Outrigger Interlock System Test392
Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting394
Stabil-TRAK Cylinder Oil Flow396
Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil out398
Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil out399
Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil out400
Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil out401
Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil out402
Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil out403
Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil out404
Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil out405
Hydraulic Circuit Operation - Locked Mode406
Hydraulic Troubleshooting - Locked Mode, will Not Frame Level Right407
Hydraulic Circuit Operation - Locked Mode, Frame Level Left408
Hydraulic Troubleshooting - Locked Mode, will Not Frame Level Left409
Boom Extend System Hydraulic Circuit Operation and Troubleshooting410
Hydraulic Circuit Operation - Extend Interlock Mode412
Hydraulic Troubleshooting - Extend Interlock Mode412
Hydraulic Circuit Operation - Outrigger Interlock Mode414
Hydraulic Troubleshooting - Outrigger Interlock Mod414

Skytrak 8042 - Page 67

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