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

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