Document Outline

• 31200796_C_6036 6042 8042 10042 10054 (T4i)_SkyTrak_Service
  • Effectivity Page
  • Table of Contents
  • Section 1 Safety Practices
    • 1.1 Introduction
    • 1.2 Disclaimer
    • 1.3 Operation & Safety Manual
    • 1.4 Do Not Operate Tags
    • 1.5 Safety Information
      • 1.5.1 Safety Alert System and Signal Words
    • 1.6 Safety Instructions
      • 1.6.1 Personal Hazards
      • 1.6.2 Equipment Hazards
      • 1.6.3 General Hazards
      • 1.6.4 Operational Hazards
    • 1.7 Safety Decals
  • Section 2 General Information and Specifications
    • 2.1 Replacement Parts and Warranty Information
    • 2.2 Thread Locking Compound
    • 2.3 Torque Charts
      • 2.3.1 SAE Fastener Torque Chart
      • 2.3.2 Metric Fastener Torque Chart
      • 2.3.3 Hydraulic Hose Torque Chart
    • 2.4 Specifications
      • 2.4.1 Travel Speeds
      • 2.4.2 Hydraulic Cylinder Performance
      • 2.4.3 Electrical System
      • 2.4.4 Engine Performance Specifications
      • 2.4.5 Tires
    • 2.5 Fluid Specifications
    • 2.6 Fluid and Lubricant Capacities
    • 2.7 Service and Maintenance Schedules
      • 2.7.1 10 & 1st 50 Hour
      • 2.7.2 50, 250 & 1st 500 Hour
      • 2.7.3 500 & 1000 Hour
      • 2.7.4 2000 Hour
    • 2.8 Lubrication Schedules
      • 2.8.1 50 Hour
      • 2.8.2 250 Hour
      • 2.8.3 1000 Hour
  • Section 3 Boom
    • 3.1 Boom System Component Terminology
    • 3.2 Safety Information
    • 3.3 Boom System - Three Section (6036, 6042, 8042 & 10042)
      • 3.3.1 Boom System Operation
    • 3.4 Boom Assembly Maintenance
      • 3.4.1 Boom Removal
      • 3.4.2 Third Boom Section Removal
      • 3.4.3 Second Boom Section Removal
      • 3.4.4 First Boom Section Removal
      • 3.4.5 First Boom Section Installation
      • 3.4.6 Second Boom Section Installation
      • 3.4.7 Third Boom Section Installation
      • 3.4.8 Boom Installation
    • 3.5 Boom System - Four Section (10054)
      • 3.5.1 Boom System Operation
    • 3.6 Boom Assembly Maintenance
      • 3.6.1 Fourth Boom Section Removal
      • 3.6.2 Third Boom Section Removal
      • 3.6.3 Second Boom Section Removal
      • 3.6.4 First Boom Section Removal
      • 3.6.5 First Boom Section Installation
      • 3.6.6 Second Boom Section Installation
      • 3.6.7 Third Boom Installation
      • 3.6.8 Fourth Boom Section Installation
    • 3.7 Boom Extend and Retract Chains
      • 3.7.1 Boom Chain Inspection
      • 3.7.2 Inspection Guidelines
      • 3.7.3 Expose Chains for Inspection
      • 3.7.4 Chain Lubrication
      • 3.7.5 Boom Chain Tension Check
      • 3.7.6 Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042)
      • 3.7.7 Boom Chain Tension Adjustment (10054)
      • 3.7.8 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042)
      • 3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042)
      • 3.7.10 Extend Chains Removal and Replacement (10054)
      • 3.7.11 Retract Chain Removal and Replacement (10054)
    • 3.8 Quick Attach Assembly
      • 3.8.1 Quick Attach Removal
      • 3.8.2 Quick Attach Installation
    • 3.9 Boom Wear Pads
      • 3.9.1 Wear Pad Inspection
      • 3.9.2 Wear Pad Installation and Lubrication
    • 3.10 Forks
    • 3.11 Troubleshooting
  • Section 4 Cab and Covers
    • 4.1 Operator Cab and Covers Component Terminology
    • 4.2 Operator Cab
      • 4.2.1 Cab Safety
      • 4.2.2 Serial Number Decal
    • 4.3 Cab Components
      • 4.3.1 Steering Column and Steering Valve
      • 4.3.2 Service Brake Pedal
      • 4.3.3 Throttle Pedal
      • 4.3.4 Joystick Assemblies
      • 4.3.5 Windshield Wiper Assembly
      • 4.3.6 Heater/Defroster System (If Equipped)
    • 4.4 Cab Removal
    • 4.5 Cab Installation
  • Section 5 Axles, Drive Shafts, Wheels and Tires
    • 5.1 Axle, Drive Shaft and Wheel Component Terminology (6036)
    • 5.2 Axle, Drive Shaft and Wheel Component Terminology (6042)
    • 5.3 Axle, Drive Shaft and Wheel Component Terminology (8042)
    • 5.4 Axle, Drive Shaft and Wheel Component Terminology (10042 & 10054)
    • 5.5 General Information
    • 5.6 Axle Assemblies
      • 5.6.1 Axle Serial Number Plate
      • 5.6.2 Axle Specifications
      • 5.6.3 Axle Internal Service
      • 5.6.4 Axle Maintenance
      • 5.6.5 Axle Replacement (6036 & 6042)
      • 5.6.6 Axle Replacement (8042, 10042 & 10054)
    • 5.7 Axle Assembly and Drive Shaft Troubleshooting
    • 5.8 Drive Shafts
      • 5.8.1 Drive Shaft Inspection and Service
      • 5.8.2 Drive Shaft Maintenance
      • 5.8.3 Drive Shaft Removal
      • 5.8.4 Drive Shaft Cleaning and Drying
      • 5.8.5 Drive Shaft Installation
    • 5.9 Wheels and Tires
      • 5.9.1 Removing Wheel and Tire Assembly from Machine
      • 5.9.2 Installing Wheel and Tire Assembly onto Machine
    • 5.10 Brakes
      • 5.10.1 Brake Disc Inspection
    • 5.11 Towing a Disabled Machine
  • Section 6 Transmission
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Transmission Serial Number
    • 6.3 Transmission Specifications and Maintenance Information
    • 6.4 Transmission Replacement
      • 6.4.1 Transmission Removal
      • 6.4.2 Transmission Inspection and Internal Repair
      • 6.4.3 Transmission Installation
      • 6.4.4 After Transmission Service or Replacement
    • 6.5 Transmission Troubleshooting
  • Section 7 Engine
    • 7.1 Introduction
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Component Terminology
    • 7.2 Engine Serial Number
    • 7.3 Specifications and Maintenance Information
    • 7.4 Engine Cooling System
      • 7.4.1 Coolant System Pressure Cap
      • 7.4.2 Radiator/Oil Cooler and Replacement
    • 7.5 Engine Electrical System
    • 7.6 Fuel System
      • 7.6.1 Diesel Fuel
      • 7.6.2 Fuel/Hydraulic Oil Tank
      • 7.6.3 After Fuel System Service
    • 7.7 Engine Exhaust System
      • 7.7.1 Exhaust System Removal
      • 7.7.2 Exhaust System Installation - LS
      • 7.7.3 Exhaust System Installation - ULS
    • 7.8 Air Cleaner Assembly
      • 7.8.1 Air Cleaner Assembly Removal - ULS
      • 7.8.2 Air Cleaner Assembly Installation - ULS
      • 7.8.3 Air Cleaner Assembly Removal - LS
      • 7.8.4 Air Cleaner Assembly Installation - LS
    • 7.9 Engine Replacement
      • 7.9.1 Engine Removal
      • 7.9.2 Engine Installation
    • 7.10 Isolation Coupler
      • 7.10.1 Isolation Coupler Removal
      • 7.10.2 Isolation Coupler Installation
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 Hydraulic Pressure Diagnosis
      • 8.3.1 Pressure Checks and Adjustments
    • 8.4 Hydraulic Circuits
      • 8.4.1 Hydraulic Pressures
      • 8.4.2 Hydraulic Schematics
    • 8.5 Hydraulic Reservoir
      • 8.5.1 Hydraulic Oil Reservoir Draining
      • 8.5.2 Hydraulic Oil Reservoir Filling
      • 8.5.3 Hydraulic Filter Replacement
      • 8.5.4 Hydraulic Oil Reservoir Replacement
    • 8.6 Hydraulic System Pump
      • 8.6.1 Pump Replacement
    • 8.7 Valves and Manifolds
      • 8.7.1 Main Control Valve
      • 8.7.2 Secondary Function Manifold
      • 8.7.3 Service Brake Valve
      • 8.7.4 Service Brake Valve Installation
      • 8.7.5 Brake Bleeding
      • 8.7.6 Power Steering Valve
      • 8.7.7 Steer Select Valve
      • 8.7.8 Unloader Valve (6036 & 6042 only)
      • 8.7.9 Outrigger Valve (10042 & 10054 only)
      • 8.7.10 Extend Lockout Valve (10054 only)
    • 8.8 Hydraulic Cylinders
      • 8.8.1 General Cylinder Instructions
      • 8.8.2 Cylinder Pressure Checking
      • 8.8.3 Steering Cylinders
      • 8.8.4 Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
      • 9.1.1 General Overview
    • 9.2 Specifications
    • 9.3 Safety Information
    • 9.4 Fuses and Relays
      • 9.4.1 Engine Compartment
      • 9.4.2 Cab Harness Fuses and Relays
    • 9.5 Electrical System Schematics
      • 9.5.1 Electrical Schematic (if equipped for ULS)
      • 9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
      • 9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
      • 9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
      • 9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
      • 9.5.2 Electrical Schematic (if equipped for LS)
      • 9.5.2 Electrical Schematic (if equipped for LS) (Continued)
      • 9.5.2 Electrical Schematic (if equipped for LS) (Continued)
      • 9.5.2 Electrical Schematic (if equipped for LS) (Continued)
      • 9.5.2 Electrical Schematic (if equipped for LS) (Continued)
    • 9.6 Engine start circuit
      • 9.6.1 Starter
    • 9.7 Charging Circuit
      • 9.7.1 Alternator
    • 9.8 Window Wiper/Washer Windshield Wiper Motor
      • 9.8.1 Windshield Wiper Motor
      • 9.8.2 Skylight Wiper Motor
      • 9.8.3 Windshield Washer Reservoir
    • 9.9 Cab Heater and Fan
      • 9.9.1 Cab Heater Controls
    • 9.10 Solenoids, Sensors and Senders
      • 9.10.1 Coolant Level Switch (if equipped for ULS)
      • 9.10.2 Hydraulic Oil Temperature Switch
      • 9.10.3 Transmission Solenoid Valves
      • 9.10.4 Transmission Temperature Sender
      • 9.10.5 Service Brake Switch
      • 9.10.6 Boom Angle Sensor
      • 9.10.7 Boom Extend Interlock Sensor (10054 only)
      • 9.10.8 Outrigger Pressure Switches (10054 Only)
    • 9.11 Display Monitor and Gauges
      • 9.11.1 Instrument Cluster
    • 9.12 Dash Switches
      • 9.12.1 Ignition Key Switch
      • 9.12.2 Dash Switches
    • 9.13 Troubleshooting
      • 9.13.1 Fault Detection
      • 9.13.2 Offboard Diagnostics
      • 9.13.3 Engine Fault Codes Chart
  • Section 10 Stabil-TRAK™ System and Boom Interlock System
    • 10.1 Stabil-TRAK™ System Component Terminology
    • 10.2 Boom Extend Interlock System Component Terminology (10054 Only)
    • 10.3 Stabil-TRAK™ Description
    • 10.4 Stabil-TRAK™ Operation
      • 10.4.1 Understanding Stabil-TRAK™ System
      • 10.4.2 Stabil-TRAK™ Solenoid Valves
      • 10.4.3 Logic Wiring Harness (10054 Only)
      • 10.4.4 Relay Testing
      • 10.4.5 Outrigger Pressure Switches (10054 Only)
    • 10.5 Boom Extend Interlock System Description
    • 10.6 Boom Extend Interlock System Operation (10054 Only)
      • 10.6.1 Extend Interlock Mode
      • 10.6.2 Outrigger Interlock Mode
    • 10.7 Stabil-TRAK™ System Test
      • 10.7.1 Stabil-TRAK™ System Test Instructions
      • 10.7.2 Stabil-TRAK™ System Test Procedures
    • 10.8 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (6042/8042/10042)
    • 10.9 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (10054)
    • 10.10 Boom/Outrigger Interlock System Test
      • 10.10.1 System Test Procedures
    • 10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting
      • 10.11.1 Stabil-TRAK™ Cylinder Oil Flow
      • 10.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out
      • 10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out
      • 10.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out
      • 10.11.5 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out
      • 10.11.6 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out
      • 10.11.7 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out
      • 10.11.8 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out
      • 10.11.9 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out
      • 10.11.10 Hydraulic Circuit Operation - LOCKED MODE
      • 10.11.11 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Right
      • 10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Right
      • 10.11.13 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Left
      • 10.11.14 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Left
    • 10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting
      • 10.12.1 Troubleshooting Symptom Chart
      • 10.12.2 Hydraulic Circuit Operation - Extend Interlock Mode
      • 10.12.3 Hydraulic Troubleshooting - Extend Interlock Mode
      • 10.12.4 Hydraulic Circuit Operation - Outrigger Interlock Mode
      • 10.12.5 Hydraulic Troubleshooting - Outrigger Interlock Mode