SkyTrak 6042 Service Manual

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.5 Accident Prevention Tag Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.8 Hazard/Emergency Information Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 6042 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.4 Metric Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

2.12 After Service Startup and Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3 Boom Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.4 Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

3.5 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65

3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68

3.7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3 Open Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.4 Enclosed Cab (Optional) Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20

4.5 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26

4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29

4.7 Access Panels and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32

Model 6042 Legacy Origin 7/02

ã 2002 OmniQuip Textron Inc.

Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21

Section 6

Transmission: ZF 4 WG-98 TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.6 Transmission Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.7 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

6.8 Towing a Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13

6.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14

Section 7

Engine: Cummins 4BT3.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.5 Standard Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

7.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15

7.9 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23

7.10 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24

7.11 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25

7.12 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37

7.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

8.4 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5

8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7

8.7 Hydraulic System Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10

8.8 Hydraulic Circuits and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

8.9 Four-Wheel Steer Indexing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.58

8.10 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60

8.11 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.61

8.12 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68

8.13 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.98

Model 6042 Legacy Origin 7/02

Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

9.4 Effective Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

9.5 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

9.7 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

9.8 Transmission Gear Selection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.60

9.9 Dash Panel Warning Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.68

9.10 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.80

9.11 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.82

9.12 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.89

9.13 Window Wiper/Washer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95

9.14 Cab Heater and Fan (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.102

9.15 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.104

Section 10

Stabil-TRAK™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

10.1 Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

10.2 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

10.3 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

10.4 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . 10.8

10.5 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . 10.12

10.6 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

Section 11

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

Accident Prevention Tags

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Section Subject Page

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Model 6042 Legacy Origin 7/02

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4.1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.4.2 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.5 Accident Prevention Tag Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

1.8 Hazard/Emergency Information Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

Model 6042 Legacy Origin 7/02

1.1

Safety Practices

1.1 INTRODUCTION

OmniQuip Textron Inc. (hereafter, OmniQuip) products

meet all applicable industry safety standards. OmniQuip actively promotes safe practices in the use and maintenance of its products through training programs, instructional manuals and the pro-active efforts of all employees involved in engineering, design, manufacture, marketing and service.

This manual is designed to provide service technicians with complete information on the maintenance and repair of the Sky Trak Model 6042 Legacy Telescopic Material Handler.

Particular effort has been made to produce a manual to serve as a reference handbook for the experienced service technician, but also provide essential step-bystep procedures for the professional development of the less experienced person. Remember, even the best manual in the world is no substitute for an appropriate education, skill development that comes through experience alone, safety, wise and judicious discernment, and ultimately, proper performance of service procedures.

This service manual provides general directions for accomplishing service and repair procedures with tested, effective techniques. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. Prior to performing any maintenance on the vehicle, consider all factors, circumstances and conditions which can have an effect upon the safety of personnel and equipment, and take appropriate action to ensure the safety of all involved.

These instructions cannot cover all details or variations in the equipment, procedures or processes described, nor provide directions for meeting every possible contingency during operation, maintenance or testing. When additional information is desired to satisfy a situation not covered sufficiently, consult the local OmniQuip Authorized Service Center (ASC) or the OmniQuip Service Department at 1-800-439-8959 (Domestic) or 1-262-268-8957 (Internationally).

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. Although equipment damage can usually be repaired in a brief period of time, death and irreparable injury are permanent. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the vehicle.

Provisions for supplementary information are made by OmniQuip in the form of Service Bulletins, Service Campaigns, Service Training Schools, the OmniQuip website, other literature, and through updates to the manual itself. Comments and suggestions for improvement are welcome and encouraged.

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. OmniQuip reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.2 OWNERS/OPERATORS MANUAL

The vehicle must be driven and operated as a consequence of, or when performing, service, maintenance and test procedures. The service technician must, therefore, thoroughly read, understand and follow the Sky Trak Model 6042 Legacy Telescopic Material Handler Owners/Operators Manual.

An owners/operators manual is supplied with each vehicle and must be kept in the owners/operators manual holder (Fig. 1-1, 1) located on the cab post to the left and below the operator’s seat.

MH0770

Figure 1-1 The Owners/Operators Manual Holder

In the event that the owners/operators manual is missing, consult the local OmniQuip Authorized Service Center (ASC) or the OmniQuip Service Department before proceeding.

1.2

Model 6042 Legacy Origin 7/02

Safety Practices

1.3 TRAINING MECHANICS AS OPERATORS

Because it is necessary to move the vehicle to service or maintain the vehicle, it is necessary that all mechanics are OSHA trained and certified as operators. A mechanic trained in the proper operation of the vehicle can better determine whether all functions are operating correctly.

At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use. When this vehicle is to be serviced or maintained by someone other than the purchaser, make certain that the mechanic is trained, in accordance with the OSHA regulations listed in the NOTICE below, and reads and understands the SKY TRAK Model 6042 Legacy Telescopic Material Handler Owners/Operators Manual

operating or maintaining the vehicle.

before NOTICE: Under OSHA rules, it is the responsibility of the

employer to provide operator training. Successful completion and certification of Safety Training for Rough Terrain Forklifts is required. Operator Training Kits are available by calling the Ken Cook Company at (414) 466-6060. An order form for these kits is available through our website, http://www.omniquip.com.

In addition, make sure that the mechanic has completed a walk-around inspection of the vehicle, is familiar with all decals and/or decal plates on the vehicle, and has demonstrated the correct use of all controls.

1.4 SAFETY INFORMATION

The following information provides general safety instructions, including examples of hazard statements with signal words, notification of hazards, methods to help avoid hazards and the consequences of failing to follow the safety information. To avoid possible death or injury, carefully read and follow all safety messages. Fully understand the potential causes of death or injury.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help ensure personal safety.

The information in this manual does not replace any other safety rules or proper judgment. Governmental authorities and employers also have their own sets of rules, codes, regulations and laws. Before starting work at a site, check with the supervisor or safety coordinator and ask about the safety policy. Learn the safety requirements in effect before operating, maintaining, servicing or testing the vehicle. Safety depends on following safety requirements.

1.4.1 Safety Alert Symbol

The exclamation mark within a triangle is the Safety Alert Symbol.

Model 6042 Legacy Origin 7/02

OP0330

This symbol means “Attention! Become Alert! Your Safety Is Involved!” The symbol is used to attract attention to safety hazards found on the vehicle safety decals and throughout this manual.

1.3

Safety Practices

1.4.2 Hazard Statements

Signal words and messages are used in conjunction with the safety alert symbol to create hazard statements. These hazard statements convey important information about safety.

Four types of hazard statements are used in this manual. Each statement indicates the existence and degree of relative risk of the hazard described within the statement that follows the signal word.

Explanations of the types of hazard statements are as follows:

DANGER:

The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING:

1.5 ACCIDENT PREVENTION TAG USAGE

MC0690

Figure 1-2 Accident Prevention Tag

The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION:

The signal word “CAUTION” indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION:

The signal word “CAUTION,” used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, could result in property damage.

For safe maintenance of the vehicle, read, understand and follow all DANGER, WARNING and CAUTION information.

Before beginning any maintenance or service, place an Accident Prevention Tag (Fig. 1-2) on both the ignition key switch and the steering wheel (Fig. 1- 3), stating that the vehicle should not be operated. Actual Accident Prevention Tags, which can be punched out and used, are included as the last page in this manual. Retain these Accident Prevention Tags for reuse at a later date.

DANGER

OH1720

1.4

Figure 1-3 Place Accident Prevention Tags on Both the

Ignition Key Switch and the Steering Wheel

Model 6042 Legacy Origin 7/02

Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider

before

Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the hazard occurs.

For all safety messages, carefully read, understand and follow the instructions before

1.6.1 Personal Hazards

HAIR and CLOTHING: DO NOT wear loose clothing or jewelry. Tie up or restrain hair. Wear the correct safety equipment for the job (including but not limited to: hard hat; safety shoes; safety glasses, goggles, or face shield; heavy gloves; hearing protection; reflective clothing; wetweather gear; respirator or filter mask).

EYE PROTECTION: Always wear appropriate eye protection when chiseling, grinding, sanding, welding, painting, repairing hydraulic systems, or checking, testing or charging the battery.

BREATHING PROTECTION: Wear respiratory protection when grinding or painting.

HEARING PROTECTION: Always wear hearing protection in a high-noise area.

FOOT PROTECTION: Wear protective footwear with reinforced toe caps and slip-resistant soles.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

performing maintenance procedures on a vehicle.

proceeding.

1.6.2 Equipment Hazards

OWNERS/OPERATORS MANUAL: Before operating the vehicle, carefully read, understand and follow the owners/ operators manual.

OPERATIONAL PROTECTION: Before operating the vehicle or returning it for operational use, check that the Operator’s Protective Structure is intact, undamaged, unmodified and secure.

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working condition and properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist or jack to support raised equipment. A hoist or jack failure can allow the equipment to fall or tip.

Always support equipment with proper capacity blocks or stands that are properly rated for the load.

COMPRESSED AIR: Before and during the use of compressed air, wear eye protection and advise other personnel in the work area that compressed air is about to be used.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

Model 6042 Legacy Origin 7/02

1.5

Safety Practices

1.6.3 General Hazards

SOLVENTS: Only use approved solvents, and solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor. Know the location of a first-aid kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the vehicle to capture fluid run-off.

1.6.4 Operational Hazards

OPERATIONAL CONSIDERATIONS: Before operating the vehicle, carefully read, understand and follow the owners/operators manual.

ENGINE: Stop the engine before performing any service. DANGEROUS START: Place Accident Prevention Tags

on both the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Disconnect battery leads. Place a warning sign on a vehicle that is dangerous to start, if leaving the vehicle unattended.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

RADIATOR CAP: Always wear steam-resistant, heatprotective gloves when opening the radiator cap. Cover cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure.

SOFT SURFACES AND SLOPES: NEVER work on a vehicle that is parked on a soft surface or slope (inclined ground or hill). The vehicle must be on a hard, level surface with the wheels blocked when performing any service. Obtain assistance, block all wheels, and add supports if necessary before beginning any work.

SUPPORTS AND STRAPS: Install safe, stable supports, slings or straps beneath or around a component or structural member before beginning any work.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fuel leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, causing infection, gangrene and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and tightened to the proper torque. Capture fluid in an appropriate container and dispose of it in accordance with prevailing environmental regulations.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedures to achieve the desired results.

LEAVING VEHICLE: Lower the attachment to the ground before leaving the vehicle.

TIRE PRESSURE: Always keep tires inflated to the proper pressure to help prevent dangerous travel and load-handling situations. DO NOT over-inflate tires.

1.7 EMERGENCY EXIT REAR WINDOW

The rear window in the enclosed cab can be used as an emergency exit by removing the latch pins (Fig. 1-4, 1) located on the two window latches (2). Once the latch pins have been removed, the window (3) can be swung open.

9 7

9 0

1 4

OH1730

1.6

Figure 1-4 Emergency Exit Rear Window Latch Pins

Model 6042 Legacy Origin 7/02

Safety Practices

1.8 HAZARD/EMERGENCY INFORMATION DECALS

Locations of vehicle hazard and other emergency information decals are shown below. As part of routine maintenance, check that ALL hazard and emergency information decals on the vehicle are present and readable. Keep all decals clean.

DANGER

AVOID CRUSHING

if vehicle tips. Jumping can

result in death

or serious

injury.

 DO NOT JUMP.  Brace yourself.  Stay in cab.  Keep seat belt on.

If a replacement decal is needed, refer to the owners/ operators manual and parts catalog for the latest parts numbers and ordering information, or, contact OmniQuip Textron Parts Worldwide directly at:

Domestic: 1-888-872-5123

International: 1-262-268-8958

FALLING OFF ATTACHMENT,

can result in death or

serious injury.

WARNING

CRUSHING,

vehicle can cause death

Allow no riders

AVOID

falling off

or serious

injury

OH17422

1. No Riders WARNING

2. Vehicle Rollaway WARNING

3. Safety Instructions

4. Electrocution DANGER

5. Tipover DANGER - Operating

6. Do Not Jump DANGER

8. Moving Parts WARNING

9. Carrying Personnel WARNING

10. Boom Extend Letters

11. Boom Angle Indicator

12. Explosive Gases WARNING

13. Emergency Exit (Enclosed Cab Only)

7. Load Chart Booklet

Note: Many of these hazard related decals are available free of charge by calling OmniQuip Textron Parts Worldwide at 1-888-872-5123 (Domestic) or 1-262-268-8958 (International).

OA14402

Model 6042 Legacy Origin 7/02

1.7

Safety Practices

This Page Intentionally Left Blank

1.8

Model 6042 Legacy Origin 7/02

Section 2

General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 6042 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

2.2.1 Service Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.2 The Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.3 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.4 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.2 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.3 SAE 37° Flare Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.4 SAE Flat Face O-Ring Seal Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.4 Metric Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.4.1 Approximate American to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.4.2 Approximate Metric to American Conversions . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

2.5.1 Vehicle Dimensions (With Standard 12-ply 13.00-24 Tires) . . . . . . . . . . . . . . . 2.14

2.5.2 Vehicle Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

2.5.3 Attachment Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

2.5.4 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

2.5.5 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2.18

2.5.6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

2.5.7 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.5.8 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

2.5.9 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.5.10 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.5.11 Miscellaneous Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.5.12 Tamper Proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.5.13 Fork Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

Model 6042 Legacy Origin 7/02

2.1

General Information and Specifications

2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.6.1 Axles (Differential Housings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

2.6.2 Axle Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.6.3 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.6.4 Lubrication Points (Grease Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.6.5 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.6.6 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.6.7 Drive Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.6.8 General Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.6.9 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.6.10 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.6.11 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.9.1 Hose and Tube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.9.2 Hose and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.10.1 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.10.2 Bearing Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.10.3 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

2.12 After Service Startup and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

2.12.1 After Service Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

2.12.2 After Electrical/Electronic Component Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

2.12.3 After Hydraulic Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

2.12.4 After Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

2.12.5 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

2.12.6 After Transmission Service or Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

2.12.7 After Tire and Wheel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

2.12.8 After Engine Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

2.12.9 After Boom Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

2.12.10 After Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

2.2

Model 6042 Legacy Origin 7/02

2.1 6042 COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this manual, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies on this vehicle. The following illustration identifies the components that are referred to throughout this manual.

Operator’s

Protective

Structure

General Information and Specifications

Boom

Assembly

Rear Door

(Not Visible)

Engine

Compartment

Cylinders (2)

Lift/Lower

Cylinders (2)

Slave

Carriage

Assembly

Extend/Retract

Cylinder

Frame Sway

Cylinder

Hydraulic

Oil Tank

MA10,0650

Model 6042 Legacy Origin 7/02

2.3

General Information and Specifications

2.2 INTRODUCTION

2.2.1 Service Methods

Appropriate service methods and proper repair procedures are essential for safe, reliable operation of this vehicle and the safety of the individual doing the work. This Service Manual provides general direction for accomplishing service and repair work with tested, effective techniques. Following them will assure reliability.

There are many variations in procedures, techniques, tools and parts for servicing vehicles, as well as work skills. This manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to depart from the instructions in this manual must first consider personal safety and then vehicle integrity.

IMPORTANT: OmniQuip recommends the use of environmentally sound waste storage and disposal practices. NEVER drain fluids on the ground or into a sewer or catch basin. Use suitable collection containers, then store and/or dispose of waste products in an approved and safe manner. Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

2.2.2 The Owners/Operators Manual

The Owners/Operators Manual provides information you need to properly operate and maintain this vehicle.

IMPORTANT: Before you operate this vehicle, read the manual completely and carefully, so that you will understand the safety instructions and the operation of the controls and safety equipment. You must comply with all Danger, Warning and Caution notices. They are for your benefit.

All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.

2.2.3 Replacement Parts and Warranty Information

For reference when ordering replacement parts or making service inquiries about the vehicle, the vehicle serial number is required to help assure the provision of correct parts and information. Before ordering parts or initiating service inquiries, make note of the serial number.

2.4

Model 6042 Legacy Origin 7/02

General Information and Specifications

The vehicle serial number plate (Fig. 2-1, 1) is located at the front of the vehicle on the frame sway cylinder upright.

OH0280

Figure 2-1 Vehicle Serial Number Plate Location

IMPORTANT: The replacement of any part on this vehicle with any other than a OmniQuip authorized replacement part can adversely affect the performance, durability, or safety of the vehicle, and will void the warranty. OmniQuip disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the OmniQuip Authorized Service Center (ASC), signed by the purchaser and returned to OmniQuip when the vehicle is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to OmniQuip.

2.2.4 Disclaimer

OmniQuip reserves the right to make changes to and to

add improvements upon its product at any time, without public notice or obligation. OmniQuip also reserves the right to discontinue manufacturing any product at its discretion at any time.

Model 6042 Legacy Origin 7/02

2.5

General Information and Specifications

2.3 TORQUES

2.3.1 Fasteners

All fasteners (nuts, bolts, washers, etc.) are equal to SAE Grade 5 (PC8.8) and are plated, unless otherwise specified.

2.3.2 Bolts and Nuts

Unless otherwise specified, the following values apply for Grade 5 (PC8.8) nuts and bolts:

Size Torque Size Torque

Inchlb-ftNmmmNmlb-ft

1/4 9 12 6,0 10 7

5/16 17 24 8,0 25 18

3/8 31 42 10,0 50 37

7/16 50 68 -- -- --

1/2 75 102 12,0 80 59

9/16 110 150 14,0 130 95

5/8 150 203 16,0 200 146

3/4 250 340 20,0 360 263

2.3.3 SAE 37° Flare Hydraulic Fittings

a. Assembly Procedure

Follow these steps when tightening hose ends, tube ends and fitting swivel ends onto fitting male end connections (Refer to Fig. 2-2).

Improper assembly of this type of joint will result in leaking joints. Over tightening can result in cracking of the female swivel seat or deformation of the male fitting tapered seat. Under tightening will result in the joint loosening during normal usage. Foreign material on either seal surfaces will cause damage to one or both mating parts when the joint is tightened, resulting in a leaking joint.

1. Inspect both the male and female sealing cone surfaces for burrs, scratches, dents, other damage, or foreign material. If any damage is found on the seat the part is to be rejected as unusable. Clean off any foreign material from the sealing surfaces before assembly.

2. Align the mating parts and check to see that the flare seats properly on the nose of the fitting.

3. Finger tighten the nut onto the fitting. If necessary a wrench may be used to snug the nut against the fitting (30 lb-in maximum torque). This is considered the “finger tight” (Fig. 2-2, 1) condition.

7/8 380 515 22,0 510 372

1.0 585 793 24.0 650 475

Figure 2-2 F.F.F.T. Tightening Method

MA10,0810

2.6

Model 6042 Legacy Origin 7/02

General Information and Specifications

4. Using a permanent type ink marker, make a mark (Fig. 2-2, 2) on one of the flats on the nut and continue it onto the static fitting or port.

5. Complete the joint by wrench tightening (Fig. 2-2, 3) the nut for the size and type of fitting. This assembly procedure is referred to as Flats From Finger Tight (FFFT).

6. A less desirable tightening method is nut torque. First follow 1 & 2 above. Apply clean petroleum based oil to the male thread. Finger tighten the nut onto the fitting. Torque the nut to the value listed in the table.

Hose Ends, Tube Ends and Fitting Swivel Ends

SAE Size

the number of flats (4) specified in the table

To Fitting Male Ends

Tube

Conn.

(FFFT)

4 2 2 16 ± 3 (22 ± 4) 5 2 2 19 ± 4 (26 ± 5) 6 1-1/2 1-1/4 25 ± 5 (34 ± 7)

8 1-1/2 1 49 ± 10 (66 ± 14) 10 1-1/4 1 74 ± 11 (100 ± 15) 12 1-1/4 1 103 ± 15 (140 ± 20) 14 1 1 121 ± 18 (164 ± 24) 16 1 1 135 ± 35 (183 ± 47) 20 1 1 166 ± 33 (225 ± 45) 24 1 1 210 ± 40 (285 ± 54) 32 1 1 314 ± 54 (426 ± 73)

Swivel Nut

Hose Conn.

(FFFT)

Torque lb-ft (Nm)

w/Oiled

Threads

b. Straight O-Ring Boss Fittings To

O-Ring Boss Ports

Improper assembly of this joint will result in leaking joints. Under tightening of the fitting will result in the fitting loosening during normal operation and the joint leaking. Damaging the o-ring during assembly will result in immediate joint leakage.

1. Inspect components to ensure that male and female port threads and sealing surfaces are free of burrs, nicks, or scratches, or any foreign material. If any damage is found the bad part must not be used. Clean any foreign material from the mating parts before assembly.

2. Lubricate the o-ring with a clean petroleum based lubricant.

3. Screw the fitting into the port.

4. Torque the fitting to the value listed in table.

O-Ring Boss Fittings To

O-Ring Boss Ports

SAE Size Torque lb-ft (Nm)

4 14 ± 1 (19 ± 1) 5 18 ± 1 (24 ± 1) 6 23 ± 1 (31 ± 1)

8 41 ± 1 (56 ± 1) 10 45 ± 3 (61 ± 4) 12 72 ± 3 (98 ± 4) 14 95 ± 4 (129 ± 5) 16 118 ± 5 (160 ± 7) 20 154 ± 7 (209 ± 10) 24 162 ± 8 (220 ± 11) 32 229 ± 11 (311 ± 15)

Model 6042 Legacy Origin 7/02

2.7

General Information and Specifications

c. Adjustable (Angle) O-Ring Boss Fittings To

O-Ring Boss Ports

Improper assembly of this joint will result in a leaking joint. Failure to position the locknut properly will result in damage to the o-ring. Under tightening of the fitting will result in the fitting loosening during normal operation and the joint leaking. Damaging the o-ring during assembly will result in immediate joint leakage.

MF0620

Figure 2- 3 Adjustable Fitting to Port

2. Back off the locknut as far as possible (Fig. 2-3, 1). Make sure the back-up washer is not loose. If the back-up washer is loose the fitting must be replaced.

3. Lubricate the o-ring (Fig. 2-3, 2) and male thread with a clean petroleum based lubricant.

4. Screw the fitting into the port as far as possible by hand (Fig. 2-3, B & C).

5. To align the tube end (Fig. 2-3, 3) of the fitting to accept the mating tube or hose, unscrew the fitting as required but not more than one turn.

6. Using two wrenches, hold the fitting in the desired position and tighten the locknut (Fig. 2-3, 4) to the appropriate torque value listed in the table in Section

2.3.3, b. “Straight O-Ring Boss Fittings To O-Ring Boss Ports.”

d. Pipe Fittings to Pipe Ports

Improper assembly of this joint will result in a leaking joint and possible damage to the port.

1. Inspect the port and fitting to insure that there are no burrs, nicks, or foreign material. If any thread damage is found the part must not be used. Clean off any foreign material.

2. Apply sealant/lubricant to male pipe thread. If Teflon tape is used it should be wrapped 1.5 to 2 turns in a clockwise direction when viewed from the pipe thread end. With any sealant the first 1 to 2 threads should be left uncovered to avoid system contamination.

3. Screw the connector into the port finger tight.

4. Wrench tighten the fitting to the appropriate Turns From Finger Tight (TFFT) from Table 4. Make sure that angle fittings are aligned with the mating tube or hose within the listed number of turns. Never back off (loosen) pipe thread connectors to achieve alignment.

Pipe Fittings To Pipe Ports

Pipe Thread Size Turns From Finger Tight

(T.F.F.T

1/8" 2 - 3 1/4" 2 - 3 3/8" 2 - 3 1/2" 2 - 3 3/4" 2 - 3

1" 1-1/2 - 2-1/2 1-1/4" 1-1/2 - 2-1/2 1-1/2" 1-1/2 - 2-1/2

2" 1-1/2 - 2-1/2

2.8

Model 6042 Legacy Origin 7/02

2.3.4 SAE Flat Face O-Ring Seal Hydraulic Fittings

a. Assembly Procedure

Improper assembly of this type of joint will result in leaking joints. Under tightening will result in the joint loosening during normal usage. Foreign material on either seal surfaces will cause damage to one or both mating parts when the joint is tightened resulting in a leaking joint. The absences of the fitting o-ring will cause the joint to leak.

1. Inspect both the male (Fig. 2-4, 1) and female (2) sealing surfaces for burrs, scratches, dents, other damage, or foreign material. If any damage is found on either surface, the part is to be rejected as unusable. Clean off any foreign material from the sealing surfaces before assembly.

2. Inspect the male fitting for the presence of the seal o-ring (Fig. 2-4, 3). Inspect the o-ring for any sign of damage. If the o-ring is missing or damaged replace it.

3. Apply clean petroleum based oil to the male thread.

4. Place the flat surface of the female connector (Fig. 2-4, 1) in full contact with the o-ring (3) in the male connector.

5. Finger tighten the nut (Fig. 2-4, 4) onto the fitting.

6. Complete the joint by tightening the nut specified in the table. For hoses and swivel fittings use a second wrench to keep the female connector from moving during tightening.

O-Ring Boss Fittings To

O-Ring Boss Ports

SAE Size Torque lb-ft (Nm)

4 19 ± 5 (26 ± 7) 6 35 ± 5 (47 ± 7)

8 52 ± 7 (70 ± 10) 10 83 ± 17 (112 ± 23) 12 120 ± 20 (163 ± 27) 16 165± 35 (224 ± 47) 20 215 ± 65 (292 ± 88) 24 252 ± 77 (342 ± 104)

to the torque

General Information and Specifications

MA10,0800

Figure 2-4 Flat Face O-Ring Seal Connections

b. Straight O-Ring Boss Fittings To

O-Ring Boss Ports

2. Lubricate the o-ring and male thread with a clean petroleum based lubricant.

3. Screw the fitting into the port.

4. Torque the fitting to the values found in table.

O-Ring Boss Fittings To

O-Ring Boss Ports

SAE Size Torque lb-ft (Nm)

4 15 ± 1 (20 ± 1) 6 25 ± 1 (34 ± 1)

8 55 ± 5 (75 ± 7) 10 76 ± 5 (103 ± 7) 12 130 ± 5 (176 ± 7) 16 210± 10 (285 ± 14) 20 245 ± 35 (332 ± 47) 24 315 ± 45 (427 ± 61)

Model 6042 Legacy Origin 7/02

2.9

General Information and Specifications

c. Adjustable (Angle) O-Ring Boss Fittings To

O-Ring Boss Ports

MA10,0820

Figure 2- 5 Adjustable Fitting to Port

2. Back off the locknut as far as possible (Fig. 2-5, 1). Make sure the back-up washer is not loose. If the back-up washer is loose the fitting must be rejected.

3. Lubricate the o-ring (Fig. 2-5, 2) and male thread with clean petroleum based lubricant.

4. Screw the fitting into the port as far as possible by hand (Fig. 2-5, B & C).

5. To align the tube end (Fig. 2-5, 3) of the fitting to accept the mating tube or hose, unscrew the fitting as required but not more than one turn.

6. Using two wrenches, hold the fitting in the desired position and tighten the locknut (Fig. 2-5, 4) to the appropriate torque value listed in the table in Section

2.3.4, b. “Straight O-Ring Boss Fittings To O-Ring Boss Ports.”

d. Pipe Fittings to Pipe Ports

Improper assembly of this joint will result in a leaking joint and possible damage to the port.

1. Inspect the port and fitting to insure that there are no burrs, nicks, or foreign material. If any thread damage is found the part must not be used. Clean off any foreign material.

3. Screw the connector into the port finger tight.

Pipe Fittings To Pipe Ports

Pipe Thread Size Turns From Finger Tight

(T.F.F.T

1/8" 2 - 3 1/4" 2 - 3 3/8" 2 - 3 1/2" 2 - 3 3/4" 2 - 3

1" 1-1/2 - 2-1/2 1-1/4" 1-1/2 - 2-1/2 1-1/2" 1-1/2 - 2-1/2

2" 1-1/2 - 2-1/2

2.10

Model 6042 Legacy Origin 7/02

General Information and Specifications

This Page Intentionally Left Blank

Model 6042 Legacy Origin 7/02

2.11

General Information and Specifications

2.4 METRIC CONVERSION FACTORS

2.4.1 Approximate American to Metric Conversions

When this is known Multiply by To find

TORQUE (moment of force)

Pound/feet (lb-ft) 1.356 Newton meters (Nm) Pound/inches (lb-in) 0.113 Newton meters (Nm)

POWER

Horsepower (hp) 745.7 Watts SPEED (velocity) Miles per hour (mph) 1.609 Kilometers per hour

(km/hr; kph)

LENGTH (distance) Inches (in) 25.4 Millimeters (mm) Inches (in) 2.5 Centimeters (cm) Feet (ft) 30.5 Centimeters (cm) Feet (ft) 0.305 Meters (m) Yards (yd) 0.9 Meters (m) Miles (mi) 1.6 Kilometers (km)

AREA

Square inches (in Square feet (ft Square yards (yd Square miles (mi Acres 0.4 Hectares (ha) MASS (weight) Ounces (oz) 28.3 Grams (g) Pounds (lb) 0.4536 Kilograms (kg) Short tons (2000 lb) 0.9 Metric ton (t)

When this is known Multiply by To find

) 6.5 Square centimeters (cm2)

) 0.09 Square meters (m2)

) 0.8 Square meters (m2)

) 2.6 Square kilometers (km2)

VOLUME

Teaspoons (tsp) 5 Milliliters (ml) Tablespoons (Tbsp) 15 Milliliters (ml)

Cubic inches (in

) 16 Milliliters (ml) Fluid ounces (fl oz) 30 Milliliters (ml) Cups (c) 0.24 Liters Pints (pt) 0.47 Liters Quarts (qt) 0.95 Liters Gallons (gal) 3.8 Liters Cubic feet (ft Cubic yards (yd

) 0.03 Cubic meters (m3)

) 0.76 Cubic meters (m3)

AIR PRESSURE

Pounds per square inch (psi) 6.895 Kilopascals (kPa)

HYDRAULIC PRESSURE

Pounds per square inch (psi) 0.069 Bar

TEMPERATURE (exact) To determine degrees Celsius (° C), subtract 32, then

multiply by 0.56; (° F -32) x 0.56 = ° C.

2.12

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.4.2 Approximate Metric to American Conversions

When this is known Multiply by To find

TORQUE (moment of force)

Newton meters (Nm) 0,738 Pounds/feet (lb-ft) Newton meters (Nm) 8,85 Pounds/inches (lb-in)

POWER

Watts 0,0013 Horsepower (hp) SPEED (velocity) Kilometers per

hour (km/hr; kph) 0,621 Miles per hour (mph) LENGTH (distance) Millimeters (mm) 0,0394 Inches (in) Centimeters (cm) 0,394 Inches (in) Meters (m) 3,281 Feet (ft) Meters (m) 1,1 Yards (yd) Kilometers (km) 0,621 Miles (mi)

When this is known Multiply by To find

AREA

Square centimeters

(cm

) 0,4 Square inches (in2) Square meters (m Square kilometers

) 0,6 Square miles (mi2)

(km Hectares (10000 m MASS (weight) Grams (g) 0,035 Ounces (oz) Kilograms (kg) 2,2 Pounds (lb) Metric ton (1000 kg) (t) 1,1 Short tons

) 1,1 Square yards (yd2)

)2,5 Acres

VOLUME

Milliliters (ml) 0,03 Fluid ounces (fl oz)

Milliliters (ml) 0,06 Cubic inches (in

) Liters 2,1 Pints (pt) Liters 1,06 Quarts (qt) Liters 0,26 Gallons (gal) Cubic meters (m Cubic meters (m

) 35 Cubic feet (ft3)

) 1,3 Cubic yards (yd3)

AIR PRESSURE

Kilopascals (kPa) 0,145 Pounds per square

inch (psi)

HYDRAULIC PRESSURE

Bar 14,5 Pounds per square

inch (psi)

TEMPERATURE (exact) To determine degrees Fahrenheit (° F), multiply degrees

Celsius (° C) by 1.8, then add 32; (° C x 1.8) + 32 = ° F.

Model 6042 Legacy Origin 7/02

2.13

General Information and Specifications

2.5 SPECIFICATIONS

2.5.1 Vehicle Dimensions (With Standard 12-ply 13.00-24 Tires)

Description (Fig. 2- 6) (A) Length (without Attachment) 220" (5588 mm) (B) Width 98" (2489 mm) (C) Height (Boom Lowered) 102" (2591 mm) (D) Wheelbase 113" (2870 mm) (E) Tread 84" (2134 mm) (F) Ground Clearance 16" (406 mm) (G) Turning Radius, Curb to Curb 165" (4191 mm) (H) Turning Radius, Clearance 168" (4267 mm) (I) Maximum Lift Height, Boom Extended 41' 11" (12,8 m) (J) Maximum Lift Height, Boom Retracted 21' 7" (6,6 m) (K) Maximum Below Grade Depth, Boom Extended 3' 1" (940 mm) (L) Maximum Reach, from Front of Front Tires 27' 11" (8,5 m) (M) Maximum Reach at Maximum Lift Angle,

Boom Extended

(N) Maximum Reach at Maximum Lift Angle,

Boom Retracted

(O) Maximum Reach at Minimum Lift Angle,

Boom Extended

(P) Maximum Boom Lift Angle 68.4° (Q) Minimum Boom Lift Angle -8° (R) Angle of Departure 27° Fork Tilt Angle: (S) At Minimum Boom Angle - UP 11° (T) At Minimum Boom Angle - DOWN -101° (U) At Maximum Boom Angle - UP 87° (V) At Maximum Boom Angle - DOWN -25° Frame Tilt Angle (Not Shown):

Right 10.0°

6' 4" (1930 mm)

-20" (-508 mm)

21' 9" (6,6 m)

Left 10.0°

2.14

Model 6042 Legacy Origin 7/02

General Information and Specifications

24.0"

Figure 2-6 Vehicle Dimensions with Standard Tires

0.0

MA10,0670

Model 6042 Legacy Origin 7/02

2.15

General Information and Specifications

2.5.2 Vehicle Weights

Curb Weight w/48" Carriage (Open Cab) 23,520 lb (10.668 kg) Curb Weight w/48" Carriage (Enclosed Cab) 23,720 lb (10.759 kg) Operating Load 6,000 lb (2721 kg) Working Weight (Machine working weight is figured with 72" carriage, two 48" pallet forks, 25%-full fuel tank, and

standard bias ply tires [no hydrofill]):

Open Cab:

Front Axle 9,030 lb (4.096 kg) Rear Axle 14,710 lb (6.672 kg) Total (Open Cab) 23,740 lb (10.768 kg)

Closed Cab:

Front Axle 9,130 lb (4.141 kg) Rear Axle 14,810 lb (6.718 kg) Total (Closed Cab) 23,940 lb (10.859 kg)

2.16

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.5.3 Attachment Weights

Std 48" Carriage with Shaft 456 lb (205 kg) Std 60" Carriage with Shaft 526 lb (239 kg) Std 72" Carriage with Shaft 677 lb (307 kg) 48" Side Tilt Carriage with Shaft and Cylinder 687 lb (312 kg) 60" Side Tilt Carriage with Shaft and Cylinder 752 lb (341 kg) 72" Swing Carriage with Shaft and Cylinder 900 lb (408 kg)

Bucket, 1.125 yd

(0,855 m3)

Broom, 8 foot (2,44 m) 1,100 lb (495 kg)

760 lb (342 kg)

Pallet Forks, 2" x 4" x 48" (5,7 x 10 x 122 cm),

278 lb (127 kg)

quantity: 2 Pallet Forks, 2.25" x 4" x 48" (5,7 x 10 x 122 cm),

312 lb (141 kg)

quantity: 2 Block Forks, 2" x 2" x 48" (5 x 5 x 122 cm),

480 lb (216 kg)

quantity: 6 Lumber Forks, 1.75" x 7" x 60" (4 x 17,8 152,4 cm),

466 lb (210 kg)

quantity: 2 Auger Drive Unit 285 lb (128 kg) Auger Mounting Frame 180 lb (81 kg) Auger (Various Sizes Available) Varies Auger Extension (Various Sizes Available) Varies

2.5.4 Performance Specifications

Note: Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable.

Travel Speed (Standard Tires, No Load)

First Gear 0-3.5 mph (0-5,6 km/hr) Second Gear 0-6 mph (0-9,7 km/hr) Third Gear 0-13.5 mph (0-21.7 km/hr) Fourth Gear 0-20 mph (0-32 km/hr)

Model 6042 Legacy Origin 7/02

2.17

General Information and Specifications

2.5.5 Hydraulic Cylinder Performance Specifications

Note: Vehicle with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature

Boom Extend Less than 19 seconds Boom Retract Less than 19 seconds Boom Lift Retracted Less than 17 seconds Boom Lower Retracted Less than 13 seconds Attachment Tilt - UP 6.5 seconds Attachment Tilt - DOWN 6 seconds Frame Sway Left to Right with Boom Down 12-15 seconds

Function Approximate Times, in Seconds

Frame Sway Left to Right with Boom Above 40 Emergency Brake Engaged

Frame Sway Right to Left with Boom Down 12-15 seconds

Frame Sway Right to Left with Boom Above 40 Emergency Brake Engaged

° and

23-33 seconds

26-52 seconds

2.18

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.5.6 Electrical System

Battery:

Type, Rating 12V DC, Negative (-) Ground, Maintenance-Free Quantity 1 Reserve Capacity 1,000 Cold Cranking Amps @ 0° F (-18° C) Group/Series C31XH Alternator 12V, 65 Amps

Fuses - Standard Blade Style:

7.5 Amps Light Switch Relay, Transmission 10 Amps Instrument Panel, Horn/Heater, Steer Select Switch,

Stabilizer, Washer/Wipers (Optional) 20 Amps Lights (Optional) 40 Amps Main, Road/Work Lights (Optional)

Relays:

Neutral Start Relay 12 Volt Park Brake Disengage Relay 12 Volt Headlight Switch Relay 12 Volt Back-up Relay 12 Volt Light Switch Relay 12 Volt Stabilizer Lock 12 Volt Boom Switch 12 Volt

Model 6042 Legacy Origin 7/02

2.19

General Information and Specifications

2.5.7 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

Engine Make/Model Cummins Turbo/4BT3.9 Displacement

Horsepower 99 HP @ 2,500 rpm Number of Cylinders 4 Engine High Idle with No Load 2,750 ±100 rpm Engine Low Idle 1,050 ±50 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements Peak Torque 278 lb-ft @ 1,500 rpm (377 Nm @ 1,500 rpm) Average Fuel Consumption, Depending on Load/Duty 2 gal/hr (1,67 Imp gal/hr, or 7,57 liters/hr)

239 in

(3,9 liters)

2.20

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.5.8 Fluid and Lubricant Capacities

Engine Crankcase Oil:

Capacity with Filter Change 11.0 qt (10,4 liters) Filter Capacity 1.0 qt (0,9 liters) Oil Type SAE 15W40 Diesel Engine Oil

(Refer to Section 2.6.6, “Engine.”)

Fuel Tank:

Total Capacity 37.0 gal (140 liters) Usable Capacity 35.7 gal (135,1 liters) Type of Fuel Above 32° F (0° C) Standard No. 2 Diesel. (Refer to Section 2.6.6, “Engine.”) Type of Fuel Below 32° F (0° C) 50/50 Mix of #1 and #2 Diesel Fuels (Refer to Section 2.6.6, “Engine.”)

Cooling System:

Capacity w/o Heater (including 1.5 qt [1,4 liters] for overflow bottle) 4.0 gal (15 liters)

Overflow Bottle Capacity 3.0 qt (2,8 liters) Type of Fluid 50/50-mix of ethylene glycol and water (Refer to Section 2.6.6, “Engine.”)

Transmission:

Capacity w/Filter Change 12.5 qt (11,8 liters) Filter Capacity 1.5 qt (1,4 liters) Type of Oil Universal Tractor Fluid (Refer to Section 2.6.3, “Transmission.”)

Axle (Differential Housing):

Capacity:

Front Axle Rear Axle

9.5 qt (9 liters)

10.6 qt (10 liters)

Type of Oil Universal Tractor Fluid. Refer to Section 2.6.1, “Axles (Differential Housings).”

Axle (Wheel Ends):

Capacity:

Front Axle Rear Axle

1.7 qt (1,6 liters)

1.3 qt (1,2 liters)

Type of Oil Universal Tractor Fluid. Refer to Section 2.6.1, “Axles (Differential Housings).”

Hydraulic System:

System Capacity 57.5 gal (217,7 liters) Reservoir Capacity 32.2 gal (122 liters) Type of Oil ISO Grade 46 Anti-Wear Hydraulic Oil

(Refer to Section 2.6.5, “Hydraulic System.”)

Model 6042 Legacy Origin 7/02

2.21

General Information and Specifications

2.5.9 Hydraulic System

Valve Relief Settings (46 GPM Bench Flow):

Main Valve Clipping Relief 3,500 ±100 psi (241,5 bar) Main Pump Standby Pressure at Pump Outlet 250-300 psi (17-21 bar) Main Relief Pressure at Unloader Valve "VG" Test Port 2900-3100 psi (172-214 bar) Parking Brake Relief 650-700 psi (45-48 bar) Port Relief Attachment Tilt (Both Sides) 3,250 ±100 psi (224 ±7 bar) Port Relief Auxiliary Hydraulics 3,250 ±100 psi (224 ±7 bar) Pressure Reducing Relieving Valve, Stabilizer 75-150 psi (5,2-10,3 bar) Parking Brake Pressure Reducing Valve 500-600 psi (34-41 bar) Steering Pressure Reducing Valve 2,500 ±100 psi (172 ±5 bar)

2.5.10 Tires

Standard Tire Size 13.00-24, 12-ply Rock Tire Size (Optional) 15.50-25, 12 ply Wheel Lug Nut Torque 430-470 lb-ft (583-637 Nm) Air Pressure:

Standard Tire Rock Tire (Optional)

70 psi (483 kPa) 65 psi (448 kPa)

Tire Ballast (Optional) (Minimum Per Tire):

Foam Filled Standard Tire 775 lb (351 Kg)

Tire Footprint Area (Gross area, over entire footprint, established under maximum tip load):

Vehicle with Standard Tires and Rated Load

Vehicle with Rock Tires (Optional) and Rated Load

230 in

(684 cm2)

(961 cm2)

Maximum Ground Pressure (Net pressure, over tread portion of footprint) (maximum ground pressure at tip = (machine weight + load) / (2 x footprint area):

Vehicle with Standard Tires and Rated Load 140 psi (865 kPa) Vehicle with Rock Tires (Optional) and Rated Load 100 psi (689 kPa)

2.5.11 Miscellaneous Specifications

Steering Wheel:

Maximum Number of Turns, Lock to Lock 3.75 turns Minimum Number of Turns, Lock to Lock 3.00 turns

Breakout Force:

Utility bucket

24,500 lb (11.113 kg)

(calculated at -24° lip angle, maximum moment)

2.22

Model 6042 Legacy Origin 7/02

2.5.12 Tamper Proofing

A tamper-proof means is in place on the following adjustable components prior to machine shipment. This can either be tamper-proof paint, or a steel tamper-proof cap. DO NOT attempt to defeat, bypass or alter any tamper-proof device.

• Main Valve Port Relief Valves (4)

• Steering Relief Valve (1)

• Attachment Tilt Cylinder Counterbalance Valve (1)

• Lift/Lower Cylinder Counterbalance Valves (2)

• Extend/Retract Cylinder Counterbalance Valve (1)

• Main System Relief Valve (1)

• Parking Brake Relief (1)

General Information and Specifications

WARNING: DO NOT exceed the total

rated capacity of the specific pair of forks being used. Forks can break causing loss of load and possible death or serious personal injury to the operator or personnel in the area. If the total rated capacity of the forks exceeds ity of the vehicle, the vehicle capacity should not be exceeded.

2.6 FLUIDS, LUBRICANTS AND CAPACITIES

2.6.1 Axles (Differential Housings)

the capac-

2.5.13 Fork Ratings

All approved forks for this vehicle are marked with a maximum load capacity rating. This rating (Fig. 2-7, 1) is stamped on the left edge of the fork, just below the fork pivot shaft. The rating is listed in U.S. pounds and based upon a 24" (610 mm) load center (2).

This rating specifies the maximum load capacity that the individual fork can safely carry at a maximum load center of 24" (610 mm).

Since forks are always used in multiples, the total rating of any combination of forks is the sum of their rated capacities. Other than block forks, use all forks in matched pairs. Use block forks in matched sets.

24"

610 mm

5000 x 24

a. Axle Lubricants

In general, use a Universal Tractor Fluid that meets the following specifications:

Nominal viscosity at 104° F (40° C) .......................55 cSt

Minimum viscosity at 212° F (100° C)...................9.1 cSt

Pour point (Maximum).............................. -32° F (-36° C)

Flash point (Minimum).............................392° F (200° C)

Minimum viscosity index ............................................135

Products known to meet these requirements include:

• JOHN DEERE: JDM J20C (HY-GARD)

• FORD/NEW HOLLAND: ESN-M2C134-D (Hydraulic Oil 134)

• MASSEY-FERGUSON: M-1141 (PERMANTRAN III)

• CHEVRON: CHEVRON 1000 THF

b. Axle Capacities

Axles (differential housings)

Front Axle ...........................................9.5 qt (9 liters)

Rear Axle........................................10.6 qt (10 liters)

Figure 2-7 Stamped Fork Rating Location

Model 6042 Legacy Origin 7/02

OH0670

2.23

General Information and Specifications

2.6.2 Axle Wheel Ends

a. Axle Wheel-End Lubricants

In general, use a Universal Tractor Fluid that meets the following specifications:

Nominal viscosity at 104° F (40° C)....................... 55 cSt

Minimum viscosity at 212° F (10° C) .................... 9.1 cSt

Pour point (Maximum) ..............................-32° F (-36° C)

Flash point (Minimum) ............................ 392° F (200° C)

Minimum viscosity index............................................ 135

Products known to meet these requirements include:

• JOHN DEERE: JDM J20C (HY-GARD)

• FORD/NEW HOLLAND: ESN-M2C134-D (Hydraulic Oil 134)

• MASSEY-FERGUSON: M-1141 (PERMANTRAN III)

• CHEVRON: CHEVRON 1000 THF

DO NOT add additional friction modifier to factory-filled wheel ends. All wheel ends are factory-filled by the manufacturer with oil. If a wheel end is drained for service, it should be refilled with the gear oils listed.

Note: DO NOT use synthetic oil without the express written consent of the manufacturer.

b. Axle Wheel-End Capacity

Wheel ends

Front Axle........................................ 1.7 qt (1,6 liters)

Rear Axle ........................................ 1.3 qt (1,2 liters)

2.6.3 Transmission

a. Transmission Fluid

In general, use a Universal Tractor Fluid that meets the following specifications:

Nominal viscosity at 10° F (40° C)......................... 55 cSt

Minimum viscosity at 212° F (100° C) .................. 9.1 cSt

Pour point (Maximum) ..............................-32° F (-36° C)

Flash point (Minimum) ............................ 392° F (200° C)

Minimum viscosity index............................................ 135

Products known to meet these requirements include:

• JOHN DEERE: JDM J20C (HY-GARD)

• FORD/NEW HOLLAND: ESN-M2C134-D (Hydraulic Oil 134)

• MASSEY-FERGUSON: M-1141 (PERMANTRAN III)

• CHEVRON: CHEVRON 1000 THF

b. Transmission Capacity

Capacity w/filter change .....................12.5 qt (11,8 liters)

Filter .......................................................1.5 qt (1,4 liters)

2.6.4 Lubrication Points (Grease Fittings)

Lubricants

When lubricating any component via the grease fittings, use multi-purpose lithium-based grease with EP additives that meets NLGI Grade 2 specifications. Products known to meet these requirements include:

•AMOCO AMOLITH EP2

• ARCO LITHOLINE EP2

• BENZ MOLY-SERVICE EP2

• CHEVRON DUROLITH EP2

• CITGO H EP2

• GULF GULFCROWN EP2

• MOBILE MOBILUX EP2

• SHELL ALVANIA EP2

• SUN PRESTIGE 742EP

• TEXACO MULTIFAX EP2

Note: Refer to the appropriate Owners/Operators manual for the maintenance schedule and checklist for lubrication intervals and grease fitting locations.

2.24

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.6.5 Hydraulic System

a. Hydraulic Fluids

The hydraulic system is factory-filled with ISO Grade 46 anti-wear hydraulic oil. When filling the hydraulic system, use an anti-wear hydraulic oil meeting ISO Grade 46 with

-40° F (-40° C) pour point/ASTM viscosity SUS 215 at 100° F (38° C), or a 10W motor oil that meets the requirements of U.S. ordinance specification MIL-L-2104C. Products known to meet these requirements include:

ISO-46 HYDRAULIC OIL

• GULF HARMONY 46 AW

•AMOCO RYKON 46

•MOBIL DTE-25

• ARCO DURO AW S-215

• SHELL TULLUS 46

• BENZ PETRAULIC 46-7C

• SUN SUNVIS 821 WR

• CHEVRON AW HYDRAULIC OIL 46

• TEXACO RANDO HD 46

• CITGO PACEMAKER XD-46

SAE 10W MOTOR OIL

2.6.6 Engine

a. Engine Fluids and Lubricants

1. Engine oil:

Diesel Engine Oil, SAE 15W40 For most climates, use 15W40 motor oil that meets API,

CD or CE (severe duty diesel engine) specifications. Additives are not necessary. In cold climates where ambient (outside air) temperatures are consistently below 32° F (0° C), 10W30 motor oil can be used; however, continuous use of low viscosity oil may cause premature engine wear.

2. Cooling system (engine coolant):

In general, use a 50/50 mix of premium-quality, ethylene glycol (commonly referred to as “anti-freeze/anti-boilover”) and water. Additives are not necessary.

3. Fuel:

In general, use No. 2 diesel fuel. From November 15 to March 15 when operating in cooler climates where ambient (outside air) temperatures are consistently at or below 32° F (0° C), use a 50/50 mix of #1 and #2 diesel fuels. Use good quality diesel fuel, and change the fuel filter regularly. Additives are not necessary.

• CASTROL/DEUSOL CRD

• ESSO ESSOLUBE D-3HP

• ESSO ESSOLUBE XD-3

• CASTROL AGRICASTROL HDD

• SHELL RIMULA CT

• SHELL RIMULA X

• SHELL RIMULA TX

Note: For -30° F to +70° F (-34° C to +21° C), 5W20 motor oil with -50° F (-45° C) pour point can be substituted. However, above 70° F (21° C), hydraulic system oil must be changed to ISO-46 hydraulic oil or SAE 10W motor oil.

b. Hydraulic System Capacity

System capacity .............................57.5 gal (217,7 liters)

Reservoir capacity.............................32.2 gal (122 liters)

b. Engine Capacities

1. Engine Oil Capacity

Capacity w/filter change ..................... 11.0 qt (10,4 liters)

Filter ..........................................................1 qt (0,9 liters)

2. Cooling System Capacity (w/o heater):

Capacity ................................................ 4.0 gal (15 liters)

Overflow bottle capacity .........................3.0 qt (2,8 liters)

3. Fuel Tank Capacity

Total capacity .................................... 37.0 gal (140 liters)

Usable capacity................................. 35.7 gal (135 liters)

Model 6042 Legacy Origin 7/02

2.25

General Information and Specifications

2.6.7 Drive Shaft Splines

IMPORTANT: DO NOT disassemble any of the drive shafts (refer to Section 5, “Axles, Drive Shafts, Wheels and Tires” of this manual for information covering drive shafts and U-joints). To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly. Refer to the appropriate parts manual for ordering information.

Respective of the above statement, should it become necessary to coat the transmission input drive shaft splines, use molybdenum disulfide grease. Molybdenum disulfide grease is specifically formulated for this purpose and is marketed by several manufacturers under various names, including:

Aldrich Chemical Co., Inc.

Product name: Aldrich MOLYBDENUM (IV) SULFIDE

Catalog Number: 23,484-2 Package Size: 5 g (0.175 oz) 100 g (3.5 oz) 500 g (17.5 oz)

Contact:

Aldrich Chemical Co., Inc. P.O. Box 335 Milwaukee, WI 53201 USA Phone: (414) 273-3850

DOW CORNING, INC.

Product name: MOLYKOTE

77 Paste

Contact:

Dow Corning Corporate Center P.O. Box 994 Midland, MI 48686-0994 USA Phone: (517) 496-4400

2.6.8 General Anti-Corrosion

a. Anti-Corrosion Compound

For general anti-corrosion protection, use a wax film rust inhibitor that provides a protective film two ten-thousandths of an inch (0.0002" or 0,00005 mm) thick. One such rust inhibitor that is specifically formulated for this purpose is LPS 3. It is marketed by:

LPS Laboratories, Inc. 4647 Hugh Howell Rd. Tucker, GA 30085-5052 USA Phone: 1-800-241-8334 Fax: (770) 493-9206

Note: Anti-corrosion protection is especially important in axle, frame and stabilizer cylinder pin support bores for protection from fretting corrosion wear.

b. Anti-Corrosion Need Areas

Coat all unplated pins and all bores for cylinder pins, attachment pivot pins, chain sheave pins, the quick attach lock pin and all quick attach lock pin bores. Also coat the fork shaft and unpainted boom slide pathways.

2.6.9 Electrical

a. Basic Ratings

Battery Rating ....................... 12V DC Negative Ground

Battery Type

Maintenance-Free ..............(1000 Cold Cranking Amps)

Series of Battery..............................................Series 31

Number of Batteries ...........................................One (1)

Alternator Rating ..............................................65 Amps

b. Fuse Ratings

Main ...................................................................40 Amp

Light Switch Relay.............................................7.5 Amp

Instrument Cluster..............................................10 Amp

Horn/Heater........................................................10 Amp

Steer Select Switch ............................................10 Amp

Stabilizer ............................................................10 Amp

Washer/Wipers (Optional)..................................10 Amp

Lights (Optional).................................................20 Amp

Transmission.....................................................7.5 Amp

Road/Work Lights (Optional)..............................40 Amp

c. Relay Ratings

Park Brake Disengage .............................................12V

Headlight Switch ......................................................12V

Light Switch..............................................................12V

Neutral Start .............................................................12V

Stabilizer Lock..........................................................12V

Boom Switch ............................................................12V

Back-up ....................................................................12V

2.26

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.6.10 Paint

Unless otherwise specified, paint components as indicated in the following sections.

a. Orange Paint

Durable, premium Sky Trak orange paint is available in both a convenient 16-ounce (480 ml) spray can for touchups, and in a production-size, one gallon (3,8 liters) container for extensive repainting. Consult the appropriate parts manual for the applicable part number and ordering information. Use orange paint on all vehicle components except as specified in paragraphs 2.6.10 B and C.

b. Black Paint

Durable, premium black paint is available in both a convenient 16-ounce (480 ml) spray can for touch-ups, and in a production-size, one gallon (3,8 liters) container for extensive repainting. Consult the appropriate parts manual for the applicable part number and ordering information.

• Boom Angle Indicator Pointer

• Brake Pedal

• Radiator

• Seat Adapter Plate

• Radiator Shroud

• Transmission Oil Cooler

•Axles

• Drive Shafts

•Forks

• Mirrors and Mirror Brackets

• Air Cleaner

• Steering Column

c. White Paint

Durable, premium white paint is available in both a convenient 16-ounce (480 ml) spray can for touch-ups, and in a production-size, one gallon (3,8 liters) container for extensive repainting. Consult the appropriate parts manual for the applicable part number and ordering information.

• Boom Extend Cylinder

• Wheels

2.6.11 Thread Locking Compound

For general thread locking purposes, Loctite® products, manufactured by Loctite Corporation, are recommended.

Contact:

Loctite Corporation 1001 Trout Brook Crossing Rocky Hill, CT 06067 USA Phone: 1-800-LOCTITE (1-800-562-8483) FAX: (860) 571-2460 Internet: http://www.loctite.com

Loctite

is a registered trademark of Loctite Corporation.

2.7 CLEANING

Dirt and abrasive dust reduce the efficient working life of parts and systems, and lead to the costly replacement of components. To help increase the service life of parts, clean the exterior of all parts before beginning any repairs.

Use cleaning fluids and solvents suitable for cleaning parts that do not create safety hazards. Certain types of cleaning fluids can cause skin irritation and damage to components (such as rubber, electrical parts, etc.)

Servicing the hydraulic system in particular requires cleanliness of the work area, as well as the components on the vehicle.

Follow these precautions before attempting to service any hydraulic component:

1. Flush hose and tube assemblies with a solvent compatible with hose materials. Blow excess solvent away with shop air.

2. Plug or cap hydraulic fittings, hoses and tube assemblies, and protect threads until time of installation. Clean up any hydraulic fluid spillage immediately.

3. Flush hydraulic reservoir, fuel tank and gear housing with a suitable solvent, to remove paint, metal chips, etc.

4. Protect hydraulic system components from airborne contaminants. Plug all cylinder, valve, reservoir, tank and pump openings until time of installation.

5. Use clean, filtered oil when filling the system. Maintain the hydraulic system at a minimum cleanliness level of ISO code 18/15-particle ration count.

Model 6042 Legacy Origin 7/02

2.27

General Information and Specifications

2.8 REPLACEMENT

ALWAYS use the correct tool when removing or replacing any part or performing any service.

Some procedures may require the use of specialized tools. If needed, many of these tools can be obtained through Snap-on

Contact:

Snap-on Incorporated P.O. Box 1410 Kenosha, WI 53141-1410 USA Phone: (262)-656-5200 Internet: http://www.snapon.com

Snap-on Technologies, Inc.

Replace o-rings, seals and gaskets whenever they are disturbed. NEVER mix new and old seals or o-rings, regardless of apparent visual condition. ALWAYS lubricate new seals and o-rings with hydraulic oil before installation.

is a registered trademark of Snap-on

tool distributors.

2.9 HOSES AND TUBES

2.9.1 Hose and Tube Inspection

1. Damaged, dented, crushed, or leaking hose and tube fittings restrict oil flow and the operation of the system being served. Fittings showing signs of movement from their original positions have failed and must be replaced. ALWAYS replace the entire hose or tube assembly if the fittings are damaged.

2. Hoses must remain in good condition. Obvious signs of external hose wear, or hydraulic fluid leaking or weeping indicate the need to replace the hose assembly. If in doubt, replace the hose.

3. Replace if any of the following conditions exist:

• Ballooning (replace hose immediately!)

• Kinking, crushing, stretching or deforming

• Concealed corrosion of wire reinforcement

• Chafed outer cover

2.9.2 Hose and Tube Installation

1. When installing a new hose, loosely connect each end, and verify that the hose takes up the designed position, and is free of twists and unnecessary bends before tightening the connection completely. Tighten any support clamps sufficiently in order to hold the hose without crushing it, preventing movement and chafing of the hose.

2. If a hose is replaced on a part that moves, move the part through its entire range of motion to verify that the hose will not make contact with any component. Adjust the hose as necessary.

3. When installing any hose, be sure that the hose does not become kinked or twisted.

4. NEVER allow free-moving or unsupported hoses to contact each other or any other component. Such contact causes chafing and reduces hose life.

2.10 BEARINGS

2.10.1 Bearing Removal

1. NEVER remove bearings unless absolutely necessary! ALWAYS use the recommended size and type of bearing puller to reduce the risk of damage to the bearing or related components.

2. When bearings or bushings are removed, verify that the bearing or bushing is free of discoloration, nicks, scuffing, or signs of overheating. If in doubt, replace the bearing or bushing.

2.10.2 Bearing Cleaning

ALWAYS wear safety glasses. Clean bearings that are

acceptable for service in a suitable solvent. NEVER spin-dry a bearing with compressed air; this can cause metal-tometal contact and damage the bearing. Compressed air can also cause a bearing to come apart. After cleaning a bearing, immerse the bearing in clean lubricating oil until needed.

2.28

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.10.3 Bearing Installation

1. Always install bearings carefully to help avoid damaging their delicate surfaces.

2. Install bearings using one of the following methods:

• PRESS FIT for installation on rotating parts such as shafts and gears

• PUSH FIT into static locations such as reduction gear housings

3. Always install the bearing into the rotating part first, whenever possible.

4. Use a press or the proper installation tools when installing a bearing or bushing.

5. In the absence of a press or proper installation tools, carefully heat the casing and/or bearing in hot oil to assist in the installation.

2.11 PRESSURE TESTING AND ADJUSTMENT

Prior to pressure testing or adjustment, verify that all hoses and tubes are in good condition and that all fittings are tight.

Use pressure gauges with the proper pressure range and ratings to measure the specified pressures.

Use correct test procedures to help prevent personal injury, and damage to the system or test equipment.

Verify that the hydraulic oil is at the proper operating temperature, 80-120° F (27-49° C), before testing any pressures or making any adjustments to any valves. If necessary, operate the vehicle to raise the oil temperature up to the operating temperature. In the absence of a temperature gauge, the oil temperature can be checked by placing your hand against the side or the bottom of the hydraulic oil reservoir. If the tank is too hot to keep the hand in contact with the tank, the oil temperature should be within the proper range.

2.12 AFTER SERVICE STARTUP AND CHECKS

2.12.1 After Service Startup

Note: Refer to the appropriate Owners/Operators manual for engine cold start procedures.

1. Check ALL fluid levels, and add fluids as required.

2. Connect the negative (-) battery cable to the negative (-) battery terminal if it was disconnected.

3. Start and idle the engine. Check for leaks from the hydraulic components, engine, radiator, axles, transmission and brakes. Check for leaks from the hydraulic oil reservoir plugs or fittings; tighten as required. Check the levels of all fluids and lubricants.

4. Purge the hydraulic system of air by operating all vehicle functions through their entire range of motion. Operate all functions several times to ensure all air is purged from the system.

5. Check for proper operation of all components.

6. Retract all cylinders fully. Turn the engine OFF, and check the hydraulic oil level in the hydraulic oil reservoir. Allow the oil to cool and recheck the level. Add oil as required to bring the oil level up to the proper level.

2.12.2 After Electrical/Electronic Component Service

1. Check the torque of all fasteners securing replaced electrical/electronic components.

2. Check wire connections to electrical components.

3. Verify that wiring components are dry and free of moisture.

4. Check connectors for broken, frayed or loose wires.

5. Check wires and wire harnesses for brittle or frayed wire shielding.

6. Connect the negative (-) battery cable to the negative (-) battery terminal if it was disconnected.

7. Check the operation of the replaced component(s).

Model 6042 Legacy Origin 7/02

2.29

General Information and Specifications

2.12.3 After Hydraulic Component Service

1. Check the torque of fasteners on replaced components.

2. Check that the hoses and tubes are properly attached, properly positioned and that all fittings are properly tightened.

3. If a hydraulic component failed and contaminated the system:

• Drain the hydraulic oil reservoir

• Flush the system using clean hydraulic oil

• Prime the pump

• Clean the hydraulic oil reservoir

• Change the hydraulic oil filter

4. After normal hydraulic component maintenance, check the hydraulic oil level, and add oil as required.

5. Start the engine and purge the hydraulic system of air. Operate all boom functions through their full range of motion several times. Cycle the lift and extend cylinders to purge air from the system. Visually check for leaks.

6. Check operation of all systems in the hydraulic circuit by operating the controls through all functions several times.

2.12.4 After Brake System Service

1. Check the oil level in the axle and replenish with Universal Tractor Fluid as required.

2. Bleed the air from the brake system.

3. Check the brake pressure.

4. Check the brake operation.

2.12.5 After Fuel System Service

1. Drain and flush fuel tank, if it was contaminated, with clean fuel.

2. Replace all fuel filters.

3. Fill fuel tank with fresh, clean fuel as required.

4. Bleed the fuel system of air.

2.12.6 After Transmission Service or Replacement

1. Check transmission oil level and fill to level with Universal Tractor Fluid as required. (Refer to Section

2.6.3, “Transmission” for information on transmission lubricants.)

2. Replace transmission filter.

3. Check torque on drive shaft yoke retaining bolts.

• Upper driveshaft 35 lb-ft (47 Nm)

• Lower driveshaft 60 lb-ft (81 Nm)

4. Refer to the ZF 4 WG-98 TC Transmission Repair Manual, OmniQuip P/N 8990455 (ZF P/N 5871 135

002) for servicing the transmission after overhaul or repair.

5. Wear suitable eye protection. When an overhauled or repaired transmission is installed, thoroughly clean the oil cooler lines to and from the transmission.

6. Drain and flush the entire system.

7. Disconnect and clean all transmission lines. When possible, remove transmissions lines from the vehicle for cleaning.

8. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.

CAUTION: DO NOT exceed 165 psi

(11,4 bar) when back flushing the oil cooler. Applying too much pressure may damage the oil cooler/radiator.

9. “Back flush” the transmission oil cooler with oil and compressed air until all foreign material is removed. Flushing in direction of normal oil flow does not adequately clean the cooler. If needed, remove the transmission oil cooler assembly from the vehicle. DO NOT use flushing compounds for cleaning purposes.

10. Reassemble all components, and fill the transmission with clean, fresh Universal Tractor Fluid through the dipstick tube opening until oil comes up to the FULL mark on the transmission dipstick.

11. Run engine for two minutes at idle to help prime the torque converter and transmission lines.

12. Recheck the level of fluid in the transmission with the engine running at idle.

13. Add Universal Tractor Fluid as necessary to bring the fluid level up to the FULL mark on the transmission dipstick. Install the oil dipstick. Recheck the oil level when it reaches operating temperature (180-200° F or 83-94° C).

14. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.

2.30

Model 6042 Legacy Origin 7/02

General Information and Specifications

2.12.7 After Tire and Wheel Service

1. Check air pressure. Maintain proper air pressure at all times.

• 13.00-24, 12 ply - 70 psi (483 kPa)

• 15.50-25, 12 ply - 65 psi (448 kPa)

2. Check wheel nut torque. Torque the wheel nuts to 430-470 lb-ft (583-637 Nm).

2.12.8 After Engine Service

Consult the qualified service agent (manufacturer’s representative and/or service manual) for proper procedures before engine startup.

2.12.9 After Boom Service

1. Check wear pads.

2. Check chain tension adjustment.

3. Apply grease at all lubrication points (grease fittings).

Note: Refer to the appropriate Owners/Operators manual for the grease fitting locations.

4. Check for proper operation by operating all boom functions through their full range of motion several times.

2.12.10 After Axle Service

1. Check fluid levels in the axle and wheel ends.

2. Check torque on drive shaft flange yoke retaining bolts. Torque these M12 bolts to 156 lb-ft (212 Nm).

3. Check the torque on the wheel nuts. Torque to 430-470 lb-ft (583-637 Nm).

4. Check toe-in if required.

5. Apply grease at all lubrication points (grease fittings).

Note: Refer to the appropriate Owners/Operators manual for the grease fitting locations.

6. Refer to the axle manufacturer’s maintenance manual for further information.

Model 6042 Legacy Origin 7/02

2.31

General Information and Specifications

This Page Intentionally Left Blank

2.32

Model 6042 Legacy Origin 7/02

Section 3

Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2.2 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3.1 Inner Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3.2 Intermediate Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

3.3.3 Outer Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

3.3.4 Outer Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

3.3.5 Intermediate Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

3.3.6 Inner Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

3.4 Boom Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

3.4.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

3.4.2 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54

3.4.3 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54

3.4.4 Boom Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55

3.4.5 Boom Extend and Retract Chains Removal and Replacement. . . . . . . . . 3.58

3.5 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65

3.5.1 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65

3.5.2 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67

3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68

3.6.1 Disconnecting from an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68

3.6.2 Connecting to an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68

3.6.3 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.69

3.6.4 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.70

3.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71

Model 6042 Legacy Origin 7/02

3.1

Boom

3.1 BOOM SYSTEM COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.

Inner Boom Section

with Gooseneck

Quick Attach

FRONT

Attachment

Tilt Cylinder

Extend Chains

Boom Extend/

Retract Cylinder

Intermediate

Boom Section

Retract Chain

Outer Boom

Section

MA9160

3.2

Model 6042 Legacy Origin 7/02

Boom

WARNING: DO NOT service the vehicle

without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury.

3.2 BOOM SYSTEM

3.2.1 Boom System Description

The boom operates via an interchange among the hydraulic and mechanical systems. Components involved include the joystick, attachment tilt cylinder, extend/retract cylinder, lift/lower cylinders, slave cylinders, extend and retract chains, various pivots, supporting hardware and other components.

3.2.2 Boom System Operation

The boom assembly consists of inner, intermediate, and outer boom assemblies with double top boom extend chains and a single retract chain. Boom extension and retraction is accomplished via hydraulic power and chain movement.

As the extend/retract hydraulic cylinder, which is anchored at the front of the intermediate boom and the rear of the outer boom, begins to extend, it forces the intermediate boom out of the outer boom.

The inner and outer booms are connected by extend and retract chains. These chains are routed around sheaves on the intermediate boom. As the intermediate boom is forced out, the extend chain pulls the inner boom out of the intermediate boom.

As hydraulic pressure is applied to the retract port on the extend/retract cylinder, the intermediate boom is pulled back into the outer boom, and the retract chain pulls the inner boom back into the intermediate boom.

This mechanical linkage formed by the chains and supporting hardware, extends and retracts the intermediate and inner booms at the same rate.

The outer boom does not extend or retract, but lifts and lowers via action of the lift/lower cylinders.

3.3 BOOM ASSEMBLY MAINTENANCE

The boom assembly consists of the inner, intermediate and outer booms and supporting hardware.

IMPORTANT: Boom replacement must be completed in sequence, one boom section at a time these instructions. Replacement of two or more boom sections as a unit requires special considerations that are not covered in these instructions.

IMPORTANT: Before removing the inner boom, the carriage or any other attachment must be removed from the quick attach.

The inner, intermediate and outer boom removal instructions must be completed in sequence. The inner boom must be removed before removing the intermediate boom. The inner boom and intermediate boom must be removed one at a time before removing the outer boom.

Note: A step ladder or some other safe means of accessing the boom will be necessary.

Before beginning, conduct a visual inspection of the vehicle, work area and task about to be undertaken. Read, understand and follow these instructions.

After servicing the boom, perform the following:

1. Check wear pads for excessive wear. (Refer to appropriate Owners/Operators Manual.)

2. Check chain wear and tension adjustment. (Refer to Section 3.4.1, “Boom Chain Inspection” and Section

3.4.3, “Boom Chain Tension Check.”)

3. Apply grease at all lubrication points (grease fittings). (Refer to appropriate Owners/Operators Manual.)

4. Check for proper operation by operating all boom functions through their full range of motion several times.

, as described in

Model 6042 Legacy Origin 7/02

3.3

Boom

3.3.1 Inner Boom Removal

WARNING: Wear protective footwear

with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.

WARNING: NEVER lift a heavy object

without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.

1. Remove any attachment from the quick attach assembly. (Refer to Section 3.6.1, “Disconnecting from an Attachment.”)

Note: This procedure will require a clear space of approximately 16 feet at the front and rear of the vehicle.

2. Park the vehicle on a hard, level surface. Move the boom to a horizontal (level) position. Extend (or retract) the boom until the boom is extended approximately two feet (610 mm). Retract the quick attach front face (Fig. 3-1, 1) until it is parallel to the ground (2). Place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake and shut the engine OFF.

3. Remove the thumbscrew (Fig. 3-2, 1), lockwasher (2) and flat washer (3) holding the rear cover (4) to the rear of the outer boom (5). Lift the rear cover straight up until the capscrew in the top of the cover clears the retaining hole in the top of the outer boom. Remove the cover from the outer boom.

MA9820

Figure 3- 2 Rear Cover on Outer Boom

4. At the rear of the boom, measure the amount of threads protruding beyond each elastic locknut (Fig. 3-3, 1) and record that measurement for reassembly. Loosen the two elastic locknuts (1) holding both extend chain clevis’ to the anchor plate (2) on the inner boom (3).

3.4

Figure 3-1 Quick Attach Parallel to Ground

MA10,0500

MH1751

Figure 3-3 Extend Chain Locknuts

Model 6042 Legacy Origin 7/02

5. Remove the elastic locknut (Fig. 3-4, 1) and shoulder bolt (2) holding the two yoke plates (3) to the mount at the front of the outer boom. Retain the shoulder bolt and discard the elastic locknut.

6. Inspect the yoke plates (Fig. 3-4, 3) for wear or distortion. If any wear or distortion is detected, both plates must be replaced. If no wear is detected, the plates can remain assembled to the extend chain clevis.

Figure 3-5 Front Top Wear Pads

Boom

MA10,0420

MA10,0410

Figure 3-4 Extend Chain Yoke Plates

7. Pull the two extend chains, with the yoke plates attached, towards the front of the boom and lay them on the top of the inner boom.

8. Remove the capscrew (Fig. 3-4, 4) and lockwasher (5) holding the extend chain sheave pin (6) to the mounting ears on the intermediate boom. Remove the pin from the mounting ears and the extend chain sheave (7). Remove the extend chain sheave and inspect the condition of the sheave bushings. Replace the bushings if showing any signs of wear.

9. Inspect the pin (Fig. 3-4, 3), and replace the pin if there are any signs of wear.

10. At the front of the intermediate boom (Fig. 3-5, 1), remove the capscrews (2) and lockwashers (3) holding the top wear pads (4), spacers (5) and shims (6) (if present) to the inside of the intermediate boom. Label the wear pads, spacers and shims as “Top Left” and “Top Right” sides. Also note the orientation of the mounting hole offset. Save the shims, spacers, capscrews, lockwashers and wear pad inserts (7).

11. At the front of the intermediate boom (Fig. 3-6, 1), remove the capscrews (2), lockwashers (3) and flat

washers (4) holding the side wear pads (5) and shims (6) to the inside of the intermediate boom. Label the wear pads and shims as “Left Upper/Lower” and “Right Upper/Lower.” Also note the orientation of the mounting hole offset. Save the shims, capscrews, flat washers, lockwashers and wear pad inserts (7).

Figure 3- 6 Front Left and Right Side Wear Pads

MA10,0430

12. Return to the cab, fasten your seat belt and start the engine. Retract the boom slightly until slack is noticed in the extend chain. Shut the engine OFF.

13. Move the attachment tilt joystick in both directions to relieve any trapped pressure in the attachment tilt system. Move the auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the auxiliary hydraulics system.

Model 6042 Legacy Origin 7/02

3.5

Boom

14. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the vehicle should not be operated. (Refer to Section 1.5, “Accident Prevention Tag Usage.”)

15. Allow the engine, transmission and hydraulic fluid to cool before proceeding.

16. Disconnect the battery negative (-) cable at the battery negative (-) terminal to prevent the engine from starting accidentally.

WARNING: Hydraulic fluid leaking under

pressure can penetrate the skin, cause infection, gangrene, and death or serious personal injury. If injured, see a doctor immediately.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any parts or component.

WARNING: Wait for the hydraulic fluid

to cool before servicing any hydraulic component. Hot hydraulic oil can cause severe burns.

17. Locate the two hoses (Fig. 3-7, 1) attached to the base of the attachment tilt cylinder (2) inside the gooseneck (3).

18. Label and remove the hoses (Fig. 3-7, 1) from the fittings (4) on the attachment tilt cylinder. Plug the hose ends and cap the fittings on the attachment tilt cylinder to prevent dirt and debris from entering the hydraulic system and/or cylinder.

19. Label and remove the two hoses (Fig. 3-8, 1) from the bulkhead fittings (2) inside the gooseneck (3). Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system.

If you are replacing the inner boom with a new inner boom: Remove the female coupler, male nipple and bulkhead fittings from the bulkhead plate inside the gooseneck.

Figure 3-8 Auxiliary Hydraulic Hoses

20. Inside the inner boom, loosen but DO NOT remove the two capscrews (Fig. 3-9, 1) securing the left side wear pad and hose clamp support bracket (2) to the top of the inner boom.

21. Remove the two capscrews (Fig. 3-9, 3), two lockwashers (4) and two flat washers (5) holding the stack clamps (6) and hose clamp support bracket (2) to the left side of the inner boom. Remove the clamps and the clamp support bracket from the inner boom.

MH0841

3.6

Figure 3- 7 Attachment Tilt Cylinder Hoses

MH1740

Model 6042 Legacy Origin 7/02

Boom

Figure 3-9 Clamp Support Bracket Inside Inner Boom

22. Pull the free ends of the attachment tilt hoses (Fig. 3-10, 1) and auxiliary hydraulic hoses (2) from inside the inner boom and out the rear of the boom (3). Allow the hoses to hang from the rear of the boom.

MH2840

OA0512

Figure 3- 11 Retract Chain Locknut

Note: Record the location of the shoulder bolt (Fig. 3-12, 1) to ensure correct installation.

24. At the rear of the boom, locate the retract chain (Fig. 3-12, 2) on the right side of the boom. In front of the retract chain sheave, locate the shoulder bolt (1) which holds the retract chain to the anchor plates on the inner boom. Remove the elastic locknut (3) from the shoulder bolt and remove the shoulder bolt. Save the shoulder bolt and discard the elastic locknut. Allow the retract chain to hang out the rear of the boom.

Figure 3-10 Attachment Tilt and Auxiliary Hydraulic Hoses

MH0870

23. At the front, on the bottom of the outer boom, measure the amount of threads protruding beyond the elastic locknut (Fig. 3 -11, 1) and record that measurement for reassembly. Loosen, but do not remove, the retract chain locknut.

Model 6042 Legacy Origin 7/02

MH2550

Figure 3-12 Retract Chain

3.7

Boom

Note: If replacing the inner boom assembly with a new inner boom, the quick attach assembly and the attachment tilt cylinder should be removed at this time.

If the inner boom is not to be replaced, the quick attach assembly and attachment tilt cylinder can remain in place. Proceed to Step 34.

25. Remove the elastic locknut (Fig. 3-13, 1) and capscrew (2) holding the attachment tilt cylinder rod end pin (3) to the quick attach assembly (4). Save the capscrew and discard the elastic locknut.

26. Support the rod end of the attachment tilt cylinder (Fig. 3-13, 5). Use a brass punch and a rawhide hammer to remove the rod end pin (3) from the quick attach assembly.

27. Inspect the pin (Fig. 3-13, 3) for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged and if it cannot be repaired, the pin must be replaced.

30. Inspect the pin for nicks or surface corrosion. Use fine emery cloth to repair minor nicks or corrosion. If damaged and if it cannot be repaired, the pin must be replaced.

Figure 3- 14 Quick Attach Pivot Pin Removal

MH0950

Figure 3- 13 Attachment Tilt Cylinder Rod

End Pin Removal

28. Remove the elastic locknut (Fig. 3-14, 1) and capscrew (2) holding the quick attach pivot pin (3) to the quick attach assembly (4). Save the capscrew and discard the elastic locknut. Place a support under the quick attach assembly to prevent it from dropping when the pivot pin is removed.

29. Use a brass punch and a rawhide hammer to remove the quick attach pivot pin (Fig. 3-14, 3) from the quick attach assembly and the bushings in the gooseneck. Record the location and quantity of the shim washers (5 and 6) as the pin is being removed. Save the washers (5 and 6) from each side of the quick attach.

MH0940

Note: The attachment tilt cylinder is heavy. Use a hoist and sling to support the attachment tilt cylinder when the base end pin is removed.

31. Remove the retaining ring (Fig. 3-15, 1) from one side of the base end pivot pin (2). Save the retaining ring. Use a brass punch and a rawhide hammer to remove the base end pivot pin from the inner boom gooseneck (3).

32. Inspect the pin for nicks or surface corrosion. Use fine emery cloth to repair minor nicks or corrosion. If damaged and if it cannot be repaired, the pin must be replaced.

Figure 3-15 Attachment Tilt Cylinder Removal

MH0960

3.8

Model 6042 Legacy Origin 7/02

33. Lower the attachment tilt cylinder (Fig. 3 -15, 4) with the hoist and remove from the backside of the gooseneck. Place the attachment tilt cylinder on a clean, level surface.

Note: Use a hoist capable of lifting 5,000 lbs (2268 kg) and two slings to remove the inner boom.

34. Place the slings around the inner boom. Pull the inner boom straight out of the intermediate boom. Reposition the slings as needed so the inner boom balances when removed from the intermediate boom. Carefully lower the inner boom onto suitable supports or to the ground. Support the boom as needed to prevent it from tipping over.

WARNING: NEVER weld or drill the

boom. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling. Failure to comply can result in death or serious personal injury.

35. Inspect the boom and welds. Contact the local

OmniQuip Authorized Service Center (ASC) or the OmniQuip Service Department if structural damage

is detected.

36. Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the inner boom removed. Replace if damaged.

37. Inspect all wear pads (Fig. 3-16, 1) for excessive wear. If the, angled cut, wear indicators (2) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.

Figure 3-16 Wear Pad Wear Indicators

Note: If you are not replacing the inner boom with a new boom section, the remaining items may stay on the boom and you can proceed to the next section. If you are replacing the inner boom with a new boom section, the following items need to be removed from the boom and installed in the same position on the new boom section:

MA2071

Boom

Figure 3- 17 Extend Chain Locknuts

39. At the rear of the inner boom (Fig. 3-18, 1), remove the capscrews (2) and lockwashers (3) holding the top wear pads (4), spacers (5) and shims (6) to the top of the inner boom. Label the wear pads, spacers and shims as “Top Left” and “Top Right” sides. Also note the orientation of the mounting hole offset. Save the spacers, shims, capscrews, lockwashers and wear pad inserts (7).

40. Remove the capscrews (Fig. 3-18, 8), lockwashers (9) and flat washers (10) holding the side wear pads (11) and shims (12) to the sides of the inner boom. Label the wear pads and shims as “Left Side Upper/ Lower” and “Right Side Upper/Lower.” Also note the orientation of the mounting hole offset. Save the shims, capscrews, lockwashers, flat washers and wear pad inserts (13).

41. Remove the capscrews (Fig. 3- 18, 14) and lockwashers (15) holding the bottom wear pad (16) and spacer (17) to the bottom of the inner boom. Label the wear pad and spacer as “Bottom.” Also note the orientation of the mounting hole offset. Save the spacer, capscrews, lockwashers and wear pad inserts (18).

4 5

MA10,0440

14 15

38. At the rear of the boom, remove the two elastic locknuts (1) and flat washers (2) holding both extend chain clevis’ (3) to the anchor plate (4) on the inner boom (5). Save the flat washers and discard the elastic locknuts.

Model 6042 Legacy Origin 7/02

Figure 3-18 Inner Boom Wear Pad Removal

MA10,0520

3.9

Boom

3.3.2 Intermediate Boom Removal

WARNING: Wear protective footwear

with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.

WARNING: NEVER lift a heavy object

without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.

1. Remove the inner boom as described in Section

3.3.1, “Inner Boom Removal.”

2. At the front of the outer boom (Fig. 3 -19, 1), remove the capscrews (2), lockwashers (3) and flat washers (4) holding the top wear pads (5) and shims (6) (if present) to the inside of the outer boom. Label the wear pads as “Top Left” and “Top Right” sides. Also note the orientation of the mounting hole offset. Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (7).

Figure 3- 20 Outer Boom Front Left and

Right Side Wear Pads

4. Remove the capscrews (Fig. 3-21, 1) and lockwashers (2) holding the center wear pad spacer mount (3) to the front of the outer boom. Save the capscrews and the lockwashers.

MA10,0460

MA10,045

Figure 3-19 Outer Boom Front Top Wear Pads

3. At the front of the outer boom (Fig. 3 -20, 1), remove the capscrews (2), lockwashers (3) and flat washers (4) holding the side wear pads (5) and shims (6) (if present) to the inside of the outer boom. Label the wear pads as “Left Side Upper/Lower” and “Right Side Upper/Lower.” Also note the orientation of the mounting hole offset. Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (7).

3.10

Figure 3- 21 Outer Boom Center Wear Pad

5. At the rear of the intermediate boom, remove the capscrew (Fig. 3-22, 1) and lockwasher (2) holding the retract chain sheave pin (3) to the mounting plate inside the boom.

Model 6042 Legacy Origin 7/02

MA10,0470

Boom

6. Remove the retract chain sheave pin (Fig. 3-22, 3) from the mount and the retract chain sheave (4). Remove the retract chain sheave from the intermediate boom.

7. Inspect the bushings inside the sheave. Replace the bushings if there are any signs of wear. Inspect the pin for wear or damage. Replace the pin if showing signs of wear.

MH1020

Figure 3-22 Intermediate Boom, Retract Chain Sheave

8. At the rear of the intermediate boom, remove the capscrews (Fig. 3-23, 1), lockwashers (2) and flat washers (3) holding the hose reel assembly (4), lower wear pad (5) and spacer (6) to the lower plate on the intermediate boom. Reassemble the capscrews, lockwashers and flat washers to hold the lower wear pad in place for intermediate boom removal.

9. Remove the capscrews (Fig. 3-24, 1), lockwashers (2) and flat washers (3) holding the hose reel side plate (4), lower left side wear pad (5) and shims (6) (if present) to the side of the intermediate boom. Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (7). Watch for the six washers (8) to fall out from between the side plate of the hose reel assembly and the side plate of the intermediate boom.

MH1040

Figure 3- 24 Intermediate Boom, Hose Reel Side Plate

2 3

5 6

Figure 3-23 Intermediate Boom, Hose Reel Assembly

Model 6042 Legacy Origin 7/02

MH1030

3.11

Boom

10. Pull the hose reel with hoses out the back of the intermediate boom. Allow the hose reel assembly to slide down the hoses and rest it on the floor.

11. Label and remove the hoses from the hose reel. The center bolt (Fig. 3-25, 1) can remain in place to hold the hose reel and side plates together.

a. Remove the 3/8-16 elastic locknut (Fig. 3-25, 2)

and 3/8" flat washer (3) from the lower retaining shoulder bolt (4). While pulling the shoulder bolt out, catch the spacers (5) from between the plates as the bolt is removed. Pull the bolt out far enough to remove the hoses from the hose reel.

b. After the hoses are removed from behind the

lower retaining bolt, insert the shoulder bolt (Fig. 3-25, 4) through the plates, inserting the spacers (5) between the plates as the bolt is inserted. Reassemble the 3/8" flat washer (3) and 3/8-16 elastic locknut (2) to hold the shoulder bolt in place. DO NOT fully tighten at this time.

c. Remove the 1/2-13 elastic locknut (Fig. 3-25, 6)

from the upper retaining capscrew (7). While pulling the capscrew out, catch the spacers (8) from between the plates as the capscrew is removed. Pull the capscrew out far enough to remove the hoses from the hose reel. Make sure that spacer (9) and washer (10) remain in place between the inside two plates (11) of the hose reel assembly.

d. After the hoses are removed, insert the capscrew

(Fig. 3-25, 7) through the plates, inserting the spacers (8) between the plates as the capscrew is inserted. Reassemble the 1/2-13 elastic locknut (6) to hold the capscrew in place.

12. At the front of the outer boom, label and remove the auxiliary hoses (Fig. 3-26, 1 and 2) from the tube assemblies (3) at the mounting plate. Plug the hose ends and cap tube ends.

13. Label and remove the attachment tilt hoses (Fig. 3-26, 4 and 5) from the tube assemblies (6) at the mounting plate. Plug the hose ends and cap tube ends.

FRONT

MA9890

Figure 3-26 Attachment Tilt and Auxiliary Hydraulic Hose

14. Pull the hose ends out from between the intermediate boom and the outer boom and out the rear of the boom.

15. Support the front of the extend/retract cylinder.

16. Remove the retaining ring (Fig. 3-27, 1) from one side of the extend/retract cylinder rod end mounting pin (2). Use a brass punch and a rawhide hammer to remove the rod end pin from the mounting ears (3) on the intermediate boom.

17. Inspect the pin (Fig. 3-27, 2) for wear or damage. Use fine emery cloth to repair minor nicks or corrosion. If the pin is damaged, replace it. Save the retaining ring.

3.12

Figure 3-25 Hose Reel Retaining Hardware

MH1491

Model 6042 Legacy Origin 7/02

Boom

Figure 3-27 Extend/Retract Cylinder Rod End Pin

MA10,0490

Note: Use a hoist with a lifting capacity of 5,000 lbs (2268 kg) and two slings to remove the intermediate boom.

18. Place the slings around the intermediate boom. Pull the intermediate boom straight out of the outer boom. Reposition the slings as needed so the intermediate boom balances when removed from the outer boom. Set the intermediate boom down on

blocks on a hard, level surface.

WARNING: NEVER weld or drill the

boom. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling. Failure to comply can result in death or serious personal injury.

19. Inspect the boom and welds. Contact the local

OmniQuip Authorized Service Center (ASC) or the OmniQuip Service Department if structural damage

is detected.

20. Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the intermediate boom removed. Replace if damaged.

21. Inspect all wear pads (Fig. 3-28, 1) for wear. If the, angled cut, wear indicators (2) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.

Figure 3-28 Wear Pad Wear Indicators

MA2071

Figure 3-29 Intermediate Boom, Lower Front Wear Pads

MA10,0480

22. If you are replacing the intermediate boom with a new boom section, the following items need to be removed from the intermediate boom and installed in the same position on the new boom section:

a. Remove the lower wear pads at the front of the

boom. Remove the capscrews (Fig. 3-29, 1) and lockwashers (2) holding the lower wear pads (3) and spacers (4) to the inside of the boom. Label the wear pads and spacers as “Left” or “Right” sides. Also note the orientation of the mounting hole offset. Save the capscrews, lockwashers, spacers and wear pad inserts (5).

Model 6042 Legacy Origin 7/02

3.13

Boom

b. Remove the capscrews (Fig. 3-30, 1), lockwashers

(2) and flat washers (3) holding the bottom wear pad (4) and spacer (5) to the intermediate boom. Label the wear pad and spacer as “Bottom.” Also note the orientation of the mounting hole offset. Save the capscrews, lockwashers, flat washers, spacer and wear pad inserts (6).

2 1

MH1070

Figure 3-30 Intermediate Boom Rear Wear Pads

MH1060

c. Remove the capscrews (Fig. 3-31, 1), lockwashers

(2) and flat washers (3) holding the upper wear pads (4) and shims (5) (if present) to the intermediate boom. Label the wear pads and shims as “Top Left,” “Top Center” or “Top Right.” Also note the orientation of the mounting hole offset. Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (6).

Figure 3- 31 Intermediate Boom Upper Rear Wear Pads

d. Remove the capscrews (Fig. 3-32, 1), lockwashers

(2) and flat washers (3) holding the side wear pads (4) and shims (5) (if present) to the intermediate boom. Label the wear pads and shims as “Left Side Top” and “Right Side Top/Bottom.” Also note the orientation of the mounting hole offset. Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (6).

Figure 3-32 Intermediate Boom Side Wear Pads

MH1080

3.14

Model 6042 Legacy Origin 7/02

Boom

3.3.3 Outer Boom Removal

WARNING: Wear protective footwear

with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.

WARNING: NEVER lift a heavy object

without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.

1. Remove both the inner boom and intermediate boom as described in Section 3.3.1, “Inner Boom Removal,” and Section 3.3.2, “Intermediate Boom Removal.”

2. Use a suitable overhead lifting device and sling attached to the lift/lower cylinder (Fig. 3- 33, 1); remove slack from the sling.

3. Securely block the outer boom section.

4. At the front of the outer boom, remove the capscrews (Fig. 3-33, 1) and lockwashers (2) holding the wear pads (3) and spacers (4) to the inside of the outer boom. Label the wear pads and spacers as “Lower Left” or “Lower Right.” Also note the orientation of the mounting hole offset. Save the capscrews, lockwashers, spacers and wear pad inserts (5).

5. At the underside of the outer boom, locate the retract chain locknut (Fig. 3-34, 1). Remove the elastic locknut and the flat washer (2). Save the flat washer and discard the locknut.

Figure 3- 34 Retract Chain Locknut

6. Remove the retract chain by pulling it out the rear of the boom. Place the retract chain on a clean surface.

MH1110

Figure 3-33 Outer Boom Lower Wear Pads

Model 6042 Legacy Origin 7/02

MA10,0510

3.15

Boom

7. At the rear left side of the outer boom, label and remove the (outer) auxiliary hose for the female coupler (Fig. 3-35, 1) and the (inner) hose (2) for the male nipple from the tubes on the mounting plate (3). Plug the hose ends and cap tube ends.

8. Label and remove the attachment tilt retract (outer) hose (Fig. 3-35, 4) and the extend (inner) hose (5) from the tubes on the mounting plate (3). Plug the hose ends and cap tube ends.

MA9790

Figure 3-35 Auxiliary Hydraulic Hoses

9. At the rear right side of the outer boom, label and remove the boom extend hose (Fig. 3- 36, 1) and retract hose (2) coming from the bulkhead plate on the frame to the tubes on the mounting plate (3). Plug the hose ends and cap tube ends.

11. At the rear right side of the outer boom, label the extend tube (Fig. 3-37, 1) and retract tube (2) Remove the bulkhead nuts (3). Lift the tube out of the bulkhead plate (4) and re-thread the nut onto the end of the tube.

12. Remove the capscrew (Fig. 3- 37, 5) and flat washers (6) holding the tube clamps (7) and clamp cover (8) to the boom. Retain the capscrew, flat washers, cover and clamps.

13. Remove both tubes (Fig. 3-37, 1 & 2) from the boom.

Figure 3-37 Extend and Retract Tubes

MA9800

14. Label the auxiliary tube assemblies (Fig. 3-38, 1) located under the attachment tilt tubes (2). Remove the capscrews (3) holding the tube clamps (4) and clamp covers (5) to the attachment tilt tube clamp stacking bolt (6) under the outer boom. Save the capscrews, clamps and clamp covers.

15. Remove the bulkhead nuts (Fig. 3-39, 1) from the auxiliary tube assemblies (2). Lift the tube out of the bulkhead plate and re-thread the nut onto the end of the tube.

Figure 3 -36 Boom Extend and Retract Hoses

10. Label and remove the boom extend hose (Fig. 3-36, 4) and the retract hose (5) from the tubes (6). Plug the hose ends and cap tube ends.

3.16

MA9780

Model 6042 Legacy Origin 7/02

Boom

16. Label the attachment tilt tube assemblies (Fig. 3- 38, 2) located under the boom. Remove the stacking bolts (6) holding the tube clamps (7), locking plates (8) and attachment tilt tubes (2) to the underside of the outer boom. Save the stacking bolts, clamps and locking plates.

8 1

MH1191

19. Remove the capscrew (Fig. 3-40, 1) and elastic locknut (2) holding the upper slave cylinder pivot pin (3) to the outer boom. Securely block (4) the slave cylinder (5) in position. Remove the pivot pin from the pin mount by pulling the pin out. It may be necessary to use an appropriate puller threaded into the pivot pin to remove the pin. Discard the elastic locknut and retain the capscrew.

20. Inspect the pivot pin (Fig. 3-40, 3) for nicks or damage. If the pin is damaged, it must be replaced.

21. Repeat Steps 19-20 to remove the other upper slave cylinder pivot pin.

Figure 3-38 Auxiliary Hydraulic and Attachment Tilt Tubes

17. Remove the bulkhead nuts (Fig. 3-39, 3) from the attachment tilt tube assemblies (4). Lift the tube out of the bulkhead plate and re-thread the nut onto the end of the tube. Cap both ends and remove the tubes from the boom.

18. Inspect all tubes (Fig. 3- 38, 1 and 2) for kinks or crushed areas. If any kinks or crushed areas exist, replace the damaged tube or tubes.

MA9810

MA9760

Figure 3-40 Upper Slave Cylinder Pivot Pin

Figure 3-39 Remove Bulkhead Nuts From Auxiliary

Hydraulic and Attachment Tilt Tubes

Model 6042 Legacy Origin 7/02

3.17

Boom

22. On the right side boom pivot mounting plate, locate the boom sensor (Fig. 3-41, 1). Remove the hex nut (2) on the inside of the mounting plate. Remove the boom sensor from the outside of the plate, re-thread the nut onto the sensor and allow the sensor to rest on top of the frame, next to the mounting plate. The sensor can remain connected to the harness.

MA9960

Figure 3-41 Boom Sensor

Note: Use a hoist capable of lifting 5,000 lbs (2268 kg) and two slings. Place the slings around the outer boom. The slings should be placed far enough apart on the outer boom so the boom will balance when the boom lift/lower cylinder mounting pins and pivot pins are removed in the following steps.

23. Remove the capscrew (Fig. 3-42, 1) and elastic locknut (2) holding the upper lift/lower cylinder pivot pin (3) to the outer boom. Securely block the lift/lower cylinder in position. Remove the pivot pin from the pin mount by pulling the pin out. It may be necessary to use an appropriate puller threaded into the pivot pin to remove the pin. Discard the elastic locknut and retain the capscrew.

24. Inspect the pivot pin (Fig. 3 -42, 3) for nicks or damage. If the pin is damaged, it must be replaced.

25. Repeat Steps 23 and 24 to remove the other lift/lower cylinder.

MA9750

Figure 3-42 Lift/Lower Cylinder Pivot Pins

26. Remove the capscrews (Fig. 3-43, 1) and elastic locknuts (2) holding the boom pivot pins (3) to the frame. Use a brass punch and a rawhide hammer to remove the pivot pins from the frame. While removing the pins, note the location, quantity and size of the shims (4) between the outer boom and frame.

MA9900

Figure 3- 43 Outer Boom Pivot Pins

3.18

Model 6042 Legacy Origin 7/02

27. Use the hoist to remove the outer boom from the frame. Position the outer boom on a hard, flat surface. Block the boom as required to allow removal of the extend/retract cylinder from the underside of the boom.

28. Use a hoist and slings to support the extend/retract cylinder. At the base end of the cylinder, remove a retaining ring (Fig. 3-44, 1) from one side of the cylinder base end pin (2). Use a brass punch and a rawhide hammer to remove the base end pin from the mounting ears on the outer boom.

29. Inspect the pin (Fig. 3-44, 2) for damage. If the pin is damaged, it should be replaced. Retain the retaining rings for reassembly.

Boom

Figure 3- 45 Rubber Bumper

33. Inspect the bearings (Fig. 3-46, 1). If the bearing rotates freely inside the outer race, the bearing can be left in place. If the bearing is damaged it must be replaced

34. Remove the self-aligning bearings (Fig. 3-46, 1) from the lift/lower cylinder mounts (2) and the slave cylinder mounts (3).

MA7761

MA9910

Figure 3-44 Extend/Retract Cylinder Base End Pin

30. Lower the base end of the extend/retract cylinder and remove the rod end of the cylinder from the retainer at the front of the boom. Place the extend/ retract cylinder on a clean, flat surface.

31. At the front of the outer boom, remove the elastic locknut (Fig. 3-45, 1) holding the rubber bumper (2) to the extend/retract cylinder retainer (3). Discard the elastic locknut.

32. Inspect the rubber bumper (Fig. 3-45, 2). If it is in good condition, the rubber bumper can be reused. If the rubber bumper is showing signs of cracking or deterioration, it should be replaced.

Model 6042 Legacy Origin 7/02

Figure 3- 46 Lift/Lower and Slave Cylinder Bearings

MA9920

3.19

Boom

35. If replacing the outer boom assembly, on the left side of the outer boom, remove the locknut (Fig. 3-47, 1), angle indicator (2) and flat washers (3) from the weld stud. Save the angle indicator and all the hardware for reassembly. If not replacing the boom section, the angle indicator can remain in place.

MA9980

Figure 3-47 Angle Indicator

WARNING: NEVER weld or drill the

boom. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling. Failure to comply can result in death or serious personal injury.

36. Inspect the boom and welds. Contact the local

OmniQuip Authorized Service Center (ASC) or the OmniQuip Service Department if structural damage

is detected.

37. Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the outer boom removed. Replace if damaged. Refer to Section 3.4.1, “Boom Chain Inspection,” and Section

3.5.1, “Boom Wear Pad Replacement.”

38. Inspect all wear pads (Fig. 3-48, 1) for wear. If the, angled cut, wear indicators (2) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as set if worn or damaged.

Figure 3-48 Wear Pad Wear Indicators

MA2071

3.20

Model 6042 Legacy Origin 7/02

Boom

3.3.4 Outer Boom Installation

WARNING: Wear protective footwear

with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.

WARNING: NEVER lift a heavy object

without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.

IMPORTANT: Light lubrication of the boom wear surfaces with a rust inhibitor/lubricant such as LPS 3 or equivalent is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended in salt air climates and when the vehicle is stored, to help prevent rusting.

Note: If you are assembling a new outer boom assembly, follow all instructions. If reassembling the existing boom assembly, go to Step 4.

1. With the boom level, hang the angle indicator pointer (1) to the weld stud (2) on the outer boom (3). Lightly place a vertical mark (4) from the point on the indicator, down approximately 3".

2. Assemble a new angle indicator decal (Fig. 3-50, 1) to the left side of the boom assembly. Place the hole in the decal around the weld stud (2) and line up 0° mark (3) on the decal with the mark (4) made in step 1.

3 4

MA9990

Figure 3 -50 Boom Angle Indicator Decal

3. Place the two flat washers (Fig. 3-51, 1) and the angle indicator (2) onto the weld stud. Secure in place with the locknut (3). After tightening the locknut, the angle indicator must pivot freely on the weld stud, in both directions. If the angle indicator binds, loosen the locknut slightly. Recheck to be sure the angle indicator pivots freely.

Figure 3-49 Assembly Mark for Boom Indicator Decal

Model 6042 Legacy Origin 7/02

MA9970

MA9980

Figure 3-51 Boom Angle Indicator

3.21

Boom

4. Install new or saved lift/lower cylinder bearings (Fig. 3-52, 1) into the lift/lower cylinder mounts (2) on each side of the boom assembly. Orient the fracture (3) in the outer race of each bearing at the 3 o’clock position. Press the bearings into position until the edge of the outer race (4) of each bearing is flush with the edge of the plate (5).

5. Install new or saved slave cylinder bearings (Fig. 3-52, 6) into the slave cylinder mounts (7) on each side of the boom assembly. Orient the fracture (3) in the outer race of each bearing at the 3 o’clock position. Press the bearings into position until the edge of the outer race (4) of each bearing is flush with the edge of the plate (5).

6. Install new 1/8 NPT male thread self tapping straight grease fittings (Fig. 3 -52, 8) into the lift/lower cylinder mounts (2) and the slave cylinder mounts (7) on the outer boom. Tighten all the grease fittings.

Note: Slings and a hoist are required to perform the following step.

7. Position the extend/retract cylinder (Fig. 3-53, 1) with the extend and retract port elbows facing down. Place the rod end of the extend/retract cylinder (2) through the extend/retract cylinder retainer at the front of the outer boom. At the rear of the extend/ retract cylinder, align the hole in the base end of the cylinder with the holes in the mounting ears (3) under the outer boom.

8. Coat the base end cylinder pin with anti-seize compound. Insert the base end cylinder pin (Fig. 3-53, 4) through both mounting ears and the base end of the extend/retract cylinder. Secure the pin in place with a retaining ring (5) on each side of the pin. Be sure the retaining rings are completely seated in the grooves on each side of the pin.

Figure 3-52 Install Lift/Lower and Slave

Cylinder Bearings

MA9930

Figure 3-53 Install the Extend/Retract Cylinder

9. Lift the rod end of the extend/retract cylinder (Fig. 3-54, 1) far enough to insert the threaded stud on the rubber bumper (2) into the hole in the extend/ retract cylinder retainer (3). Secure the rubber bumper in place with a new 3/8-16 elastic locknut (4). Tighten securely. Lower the rod end of the extend/retract cylinder, and allow it to rest on the rubber bumper.

MA9940

3.22

Model 6042 Legacy Origin 7/02

Figure 3-54 Rubber Bumper

MA10,0530

Note: Use a hoist capable of lifting 5,000 lbs (2268 kg) and two slings to install the outer boom.

10. Using a capable hoist and slings, lift the outer boom assembly and position the boom on the frame. Align the mounting plates (Fig. 3-55, 1) on the frame between the mounting hubs (2) on each side of the boom assembly. Be sure the lift/lower and slave cylinder mounts on the boom go between the cylinder rod ends (3). Lower the boom assembly until the holes in the boom assembly and the mounting plates align.

Boom

11. On the end of the boom pivot pin (Fig. 3-56, 1), closest to the capscrew hole, mark the capscrew mounting hole location. Coat the entire pin with anti-seize compound.

12. Insert the pivot pin (Fig. 3-56, 1) from the outside of the boom assembly, making sure the marks for the capscrew mounting hole stay in line with the capscrew mounting holes in the boom mounting hub. If necessary, use a rawhide hammer to install the pivot pin.

13. Shim the boom as required using the shims (Fig. 3-56, 2), saved, to maintain a .10" (2,5 mm) maximum gap (3) between the boom mounting hub (4) and the self aligning bearing (5) in the frame. If an additional shim is required to maintain the maximum gap, insert the extra shim on the right side of the boom.

Figure 3-55 Outer Boom Installation

Model 6042 Legacy Origin 7/02

Figure 3-56 Boom Pivot Pin and Shims

MA9740

14. After the pivot pin and shims are in place, use a tapered punch to align the capscrew hole in the pin with the mounting holes in the hub. Insert the

MA9730

capscrew (Fig. 3-56, 6), saved, through the hub and the pin. Secure the capscrew in place with a new 5/8-11 elastic locknut (7). Tighten the elastic locknut securely.

3.23

Boom

15. Align the rod end of one of the lift/lower cylinders (Fig. 3-57, 1) with the self-aligning bearing on the outer boom assembly.

16. Coat the entire lift/lower cylinder pivot pin (Fig. 3-57, 2) with anti-seize compound. Insert the pin through the rod end of the cylinder and the self-aligning bearing. If necessary, use a rawhide hammer to install the pin.

17. Use a tapered punch to align the capscrew mounting hole in the pin with the mounting tabs on the rod end of the cylinder. Secure the pin in place with the capscrew (Fig. 3- 57, 3), saved, and a new 1/2-13 elastic locknut (4). Tighten the elastic locknut securely.

18. Repeat Steps 15-17 to install the lift/lower cylinder on the other side of the outer boom.

19. Remove the blocks that were used to hold the lift/lower cylinder in place.

20. Use a hoist and sling to position the rod end of the slave cylinder (Fig. 3- 58, 1) in line with the selfaligning bearing on the outer boom.

21. Coat the upper pivot pin (Fig. 3-58, 2) with anti-seize compound. Insert the pin through the rod end of the slave cylinder. If necessary, use a rawhide hammer to install the upper pivot pin. Use a tapered punch to align the capscrew hole in the pin with the mounting tabs on the cylinder. Secure the upper pivot pin in place with the capscrew (3), saved, and a new 1/2-13 elastic locknut (4). Tighten the elastic locknut securely.

22. Repeat Steps 20-21 to install the other slave cylinder to the other side of the outer boom.

23. Remove the blocks (5) that were used to hold the slave cylinder in place.

Figure 3- 57 Lift/Lower Cylinder Reassembly

MA9750

Figure 3-58 Slave Cylinder Reassembly

MA9760

3.24

Model 6042 Legacy Origin 7/02

24. Insert the boom sensor (Fig. 3-59, 1) through the hole in the right side mounting plate (2). Install the jam nut (3), saved, onto the boom sensor on the inside of the plate. Adjust the inner and outer jam nuts on the boom sensor until the gap (4) between the sensor and the boom is .12" (3 mm). Torque the inside jam nut to 36 lb-in (4,1 Nm), to hold the boom sensor in position.

MA9770

Figure 3-59 Reassemble Boom Sensor

25. Assemble the boom extend tube (Fig. 3- 60, 1) to the inside hole in the mounting plate (2) on the right side of the boom. Loosely install the nut (3) to the end of the tube.

26. Assemble the boom retract tube (Fig. 3-60, 4) to the outside hole in the mounting plate (2) on the right side of the boom. Loosely install the nut (5) to the end of the tube.

Boom

Figure 3-60 Extend and Retract Tubes

27. Assemble one tube clamp half (Fig. 3-60, 6) to the weld nut on the right side of the outer boom. Assemble the other clamp half (6) with the tubes onto the first clamp half. Place a clamp cover (7) over the outside clamp half. Secure in place with the 5/16-18 x 2" capscrew (8) and three flat washers (9), saved. Tighten the capscrew securely.

28. Finish securing both the extend (Fig. 3-60, 1) and retract (4) tubes to the mounting plate by tightening the bulkhead nuts (3 and 5) securely.

MA9800

Model 6042 Legacy Origin 7/02

3.25

Boom

29. Assemble the inside boom extend hose (Fig. 3-61, 1), coming from the frame bulkhead plate, to the boom extend tube (2), mounted to the inside of the mounting plate (3). Remove all twists from the hose, and tighten the end securely to the end of the tube.

30. Assemble the outside boom retract hose (Fig. 3-61, 4), coming from the frame bulkhead plate, to the boom retract tube (5), mounted to the outside of the mounting plate (3). Remove all twists from the hose, and tighten the end securely to the end of the tube.

MA10,0150

Figure 3 -61 Boom Extend and Retract Hoses

31. Assemble the front boom extend cylinder hose (Fig. 3-61, 6), coming from the extend cylinder under the boom, to the boom extend tube (2). Remove all twists from the hose, and tighten the end securely to the end of the tube.

32. Assemble the rear boom retract cylinder hose (Fig. 3-61, 7), coming from the extend cylinder under the boom, to the boom retract tube (5). Remove all twists from the hose, and tighten the end securely to the end of the tube.

33. Position the attachment tilt cylinder extend tube assembly (Fig. 3- 62, 1) in the bottom inside hole on the mounting plate (2). Assemble the nut (3) on the end of the tube assembly; DO NOT fully tighten until both attachment tilt tubes are assembled in the tube clamps under the boom.

34. Position the attachment tilt cylinder retract tube assembly (Fig. 3-62, 4) in the top inside hole on the mounting plate (2). Assemble the nut (5) on the end of the tube assembly; DO NOT fully tighten until both attachment tilt tubes are assembled in the tube clamps under the boom.

35. Assemble the upper tube clamps (Fig. 3-63, 1), saved, to the underside of the outer boom in all three positions. Place the upper clamp halves (1) on each side of the attachment tilt (upper) tubes (2). Loosely secure the clamp halves to the boom with a stacking bolt (3), saved. Verify that the tubes sit properly in all three tube clamp positions and the mounting plate. Tighten the stacking bolts securely to hold the upper tubes and the locking plate (4), saved, in place in all three positions.

36. Fully tighten both attachment tilt tube bulkhead nuts (Fig. 3-62, 3 and 5).

37. Position the auxiliary tube assembly (Fig. 3-62, 6),

going to the male coupler, in the bottom outside hole on the mounting plate (2). Assemble the nut (7) on the end of the tube assembly; DO NOT fully tighten until both attachment tilt tubes are assembled in the tube clamps under the boom.

38. Position the auxiliary tube assembly (Fig. 3-62, 8), going to the female coupler, in the top outside hole on the mounting plate (2). Assemble the nut (9) on the end of the tube assembly; DO NOT fully tighten until both attachment tilt tubes are assembled in the tube clamps under the boom.

MA9810

3.26

Figure 3-62 Attachment Tilt and Auxiliary Hydraulic

Tube Assemblies

Model 6042 Legacy Origin 7/02

Boom

39. Place the lower clamp halves (Fig. 3-63, 5) on each side of the auxiliary hydraulic (lower) tubes (6). Loosely secure the lower clamp halves to the stacking bolt with a clamp cover (7), saved, and a 5/16-18 x 1-1/4" capscrew (8), saved. Verify that the tubes sit properly in all three tube clamp positions and the mounting plate. Tighten the capscrews securely to hold the lower tubes in place in all three positions.

40. Fully tighten both auxiliary tube bulkhead nuts (Fig. 3-62, 7 and 9).

MH1191

41. Connect the attachment tilt extend hose (Fig. 3-64, 1), coming from the front tee on the bulkhead plate on the frame, to the attachment tilt cylinder extend tube assembly (2), on the mounting plate (3) on the rear left side of the boom. Remove all twists from the hose, and tighten the end securely to the end of the tube.

42. Connect the attachment tilt retract hose (Fig. 3-64, 4), coming from the rear tee on the bulkhead plate on the frame, to the attachment tilt cylinder retract tube assembly (5), on the mounting plate (3) on the rear left side of the boom. Remove all twists from the hose, and tighten the end securely to the end of the tube.

43. Connect the auxiliary hydraulic hose (Fig. 3-64, 6) for the male nipple, coming from the front 45° fitting on the bulkhead plate on the frame, to the auxiliary tube assembly (7), on the mounting plate (3) on the rear left side of the boom. Remove all twists from the hose, and tighten the end securely to the end of the tube.

44. Connect the auxiliary hydraulic hose (Fig. 3-64, 8) for the female nipple, coming from the rear 45° fitting on the bulkhead plate on the frame, to the auxiliary tube assembly (9), on the mounting plate (3) on the rear left side of the boom. Remove all twists from the hose, and tighten the end securely to the end of the tube.

Figure 3-63 Auxiliary Hydraulic and

Attachment Tilt Tube Clamps

Figure 3- 64 Auxiliary Hydraulic and Attachment Tilt Hoses

MA9790

Model 6042 Legacy Origin 7/02

3.27

Boom

45. Make sure the retract chain has been inspected before installing it in the outer boom. Refer to Section 3.4.1, “Boom Chain Inspection.”

46. Inside the rear of the outer boom, slide the threaded clevis end (Fig. 3-65, 1) of the retract chain down the right side of the boom. Guide the threaded part of the clevis out through the hole in the tab (2) on the bottom of the outer boom. Pull threaded part of clevis all the way through the tab.

47. Coat the entire threaded portion of the clevis (Fig. 3-65, 1) with multi-purpose grease. Install one 3/4" flat washer (3), saved, onto the threaded clevis and assemble a new 3/4-16 elastic locknut (4). Thread the nut onto the clevis until the threads are flush with the top of the nut.

48. At the front of the outer boom, reassemble the lower outside wear pads (Fig. 3-66, 1) and wear pad spacers (2):

a. Place the wear pad inserts (Fig. 3-66, 3) into the

cavities in the wear pad. Be sure the inserts are seated completely in the cavities.

b. Place a wear pad (Fig. 3-66, 1) and a spacer (2)

into the outer boom with the hole offset of the wear pad toward the middle of the boom. Align the holes in the spacer and wear pads with the holes in the bottom of the boom.

c. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1-1/2" capscrews (Fig. 3-66, 4), saved. Insert the capscrews with lockwashers (5), saved, through the bottom of the boom and into the wear pads. Be careful not to push the wear pad inserts out of the wear pads.

d. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

e. Fill wear pad cavities with a good grade of

lithium-based EP grease.

f. Repeat Steps a-e to install the lower wear pad on

the other side of the outer boom.

Figure 3-65 Retract Chain and Hardware

MA9510

Figure 3- 66 Outer Boom Wear Pads

MH1470

3.28

Model 6042 Legacy Origin 7/02

Boom

49. Install the intermediate boom, retract chain and attaching hardware. (Refer to Section 3.3.5, “Intermediate Boom Installation.”)

50. Install the inner boom, extend chain and attaching hardware. (Refer to Section 3.3.6, “Inner Boom Installation.”)

51. Clean up all debris, hydraulic fluid, etc., in, on, near and around the vehicle.

WARNING: Avoid prolonged engine

operation in closed areas without adequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious personal injury.

52. With the ignition in the RUN position, check that the indicator light on the boom sensor is OFF.

53. Start the engine and raise the boom above 40°. Check to be sure that the Stabil-TRAK™ indicator light (Fig. 3- 67, 1) is ON.

54. If the Stabil-TRAK™indicator light does not come on you may have to adjust the boom sensor or the Stabil-TRAK system is not functioning properly. Follow the procedures in Section 10.4, “Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting,” or Section 10.5, “Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting,” to repair the system.

55. Operate all boom functions several times. Check the chain tension again and adjust as necessary. Check for leaks, and check the hydraulic fluid level in the tank; add fluid if required.

56. Apply grease at all lubrication points (grease fittings). (Refer to appropriate Owners/Operators Manual.)

0000 00

Figure 3-67 Stabil-TRAK™ Indicator Light

OH1810

Model 6042 Legacy Origin 7/02

3.29

Boom

3.3.5 Intermediate Boom Installation

WARNING: Wear protective footwear

with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.

WARNING: NEVER lift a heavy object

without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.

1. At the rear of the intermediate boom, assemble the retract chain sheave (Fig. 3-68, 1) to the mounting ears on the right side of the boom. Place the sheave between the ears and insert the sheave pin (2) from the left side. Align the hole in the pin retainer plate with the threaded hole in the left ear. Secure the pin in place with the 1/2-13 x 1" capscrew (3), saved, and the 1/2" lockwasher (4), saved. Tighten the capscrew securely.

2. Apply grease to the grease fitting (Fig. 3-68, 5) in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly.

MH1480

Figure 3- 68 Retract Chain Sheave

Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07-.13" (1,8-3,3 mm) in the horizontal direction.

3. Assemble the hose reel assembly, left side and bottom wear pads to the rear of the intermediate boom:

a. Apply Loctite® 242 threadlocker to the threads of

the two 3/8-16 x 1" capscrews (Fig. 3-69, 1), saved. Insert a capscrew with a 3/8" lockwasher (2), saved, and a 3/8" flat washer (3), saved, through each of the mounting holes in the left side plate of the hose reel assembly. Place three 3/8" flat washers (3), saved, onto each of the capscrews and insert the capscrews through the mounting holes in the left side of the boom.

b. Place the wear pad shims (Fig. 3-69, 4), saved if

present, onto the capscrews. Place the shims onto the capscrews with the holes offset as noted in disassembly.

3.30

Model 6042 Legacy Origin 7/02

Boom

c. Place the wear pad inserts (Fig. 3 -69, 5), saved,

into the cavities in the wear pad (6). Be sure the inserts are seated completely in the cavities.

d. Install the wear pad (Fig. 3-69, 6) onto the

capscrews. Be careful not to push the wear pad inserts out of the wear pads.

e. Apply Loctite® 242 threadlocker to the threads of

the two 3/8-16 x 1-1/2" capscrews (Fig. 3-69, 7), saved. Insert a capscrew with a 3/8" lockwasher (8), saved, and a 3/8" flat washer (9), saved, through each of the mounting holes in the right side plate of the hose reel assembly.

f. Place the wear pad inserts (Fig. 3-69, 10),

saved, into the cavities in the wear pad (11), saved. Be sure the inserts are seated completely into the cavities.

g. Place the wear pad spacer (Fig. 3-69, 12),

saved, and the wear pad under the intermediate boom. With the holes offset as noted in disassembly, align the holes in the wear pad, and secure the hose reel, wear pad spacer and wear pad to the intermediate boom. Be careful not to push the wear pad inserts out of the wear pads.

h. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

i. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

4. Install the intermediate boom side wear pads: a. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 3/4" capscrews (Fig. 3-70, 1), saved. Insert a capscrew with a 3/8" lockwasher (2), saved, and a 3/8" flat washer (3), saved, through each of the wear pad mounting holes in the side plates of the intermediate boom.

b. Place the wear pad shims (Fig. 3-70, 4), saved if

present, onto the capscrews. Place the shims onto the capscrews with the holes offset as noted in disassembly.

c. Place the wear pad inserts (Fig. 3-70, 5), saved,

into the cavities in the wear pad (6). Be sure the inserts are seated completely in the cavities.

d. Install the wear pad (Fig. 3- 70, 6) onto the

capscrews. Be careful not to push the wear pad inserts out of the wear pads.

e. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

f. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

Figure 3-69 Hose Reel and Wear Pads

Figure 3-70 Side Wear Pads

MH1510

8 9

MH1500

Model 6042 Legacy Origin 7/02

3.31

Boom

Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07-.13" (1,8- 3,3 mm) in the vertical direction.

5. Assemble the top wear pads to the top of the intermediate boom. Position the wear pads so the wear pad mounting holes are offset as noted in disassembly:

a. Apply Loctite

242 threadlocker to the threads of

the 3/8-16 x 1" capscrews (Fig. 3-71, 1), saved.

b. Place the wear pad shims (Fig. 3-71, 2), saved if

present, onto the top of the boom. Align the holes in the shims with the holes in the boom.

c. Place the wear pad inserts (Fig. 3 -71, 3), saved,

into the wear pad (4) cavities in the wear pad. Be sure the inserts are seated completely in the cavities. Place the wear pads on top of the shims.

d. Insert a capscrew with a 3/8" lockwasher

(Fig. 3-71, 5) and a 3/8" flat washer (6), saved, through each of the mounting holes in the top of the intermediate boom. Be careful not to push the wear pad inserts out of the wear pads.

e. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

f. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

7. Before installing the intermediate boom into the outer boom, place a string (heavy enough to pull the attachment tilt and auxiliary hydraulic hoses) down the inside of the outer boom. Allow the string to hang out the rear of the boom. Pull the other end out the opening on the left side of the boom where the hoses will exit the boom. Place one string for each hose in the boom. Position the strings all the way to the left side of the outer boom.

8. Using a hoist capable of lifting 5,000 lbs (2268 kg) and slings, lift the intermediate boom. Carefully slide the hose reel end of the boom into the front of the outer boom. Push the boom in until the rod end of the extend/retract cylinder lines up with the mounts on the intermediate boom.

9. Use the hoist and slings to slightly lift the front of the intermediate boom to allow installation of the center wear pad:

a. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

b. Slide the center wear pad mount (Fig. 3 -72, 1)

into the outer boom with the wear pad offset toward the right side. Line up the threaded holes in the wear pad mount with the holes in the bottom of the outer boom.

c. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1" capscrews (Fig. 3-72, 2), saved. Secure the wear pad mount to the outer boom with the capscrews (2) and lockwashers (3), saved.

d. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

Figure 3-71 Intermediate Boom Top Wear Pads

6. Spray the wear pad pathways on the inside of the outer boom, inside of the intermediate boom and the underside of the intermediate boom with LPS3 or equivalent.

3.32

MH1520

3 2

Figure 3-72 Outer Boom Center Wear Pad Mount

with Wear Pad

Model 6042 Legacy Origin 7/02

MA10,0540

Boom

10. Remove the slings and the hoist from the intermediate boom.

11. Install the side wear pads to the outer boom:

a. Slide the intermediate boom over to one side as

far as it will go, to allow wear pad installation.

b. Place the wear pad inserts (Fig. 3-73, 1), saved,

into the cavities of the side wear pads (2), saved.

c. Place the shims (3), saved if present, onto the

wear pad and align the holes.

d. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

e. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 3/4" capscrews (Fig. 3-73, 4), saved. Slide the wear pad with shims between the intermediate boom and the outer boom with the offset of each wear pad the same as noted in disassembly. Align the holes and secure in place with the capscrews (4), 3/8" lockwashers (5), saved, and 3/8" flat washers (6), saved. Be careful not to push the wear pad inserts out of the wear pads.

f. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

g. Repeat Steps a-f to install the side wear pads on

the other side of the outer boom.

12. Assemble the top wear pads to the inside of the outer boom:

a. Place the wear pad inserts (Fig. 3-74, 1), saved,

into the cavities of the top wear pads (2), saved. Add shims (3), saved if present.

b. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

c. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1" capscrews (Fig. 3-74, 4), saved. Slide the wear pad between the intermediate boom and the outer boom with the offset of each wear pad the same as noted in disassembly. Align the holes and secure in place with the capscrews (4), 3/8" lockwashers (5), saved, and 3/8" flat washers (6), saved. Be careful not to push the wear pad inserts out of the wear pads.

d. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

Figure 3-73 Outer Boom Side Wear Pads

MA10,0550

Figure 3-74 Outer Boom Top Wear Pads

MA10,0560

Model 6042 Legacy Origin 7/02

3.33

Boom

13. Use a hoist and sling to lift the rod end of the extend/ retract cylinder (Fig. 3-75, 1). Align the rod end of the extend/retract cylinder with the mounts (2) at the front of the intermediate boom.

14. Coat the extend/retract cylinder rod end pin (Fig. 3-75, 3), saved, with anti-seize compound. Insert the rod end pin through the mounts and secure in place with the retaining rings (4), saved. Be sure the retaining rings are securely seated in the rod end pin grooves.

c. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1-1/2" capscrews (Fig. 3-76, 4), saved. Align the holes and secure in place with the capscrews (4) and 3/8" lockwashers (5), saved. Be careful not to push the wear pad inserts out of the wear pads.

d. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

e. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

16. Install the inner boom, extend chain and attaching hardware. (Refer to Section 3.3.6, “Inner Boom Installation.”)

Figure 3- 75 Extend/Retract Cylinder Rod End Pin

MA10,0490

15. Install the intermediate boom front, bottom wear pads: a. Place the wear pad inserts (Fig. 3 -76, 1), saved,

into the cavities of the front bottom wear pads (2), saved.

b. Place the wear pads and spacers (Fig. 3-76, 3),

saved, into the intermediate boom with the offset of each wear pad the same as noted in disassembly.

Figure 3-76 Intermediate Boom Front Wear Pads

MA10,0480

3.34

Model 6042 Legacy Origin 7/02

Boom

3.3.6 Inner Boom Installation

WARNING: Wear protective footwear

with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.

WARNING: NEVER lift a heavy object

without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.

1. Stretch the attachment tilt and auxiliary hydraulics hoses out straight on a flat surface. Measure from the male end (Fig. 3-77, 1) of each hose back 196" (498 cm) and apply tape (2) around each hose at that point. The tape is for proper tensioning of the hoses during reassembly of the hose clamps.

3. Slide the elbow ends of the two attachment tilt hoses (Fig. 3-78, 1 and 2) down the inner boom and out to the gooseneck. Keep the hoses next to each other as they are being pushed down the inner boom.

At the opening in the gooseneck, pull both hoses out. Be careful not to cross the hoses as you pull them out.

4. Slide the female end of the two auxiliary hydraulics hoses (Fig. 3 -78, 3 and 4) down the inner boom and out the gooseneck. Keep the auxiliary hoses to the left and right sides of the attachment tilt hoses (1 and 2).

At the opening in the gooseneck, pull both hoses out and down toward the bulkhead plate for the couplers. Keep the left side hose (Fig. 3- 78, 3) on the left side and the right side hose (4) on the right side.

196.00

(498 cm)

Figure 3-77 Hose Measurement for Tensioning

2. If you are re-using the hoses, the hoses should be labeled on both ends. If installing new hoses, label both ends of the hoses.

Label both ends of the left side auxiliary hydraulics hose (Fig. 3- 77, 3) as “Retract” and the right side hose (4) as “Extend.” Label both ends of the left side attachment tilt hydraulics hose (5) as “Female Coupler” and the right side hose (6) as “Male Coupler.”

MH1400

Figure 3-78 Attachment Tilt and Auxiliary

Hydraulics Hoses

MH1610

Model 6042 Legacy Origin 7/02

3.35

Boom

5. Keep the four hoses in line (left to right) as they come out of the rear of the inner boom. Place a 5/16" lockwasher (Fig. 3-79, 1), saved, and a 5/16" flat washer (2), saved, onto each 5/16-18 x 5" capscrew (3), saved. Insert the capscrews through the hose clamp support bracket (4), saved. Insert the capscrews from the side as shown.

6. Place a 3/4" diameter hose clamp half (Fig. 3 -79, 5), saved, onto the capscrews. Place the right auxiliary hydraulic hose (6) and another 3/4" diameter hose clamp half (5) onto the capscrews.

7. Place a 5/8" diameter hose clamp half (Fig. 3 -79, 7), saved, the right attachment tilt hose (8) and another 5/8" diameter hose clamp half (7) onto the capscrews.

8. Place two more 5/8" diameter hose clamp halves (Fig. 3-79, 7), the left attachment tilt hose (9) and another 5/8" diameter hose clamp half onto the capscrews.

9. Place a 3/4" diameter hose clamp half (Fig. 3 -79, 5), saved, the left auxiliary hydraulic hose (10) and another 3/4" diameter hose clamp half (5) onto the capscrews. Assemble the capscrews to the left side of the inner boom. Tighten the capscrews only enough to hold the hoses in place.

10. Assemble the hose clamp support bracket to the top of the inner boom:

Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07-.13" (1,8 to 3,3 mm) in the vertical direction.

a. Place the wear pad inserts (Fig. 3-80, 1), saved,

into the cavities of the inner boom top left side wear pad (2), saved.

b. Place the wear pad, spacer (Fig. 3-80, 3), saved,

and shims (4), saved if present, onto the inner boom with the offset of the wear pad the same as noted in disassembly.

c. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1-3/4" capscrews (Fig. 3-80, 5), saved. Align the holes and secure the wear pad and hose clamp support bracket (6) in place with the capscrews (5) and 3/8" lockwashers (7), saved. Be careful not to push the wear pad inserts out of the wear pads.

d. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

e. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

Figure 3-79 Attachment Tilt and Auxiliary Hydraulic Hose

Clamps Inside Inner Boom

MH1630

3.36

MA10,0570

Figure 3- 80 Inner Boom Upper Left Side Wear Pad

11. Position the attachment tilt and auxiliary hydraulic hoses with the edge of the tape (Fig. 3 -79, 11) at the hose clamps. Hold the hoses in this position, and tighten the two capscrews securely to hold the hoses.

Model 6042 Legacy Origin 7/02

Boom

12. Assemble the remaining wear pads to the rear of the inner boom. The upper left wear pad has already been assembled.

Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07-.13" (1,8 to 3,3 mm) in the horizontal direction.

a. Place the wear pad inserts (Fig. 3-81, 1), saved,

into the cavities of the inner boom top left and right side wear pads (2), saved.

2 3

16 17

10 6 5

15 14

Figure 3-81 Inner Boom Wear Pads

MA10,0520

b. Place the wear pads, spacers (Fig. 3-81, 3),

saved, and shims (4), saved if present, onto the inner boom with the offset of the wear pads the same as noted in disassembly.

c. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1-3/4" capscrews (Fig. 3-81, 5), saved. Align the holes and secure the wear pads in place with the capscrews (5) and 3/8" lockwashers (6), saved. Be careful not to push the wear pad inserts out of the wear pads.

d. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

e. Place the wear pad inserts (Fig. 3 -81, 7), saved,

into the cavities of the inner boom left and right side upper and lower wear pads (8), saved.

f. Place the wear pads and shims (Fig. 3-81, 9),

saved if present, onto the sides of the inner boom with the offset of the wear pads the same as noted in disassembly.

g. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 3/4" capscrews (Fig. 3-81, 10), saved. Align the holes and secure the wear pads in place with the capscrews (10), 3/8" lockwashers (11), saved, and 3/8" flat washers (12), saved. Be careful not to push the wear pad inserts out of the wear pads.

h. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

i. Place the wear pad inserts (Fig. 3-81, 13),

saved, into the cavities of the inner boom bottom wear pad (14), saved.

j. Place the wear pad and spacer (Fig. 3-81, 15),

saved, onto the bottom of the inner boom with the offset of the wear pad the same as noted in disassembly.

k. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1-1/4" capscrews (Fig. 3-81, 16), saved. Align the holes and secure the wear pads in place with the capscrews (16) and 3/8" lockwashers (17), saved. Be careful not to push the wear pad inserts out of the wear pads.

l. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

m. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

Model 6042 Legacy Origin 7/02

3.37

Boom

13. Make sure that both extend chains have been inspected before installing them on the inner boom. Refer to Section 3.4.1, “Boom Chain Inspection.”

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

14. Lay the two extend chains (Fig. 3-82, 1) on the top of the inner boom with the threaded clevis ends (2) toward the rear of the boom. Coat the threads on each clevis with multi-purpose grease, and insert the clevis’ through the holes in the anchor plate. Install a 3/4" flat washer (3), saved, onto each clevis. Install a new 3/4-16 elastic locknut (4) onto each clevis. Tighten the elastic locknut far enough so the threads are even with the top of the locknut.

c. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 3/4" capscrews (Fig. 3-83, 4), saved. Slide the wear pad (2) with shims (3) between the inner boom and the intermediate boom with the offset of each wear pad the same as noted in disassembly. Align the holes and secure in place with the capscrews (4), 3/8" lockwashers (5), saved, and 3/8" flat washers (6), saved. Be careful not to push the wear pad inserts out of the wear pads.

d. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

e. Fill all wear pad cavities with a good grade of

lithium-based EP grease.

f. Repeat Steps a-e to install the side wear pads on

the other side of the intermediate boom.

MA10,0620

Figure 3- 82 Extend Chains

15. At the rear of the inner boom, place the male ends of the hoses (attachment tilt and optional auxiliary hydraulics) inside the inner boom. Be sure the hoses are coiled up and inside the boom completely.

16. Spray the wear pad pathways on the underside of the inner boom with LPS3 or equivalent.

17. Using a hoist capable of lifting 5,000 lbs (2268 kg) and slings lift the inner boom. Carefully slide the end of the boom into the front of the intermediate boom. Push the boom in as far as possible.

18. Assemble the side wear pads to the intermediate boom:

Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07-.13" (1,8 to 3,3 mm) in the horizontal direction.

a. Slide the inner boom over to one side as far as it

will go, to allow wear pad installation.

b. Place the wear pad inserts (Fig. 3-83, 1), saved,

into the cavities of the side wear pads (2), saved. Place the shims (3), saved if present, onto the wear pad and align the holes.

Figure 3-83 Intermediate Boom Front Side Wear Pads

19. Install the top wear pads to the inside of the intermediate boom:

a. Place the wear pad inserts (Fig. 3-84, 1), saved,

into the cavities of the top wear pads (2), saved. Place the shims (3), saved if present, onto the wear pad and align the holes.

b. Apply Loctite

242 threadlocker to the threads of the 3/8-16 x 1-1/2" capscrews (Fig. 3 -84, 4), saved. Slide the wear pads (2) and shims (3) with the spacers (5), saved, between the inner boom and the intermediate boom, with the offset of each wear pad the same as noted in disassembly. Align the holes and secure in place with the capscrews (4) and 3/8" lockwashers (6), saved. Be careful not to push the wear pad inserts out of the wear pads.

MA10,0430

3.38

Model 6042 Legacy Origin 7/02

Boom

c. Torque all wear pad mounting capscrews to

31 ±3 lb-ft (42 ±4 Nm).

d. Fill all wear pad cavities with a good grade of

lithium-base EP grease.

Figure 3-84 Front Intermediate Wear Pads

MA10,0420

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

b. Insert the retaining capscrew (Fig. 3-85, 2) back

through the plates of the hose reel, inserting the spacers (3) back in position between the plates as the capscrew is inserted. Make sure that spacer (4) and washer (5) remain in place between the inside two plates (6) of the hose reel assembly. Secure the retaining capscrew in place with a new 1/2-13 elastic locknut (1). Tighten the elastic locknut securely.

c. Remove the 3/8-16 elastic locknut (Fig. 3 -85, 11)

and 3/8" flat washer (12) from the lower retaining shoulder bolt (13). While pulling the shoulder bolt out, catch the spacers (14) from between the plates as the shoulder bolt is removed. Place the attachment tilt hoses and the auxiliary hydraulic hoses around the hose reel.

d. Insert the shoulder bolt (Fig. 3-85, 13) through

the plates of the hose reel, inserting the spacers (14) back in position between the plates as the shoulder bolt is inserted. Place the 3/8" flat washer (12) onto the shoulder bolt and secure in place with a new 3/8-16 elastic locknut (11). Tighten securely.

20. Pull the male ends of the hoses out the rear of the inner boom. Stretch the hoses out straight behind the vehicle.

21. Assemble the hoses to the hose reel at the back of the boom:

IMPORTANT: Keep the hoses in the same order as they come from the hose clamps. DO NOT allow the hoses to cross.

a. Remove the 1/2-13 elastic locknut (Fig. 3-85, 1)

from the upper retaining capscrew (2). While pulling the capscrew out, catch the spacers (3) from between the plates as the capscrew is removed. Pull the capscrew out far enough to place the hoses around the hose reel. Make sure that spacer (4) and washer (5) remain in place between the inside two plates (6) of the hose reel assembly.

Place the left side auxiliary hydraulic hose (Fig. 3-85, 7) into the left position on the hose reel. Place the left side attachment tilt hose (8) into the second position from the left on the hose reel.

Place the right side attachment tilt hose (Fig. 3-85, 9) into the second position from the right on the hose reel.

Place the right side auxiliary hydraulic hose (Fig. 3-85, 10) into the right position on the hose reel.

Figure 3-85 Assemble Hoses to Hose Reel

MA10,0580

Model 6042 Legacy Origin 7/02

3.39

Boom

22. Tie the strings (positioned inside the outer boom) to the male end of each of the attachment tilt hoses and the auxiliary hydraulic hoses.

IMPORTANT: Keep the hoses in the same order as they come off the hose reel. DO NOT allow the hoses to cross.

23. Working from the front of the boom, pull each hose through the boom assembly:

a. Pull the right side auxiliary hydraulic hose

(Fig. 3-86, 1) through the boom assembly. Pull the hose out of the opening (2) at the bottom of the outer boom.

b. Pull the right side attachment tilt hose

(Fig. 3-86, 3) through the boom assembly, keeping the hose to the left of the right side auxiliary hydraulic hose. Pull the hose out of the opening (2) at the bottom of the outer boom.

c. Pull the left side attachment tilt hose (Fig. 3-86, 4)

through the boom, keeping the hose to the left of the hoses installed. Pull the hose out of the opening (2) at the bottom of the outer boom.

d. Pull the left side auxiliary hydraulic hose

(Fig. 3-86, 5) through the boom, keeping the hose to the left of the hoses already installed. Pull the hose out of the opening (2) at the bottom of the outer boom.

3 4

1 5

MH1410

25. At the front of the outer boom, assemble the hose assemblies to the tube assemblies:

Note: Where the hose assemblies come out of the outer boom, lubricate the radius in the outer boom with soap and water to allow proper tensioning of hoses.

Note: ALWAYS use new o-rings when servicing the vehicle.

a. Assemble the right side attachment tilt hose

(Fig. 3-87, 1) as it comes down the outer boom to the upper right side tube. Tighten the upper right side attachment tilt tube assembly (2) to the hose assembly. Tighten the tube assembly nut securely to hold the tube and hose assemblies together.

b. Assemble the left side attachment tilt hose

(Fig. 3-87, 3) as it comes down the outer boom to the upper left side tube. Tighten the upper left side attachment tilt tube assembly (4) to the hose assembly. Tighten the tube assembly nut securely to hold the tube and hose assemblies together. Tighten the bulkhead nut, on the mounting plate, at the other end of the tube assembly at the rear of the boom.

c. Assemble the right side auxiliary hydraulic hose

(Fig. 3-87, 5) as it comes down the outer boom to the lower right side tube. Tighten the lower right side auxiliary hydraulic tube assembly (6) to the hose assembly. Tighten the tube assembly nut securely to hold the tube and hose assemblies together. Tighten the bulkhead nut, on the mounting plate, at the other end of the tube assembly at the rear of the boom.

d. Assemble the left side auxiliary hydraulic hose

(Fig. 3-87, 7) as it comes down the outer boom to the lower left side tube. Tighten the lower left side auxiliary hydraulic tube assembly (8) to the hose assembly. Tighten the tube assembly nut securely to hold the tube and hose assemblies together. Tighten the bulkhead nut, on the mounting plate, at the other end of the tube assembly at the rear of the boom.

Figure 3- 86 Attachment Tilt and Auxiliary

Hydraulic Hoses

24. Remove the strings from the hoses.

3.40

Model 6042 Legacy Origin 7/02

Boom

Figure 3-88 Retract Chain

MH2340

28. Place the double extend chain sheave (Fig. 3 -89, 1),

saved, between the mounts at the front of the intermediate boom. Insert the sheave pin (2), saved, through the mounts and the double sheave. Align the

mounting hole in the sheave pin with the threaded hole in the sheave mount and secure in place with the 1/2-13 x 1" capscrew (3), saved, and the 1/2"

MA10,0160

lockwasher (4), saved. Tighten securely.

29. After the sheave is assembled, grease the sheave with a good grade of multi-purpose grease. Turn the sheave by hand to distribute the grease evenly.

Figure 3- 87 Attachment Tilt and Auxiliary

Hydraulic Hoses and Tubes

26. Place the retract chain (Fig. 3- 88, 1) up around the retract chain sheave on the right side of the boom. Stretch the chain forward and place the clevis between the two anchor plates (2). Align the hole in the clevis with the second hole from the rear of the anchor plates.

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

27. Insert the shoulder bolt (Fig. 3-88, 3), saved, from the top down and secure in place with a new 3/8-16 elastic locknut (4). Tighten the locknut securely.

MA10,0590

Figure 3-89 Extend Chain Sheave

Model 6042 Legacy Origin 7/02

3.41

Boom

30. Assemble the two extend chains to the outer boom mount if the yoke plates were removed from the extend chains. If the yoke plates were not replaced, proceed to Step 33.

31. Assemble the yoke plates (Fig. 3-90, 1) to the mount on the front of the outer boom. Coat the shoulder bolt (2), saved, with anti-seize compound and insert the shoulder bolt through a yoke plate (1), the mount on the boom and through a second yoke plate (1) on the bottom. Secure in place with a new 1/2-13 elastic locknut (3). Tighten the locknut securely; but the yoke plates must pivot freely.

32. Assemble the clevis’ on the two extend chains (Fig. 3-90, 4) between the yoke plates. Align the holes in each clevis with the holes in the yoke plates. Coat the hex socket head capscrews (5), saved, with anti-seize compound and insert the capscrews through the yoke plates and the clevis. Secure in place with new 3/8-16 elastic locknuts (6). Tighten the locknuts securely; but the extend chain clevis’ must pivot freely.

33. Align the holes in the yoke plates (Fig. 3-91, 1) with the hole in the mount on the outer boom. Coat the shoulder bolt (2), saved, with anti-seize compound and insert the shoulder bolt through the yoke plates and the mount on the boom. Secure in place with a new 1/2-13 elastic locknut (3). Tighten the locknut securely; but the yoke plates must pivot freely.

MA10,0610

Figure 3- 91 Outer Boom Extend Chain Yoke Plates

Figure 3-90 Extend Chains and Yoke Plates

MA10,0600

34. Assemble the quick attach to the gooseneck. Align the quick attach (Fig. 3-92, 1) between the mounts on the gooseneck. Assemble a washer (2), saved, on each side of the quick attach. Reassemble the shims (3), saved, between the quick attach and the gooseneck. DO NOT put all the shims on one side. The quick attach should be centered in the gooseneck.

35. Coat the quick attach pivot pin (Fig. 3-92, 4) with anti-seize compound. Insert the quick attach pivot pin through the gooseneck, washers, shims and quick attach. Use a tapered punch to align the hole in the pivot pin with the hole in the quick attach. Insert the 5/8-11 x 5" capscrew (5), saved, through the quick attach and pin. Secure the capscrew in place with a new 5/8-11 elastic locknut (6). Tighten securely.

3.42

Model 6042 Legacy Origin 7/02

Boom

Figure 3-92 Quick Attach

36. If the inner boom has been replaced with a new boom, the auxiliary hydraulic fittings need to be reassembled:

a. Assemble the two bulkhead fittings (Fig. 3-93, 1)

from the original boom to the bulkhead plate inside the gooseneck. Insert the bulkhead fittings from the top and secure in place with the bulkhead fitting nut (2) on the bottom side. Tighten securely.

b. Assemble the two swivel straight connectors

(Fig. 3-93, 3) to the two bulkhead fittings.

c. Assemble the male nipple (Fig. 3-93, 4) and dust

cap (5) to the right side swivel connector fitting. Tighten the swivel connector and male nipple securely. Assemble the dust cap onto the male nipple. Assemble the female coupler (6) and dust plug (7) to the left side swivel connector fitting. Tighten the swivel connector and female coupler securely. Insert the dust plug into the female coupler.

MH1720

Figure 3-93 Auxiliary Hydraulic Coupler and Nipple

MH1730

d. Assemble the left auxiliary hydraulic hose

(Fig. 3-94, 1) labeled “Female Coupler” from inside the gooseneck to the female coupler (2) bulkhead fitting. Tighten securely.

e. Assemble the right auxiliary hydraulic hose

(Fig. 3-94, 3) labeled “Male Nipple” from inside the gooseneck to the male nipple (4) bulkhead fitting. Tighten securely.

MH0841

Figure 3-94 Auxiliary Hydraulic Hoses

Model 6042 Legacy Origin 7/02

3.43

Boom

37. Use a hoist and slings to position the attachment tilt cylinder (Fig. 3-95, 1) inside the gooseneck (2). Be sure the attachment tilt cylinder is positioned with the tube for the rod end positioned inside the gooseneck.

38. Coat the base end pivot pin (Fig. 3-95, 3), saved, with anti-seize compound. Align the hole in the cylinder base end with the mounting holes in the gooseneck and insert the pivot pin through the gooseneck. Secure the pivot pin to the gooseneck with the two retaining rings (4), saved. Be sure the retaining rings are resting squarely in the grooves on the pivot pin.

Figure 3- 95 Attachment Tilt Cylinder Base End Pivot Pin

MH0960

39. Coat the rod end pivot pin (Fig. 3 -96, 1), saved, with anti-seize compound. Swing the rod end (2) of the attachment tilt cylinder up and line up the rod end with the mounting holes in the quick attach (3).

40. Insert the rod end pivot pin (Fig. 3-96, 1) through the lined-up holes. Use a tapered punch to line up the capscrew hole in the pivot pin and the mounting hole in the quick attach hub. Insert the 1/2-13 x 5" capscrew (4), saved, through the quick attach hub from the backside and secure in place with a new 1/2-13 elastic locknut (5). Tighten securely.

Figure 3-96 Rod End Pivot Pin

41. Assemble the attachment tilt hoses from the backside of the gooseneck to the fittings on the base end of the attachment tilt cylinder. Assemble the left side hose (Fig. 3 -97, 1) labeled as “Retract” to the retract port (upper) fitting (2) on the base end of the attachment tilt cylinder. Index the elbow end of the hose to remove any undo tension and tighten the elbow completely to the fitting on the cylinder.

MH0940

3.44

Model 6042 Legacy Origin 7/02

42. Assemble the right side hose (Fig. 3-97, 3) labeled as “Extend” to the extend port (lower) fitting (4) on the base end of the attachment tilt cylinder. Index the elbow end of the hose to remove any undo tension and tighten the elbow completely to the fitting on the cylinder.

Boom

Figure 3- 97 Attachment Tilt Hoses

43. Clean up all debris, hydraulic fluid, etc., in, on, near and around the vehicle.

44. Connect the battery negative (-) ground cable.

MH1740

WARNING: Avoid prolonged engine

operation in closed areas without adequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious personal injury.

45. Assemble the rear cover to the rear of the outer boom. At the rear of the outer boom (Fig. 3-98, 1), position the rear cover (2) in place. Secure the cover in place with the 5/16" flat washer (3), saved, lockwasher (4), saved, and thumbscrew (5), saved. Insert the thumbscrew through the bottom of the outer boom and into the rear cover. Tighten the thumbscrew securely to hold the cover in place.

MA9820

Figure 3-98 Rear Cover to Outer Boom

46. Start the engine and operate all boom functions several times.

47. Retract the boom completely and turn the engine OFF.

48. Check the inner to intermediate boom reference dimension. (Refer to Section 3.4.4, a. “Component/ Assembly Verification.”)

WARNING: Hydraulic oil leaking under

pressure can penetrate the skin and cause severe personal injury. DO NOT use your hand or any part of your body to check the hydraulic leaks. When checking for hydraulic leaks, wear safety glasses and gloves to help provide protection from spraying hydraulic oil. Use a piece of cardboard or paper to search for leaks.

49. Start the engine and operate all boom functions several times. Check the chain tension again and adjust as necessary. (Refer to Section 3.4.3, “Boom Chain Tension Check,” and Section 3.4.4, “Boom Chain Tension Adjustment.”) Check for leaks, and check the hydraulic fluid level in the tank; add fluid if required.

Model 6042 Legacy Origin 7/02

3.45

Boom

3.4 BOOM CHAINS

This vehicle uses double extend chains to extend the boom and a single retract chain to retract the boom. The extend and retract chains are constructed of 3/4" pitch links with 6 x 6 leaf lacing.

Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all the chains and clevis’ be replaced at the same time.

3.4.1 Boom Chain Inspection

250

MS21702

MM2130

Figure 3-99 Every 250 Hours of Engine Operation,

Inspect Boom Extend Chain Condition

WARNING: Worn pins, stretched or

cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or vehicle instability, and could cause death or serious injury and/or property damage.

Under normal operating conditions the extend chains will need to be inspected every 250 hours of operation. The retract chain will need to be exposed and inspected every 1000 hours of operation. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operating conditions and require more frequent inspection intervals.

Environments in which material handling vehicles operate can vary widely, from outdoor moisture to mildly corrosive or highly corrosive industrial atmospheres, in addition to abrasive exposures such as sand and grit. Some effects can be as follows:

• Moisture - Corrosive rusting reduces chain strength by pitting and cracking.

• Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation.

• Chemical Solutions or Vapors - Corrosive attack on the chain components and/or the mechanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time.

• Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins and plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye.

Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain:

• High velocity movement of load, followed by sudden, abrupt stops.

• Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes and rough terrain.

• Attempting to “inch” loads which are beyond the rated capacity of the vehicle.

The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted.

The boom chain’s normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3% of pitch. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulation.

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Model 6042 Legacy Origin 7/02

Boom

a. Inspection Guidelines

Expose the extend and retract chains (refer to Section 3.4.1, b. “Expose Extend Chain for Inspection,” or Section 3.4.1, c. “Expose Retract Chain for Inspection”) and inspect the chains for the following conditions:

Elongation

When the original length (Fig. 3-100, 1) of 12" (305 mm) per foot of new chain has elongated from wear to a length (2) of 12-3/8" (313 mm), the chain must be discarded and replaced. (Refer to Section

3.4.5, Boom Extend and Retract Chains Removal and Replacement.)

It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading.

Measure across a span of 17 pins at the center of the extend chain. Measure from pin center to pin center.

The maximum measurement allowed is 12-3/8" (313 mm). If the measurement is more than 12-3/8" (313 mm), the chain must

be replaced. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

Edge Wear

Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material must not exceed 5%. This can be compared to a normal link plate height by measuring a portion of chain that does not run over the sheave.

The new chain link measures .713" (18 mm) (Fig. 3-101, 3). If the measurement of the worn chain is less than .677" (17 mm) (4), the chain must be replaced. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

Figure 3-101 Inspect Link Plates for Edge Wear

Distorted or Battered Link Plates

Distorted or battered link plates (Fig. 3- 102, 5) on a leaf chain can cause tight joints and prevent flexing.

MM2051

Figure 3- 100 Check for Chain Elongation

Model 6042 Legacy Origin 7/02

MA9340

MM2120

Figure 3-102 Inspect Link Plates for Distortion

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Boom

Turning or Protruding Pins

Highly loaded chain, operating with inadequate lubrication, can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.

Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (Fig. 3-103, 1). Chain with rotated/displaced heads (2) or abnormal pin protrusion (3) must be replaced immediately. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored.

Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and must be corrected.

Figure 3-103 Inspect the Pin Head Rivets

Cracked Plates

Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain must be replaced in its entirety. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

MM2060

• Fatigue Cracking - Fatigue cracks (Fig. 3-104, 4)

are a result of repeated cyclic loading beyond the chain’s endurance limit. The size of the load and the frequency of its occurrence are factors which determine when fatigue failure will occur. The loading can be continuous or intermittent (impulse load).

• Stress Corrosion Cracking - The outside link

plates are particularly susceptible to stress corrosion cracking (Fig. 3-104, 5). Like fatigue cracks, these initiate at the point of highest stress but tend to extend in an arc-like path between holes in the pin plate. More than one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere.

Stress corrosion is an environmentally assisted failure. Two conditions must be present: corrosive agent and static stress. In the chain, static stress is present at the aperture due to the press fit pin. No cyclic motion is required, and the plates can crack during idle periods.

• Corrosion Fatigue Cracking - Corrosion fatigue

cracks are very similar to fatigue cracks (Fig. 3-104, 4) in appearance. They generally begin at the aperture and grow perpendicular to the chain pitch line. Corrosion fatigue is not the same as stress corrosion. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress, not a static stress alone, as in stress corrosion.

MM2070

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MM2080

Figure 3-104 Inspect Plates for Cracks

Model 6042 Legacy Origin 7/02

Boom

Other Modes of Failure

• Ultimate Strength Failure - These types of

failures are caused by overloads far in excess of the design load. Either fractured plates (Fig. 3-105, 6) or enlarged holes (7) can occur. If either of these failures occurs, the chain must be replaced immediately. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

Note: The tight joints inspection must be done with the chain disconnected from the boom. (Refer to Section

3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

• Tight Joints - All joints in the chain must flex

freely. Tight joints (Fig. 3 -105, 8) resist flexing and increase internal friction, thus increasing chain tension required to lift a given load. Increased tension accelerates wear and fatigue problems.

If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain.

If the problem is caused by corrosion and rust or bent pins, replace the chain. (Refer to Section

3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

MM2090

b. Expose Extend Chain for Inspection

1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position.

2. Fully extend the boom until the extend chain is taut. Shut the engine OFF.

The extend chains will be visible for inspection with the vehicle in this state.

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

If during the inspection, any chain is found to be damaged or stretched, the chain must

be replaced. It is recommended that when any chain is replaced, that all the chains and clevis’

be replaced at the same

time.

3. If the chain needs to be replaced, refer to Section

3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”

4. If the chain does not need to be replaced, lubricate the chain. (Refer to Section 3.4.2, “Chain Lubrication.”)

Figure 3-105 Other Chain Failure Modes

Model 6042 Legacy Origin 7/02

MM2100

MM2110

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c. Expose Retract Chain for Inspection

The retract chain must be removed from the boom in order to be visually inspected. This must be done every 1000 hours or whenever the retract chain is removed from the boom. (If removal of the chain is required refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

If during the inspection, any chain is found to be damaged or stretched, the chain must recommended that when any chain is replaced, that all the chains and clevis’ be replaced at the same time.

1. Park the vehicle on a hard, level surface.

2. Fully retract the boom and raise the boom to a horizontal position. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF.

3. Remove the thumbscrew (Fig. 3-106, 1), lockwasher (2) and flat washer (3), holding the rear cover (4) to the rear of the outer boom (5). Lift the rear cover straight up until the capscrew in the top of the cover clears the retaining hole in the top of the outer boom. Remove the cover from the outer boom.

be replaced. It is

MA9820

Figure 3-106 Assembly of Rear Cover to Outer Boom

4. At the front underside of the boom, record the amount of threads extending beyond the elastic locknut (Fig. 3-107, 1). This measurement will be the starting point for adjustment of the boom retract chain.

5. Loosen the elastic locknut (Fig. 3-107, 1) far enough so that it can be removed by hand.

3.50

Figure 3-107 Retract Chain Locknut

Model 6042 Legacy Origin 7/02

MH1110

6. If the chain clevis has a threaded hole on the end (Fig. 3-108, 1), a string or wire can be attached to the retract chain clevis using a threaded eye (2) or a flat washer tack welded to a capscrew (3). The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. The string or wire will be used to pull the chain back through the boom during the reassembly.

If there is no threaded hole on the end of the clevis, a phillips screwdriver will be needed to catch the countersunk hole in the end of the clevis and guide it through the tab during reassembly.

Boom

MH1110

Figure 3-108 Threaded Hole In End of Clevis

MA9430

7. Remove the elastic locknut (Fig. 3-109, 1) and flat washer (2) holding the retract chain threaded clevis (3) to the mounting tab. Save the flat washer and discard the elastic locknut.

Figure 3-109 Retract Chain Locknut

8. If a threaded eye or capscrew with flat washer (Fig. 3-108, 2 or 3) was installed in step 6, attach a string or wire to the end of the retract chain clevis. The string or wire must be long enough to pull the clevis and chain through the outer boom.

9. Place a pan or tarp, free of dirt, at the rear of the vehicle, for the chain to rest on as it is being removed from the boom. From the rear of the boom, pull the retract chain out of the rear of the boom.

10. With the chain hanging from the rear of the boom, inspect wear and condition of the chain, clevis’, chain sheaves, chain pins, clevis anchors and all mounting hardware. Replace a worn or damaged chain. DO NOT attempt to make any repairs to the chain.

Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all

chains and

clevis’ be replaced at the same time.

Model 6042 Legacy Origin 7/02

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Boom

11. Measure the chain elongation. Measure across 17 pins (Fig. 3-110, 1), somewhere between the chain sheave and where the chain is laying in the pan or on the tarp. The maximum measurement allowed is 12-3/8" (313 mm). If the measurement is more than 12-3/8" (313 mm), the chain must

be replaced. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”)

14. Coat the threads of the threaded clevis (Fig. 3-111, 1) with multi-purpose grease.

Note: Have a second person help with the installation of the retract chain between the intermediate and outer boom assemblies.

If a string or wire was installed to the end of the clevis:

15. From the rear of the boom, one person should push the threaded clevis end (Fig. 3 -111, 1) of the retract chain (3) under the chain sheave and down between the intermediate boom and the outer boom. The person at the front of the boom should pull the clevis using the string or wire ( 2) attached to the clevis in step 6. Push and pull the threaded clevis down to the tab (4) at the front underside of the outer boom.

16. The person at the front of the boom should guide the threaded end of the clevis (Fig. 3-111, 1) through the hole in the tab (4).

MA9350

Figure 3-110 Retract Chain Exposed for Inspection

Note: Chains and clevis’ are wear items and experience the same stress. DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis’.

12. If the chain needs to be replaced, refer to Section

3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”

13. Lubricate the chain, while it is exposed, if it does not need to be replaced. (Refer to Section 3.4.2, “Chain Lubrication.”)

MA9440

Figure 3-111 Chain Clevis through Tab in Outer Boom

17. Remove the string or wire, and the threaded eye or capscrew with flat washer, from the end of the clevis.

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Model 6042 Legacy Origin 7/02

If no string or wire was installed to the end of the clevis:

18. From the rear of the boom, one person should push the threaded clevis end (Fig. 3 -112, 1) of the retract chain (2) under the chain sheave and down between the intermediate boom and the outer boom. Keep the retract chain (2) to the right side of the boom, push the threaded clevis down to the tab (3) at the front underside of the outer boom.

19. The person at the front of the boom should guide the threaded end of the clevis (Fig. 3-112, 1) through the hole in the tab (3) using a Phillips screwdriver (4). Insert the screwdriver through the hole in the tab and catch the countersunk hole in the end of the clevis. Guide the threaded clevis out as the person at the rear of the boom pushes the retract chain forward.

Boom

MA9510

Figure 3-113 Retract Chain Clevis to Tab in Outer Boom

23. After adjustment is complete, assemble the rear cover to the rear of the outer boom. At the rear of the outer boom (Fig. 3- 114, 1), position the rear cover (2) in place. Secure the cover in place with the 5/16" flat washer (3), saved, lockwasher (4), saved, and thumbscrew (5), saved. Insert the thumbscrew through the bottom of the outer boom and into the rear cover. Tighten the thumbscrew securely to hold the cover in place.

MA9520

Figure 3-112 Chain Clevis through Tab in Outer Boom

Once the threaded clevis is through the tab on the outer boom:

20. Reassemble the flat washer (Fig. 3-113, 1), saved, and a new 3/4-16 elastic locknut (2) onto the threaded clevis (3). Tighten the locknut until the threaded end of the clevis is flush with the top of the locknut.

21. Tighten the elastic locknut (Fig. 3-113, 2) on the retract chain clevis (3) until the amount of threads protruding beyond the elastic locknut is the same as the measurement recorded during removal of the retract chain.

22. Adjust retract chain tension. (Refer to Section 3.4.3, “Boom Chain Tension Check.”)

MA9820

Figure 3-114 Assembly of Rear Cover to Outer Boom

Model 6042 Legacy Origin 7/02

3.53

Boom

3.4.2 Chain Lubrication

After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent).

The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links.

To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that the lubricant can penetrate to the working surfaces.

Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant, and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation.

Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often.

3.4.3 Boom Chain Tension Check

1. Make sure the carriage is attached to the gooseneck before doing the tension check.

2. Start the engine. If necessary, attach carriage to gooseneck. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position.

3. Slowly, fully extend the boom and retract it about halfway. Fully extend the boom, then retract it 2" (51 mm) (one inch per section). Turn the engine OFF.

4. Measure the sag in the top boom extend chains (Fig. 3-115, 1) between the bottom of the extend chains and the top of the intermediate boom at their closest point (2). Acceptable boom chain sag (3) is between 1-1/2" (38 mm) and 2-1/2" (64 mm).

OA0492

Figure 3 -115 Extend Chain Sag

If the measurement is either less than, or greater than the range given, the boom chains need to be adjusted. Continue with Section 3.4.4, “Boom Chain Tension Adjustment” to adjust the chain system.

5. Start the engine, retract the boom completely and turn the engine OFF.

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Model 6042 Legacy Origin 7/02

SkyTrak 6042 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual