Skytrak 3606 Service Manual manuals

Skytrak 3606 Service Manual User Manual (412 pages)

Brand: Skytrak | Category: Special machinery | Size: 19.35 MB |

English

Table of contents

OCTOBER 1999

1

Foreword

3

Section Contents

4

1.1 INTRODUCTION

8

1.2 OWNERS/OPERATORS MANUAL

8

1.3 SAFETY INFORMATION

8

1.4 ACCIDENT PREVENTION TAGS

9

1.5 SAFETY INSTRUCTIONS

10

1.6 SAFETY DECALS

11

1-888-872-5123

11

Safety Decal List –

12

Section 1

14

Model 3606

15

Origin 10/99

15

Section 2

17

Section 2

18

2.1 REPLACEMENT PARTS AND

19

WARRANTY INFORMATION

19

2.2 SERIAL NUMBER LOCATIONS

19

2.3 TORQUE VALUES

19

°F), multiply degrees

21

2.4.1 Vehicle Dimensions

22

(Fig. 2-1)

22

2.4.3 Weights

23

4000 x 24

24

2.5 FLUIDS, LUBRICANTS AND

25

CAPACITIES

25

2.5.4 Hydraulic System

26

2.5.5 Engine

26

2.5.6 Transmission

27

2.5.7 Drive Shaft Splines

28

2.5.8 General Anti-corrosion

28

2.5.9 Electrical

28

2.5.10 Paint

29

2.6 CLEANING

30

2.7 REPLACEMENT

30

2.8 HOSES AND TUBES

30

2.9 BEARINGS

30

2.10 PRESSURE TESTING AND

31

ADJUSTMENT

31

2.12 MAINTENANCE INSTRUCTIONS

33

2.12.3 Air Cleaner

36

2.12.5 Engine Cooling System

38

2.12.6 Engine Oil and Filter

39

2.12.7 Engine Fuel System

41

2.12.8 Engine Fan Belt

44

2.12.11 Axle Oil

48

2.12.12 Wheel End Oil

49

2.12.13 Transfer Case Oil

50

2.12.14 Wheels and Tires

50

2.12.15 BATTERY

51

2.12.17 Boom Chains

55

VIEW IN DIRECTION OF ARROW B

56

VIEW IN DIRECTION OF ARROW A

56

2.13 EMERGENCY OPERATIONS

57

4.1 SERIAL NUMBER DECAL

90

4.2 CAB REPLACEMENT

90

4.2.2 Cab Installation

94

4.2.4 Controls

98

4.2.6 Joystick Replacement

99

Section 4

100

Cab, Covers and Mirrors

101

4.2.9 Mirror Replacement

106

4.3 CAB COVERS AND GUARDS

107

Hood and Covers Parts Legend

108

Section 5

111

Axles, Wheels and Tires

111

Introduction

112

General Overview

113

5.1 GENERAL INFORMATION

114

5.2 AXLE ASSEMBLIES

114

5.2.1 Axle Replacement

115

5.3 WHEELS AND TIRES

119

Model 3606 • Origin 10/99

121

Section 6

125

6.1 GENERAL INSTRUCTIONS

128

6.2 SPECIFICATIONS

128

6.3 TRANSFER CASE

128

6.3.3 Transfer Case Removal

129

6.4 DRIVE SHAFTS

130

6.4.3 Drive Shaft Removal

131

6.4.4 Drive Shaft Disassembly

131

6.4.6 Drive Shaft Assembly

131

6.4.8 Slip Yokes

132

6.5 TROUBLESHOOTING

133

Problem Cause Remedy

133

Section 7

135

7.3 TOWING A DISABLED VEHICLE

138

7.4 TRANSMISSION MAINTENANCE

139

7.5 TRANSMISSION REPLACEMENT

140

Model 3606 • Origin 10/99

141

7.5.2 Transmission Inspection

142

Transmission

143

Replacement

144

Section 8A

147

Engine: Perkins 1004 Series

147

8A.1 SAFETY INFORMATION

150

Perkins Engine

151

8A.5.1 Radiator Pressure Cap

153

8A.5.2 Thermostat Replacement

153

8A.6 PERKINS ENGINE

156

ELECTRICAL SYSTEM

156

8A.7.1 Diesel Fuel

158

8A.7.2 Fuel Tank

158

8A.7.4 Fuel Lift Pump Testing

159

8A.7.5 Fuel Filter

160

8A.7.7 Fuel Injectors

160

8A.9.1 Engine Removal

162

8A.9.3 Engine Installation

165

8A.10 PERKINS ENGINE STORAGE

168

8A.11 TROUBLESHOOTING

169

Section 8B

171

Engine: Cummins 4BT3.9

171

8B.1 SAFETY INFORMATION

174

Cummins Engine

175

1137-X0865

176

8B.5.1 Radiator Pressure Cap

177

8B.5.2 Thermostat Replacement

177

8B.7.1 Diesel Fuel

181

8B.7.2 Fuel Tank

182

8B.8 CUMMINS ENGINE EXHAUST

185

8B.9.1 Engine Removal

186

8B.9.3 Engine Installation

190

8B.10 CUMMINS ENGINE STORAGE

192

8B.11 TROUBLESHOOTING

193

Section 9

195

Hydraulic System

195

3606 HYDRAULIC TESTING

201

9.4 HYDRAULIC FLUID

202

9.6 HYDRAULIC RESERVOIR

204

9.7 HYDRAULIC SYSTEM PUMP

206

9.7.3 Pump Replacement

208

Legend for Pump

210

9.8 HYDRAULIC CIRCUITS

213

9.8.1 Brake Circuit

214

Legend for Brake Circuit

216

9.8.4 Frame Tilt Circuit

226

Frame Tilt/Stabilizer Legend

228

Free Pivot Mode

231

Final Positioning Mode

233

Locked Mode

235

9.8.6 Steering Circuit

236

Steering Circuit Legend

241

Joystick Circuit Legend

248

Valve Plate Assembly Legend

251

(with auxiliary hydraulics)

253

Auxiliary Hydraulics Legend

257

Unloader Valve Legend

259

9.9.2 Main Control Valve

260

Sections for Reference Only

268

Main Control Valve Legend

269

Attachment Tilt and

272

Frame Tilt Sections for

272

Reference Only

272

9.9.4 Joystick Valve

275

9.9.5 Pilot Select Manifold

276

9.9.8 Shuttle Valve

278

9.9.9 Service Brake Valve

279

9.10 CYLINDERS

280

9.10.2 Slave Cylinders

284

Slave Cylinder Legend

285

Hoist/Lower Cylinder Legend

291

See “ Swing

301

Carriage Cylinder”

301

Side Tilt Carriage Legend

306

See “ Side Tilt

307

9.10.8 Steer Cylinders

310

9.11 TROUBLESHOOTING

311

Section 10

319

Electrical System

319

Legend for Engine Harness

325

10.2 SPECIFICATIONS

326

10.4 WIRING HARNESSES

327

10.4.4 Engine Harness

350

CLOSED CAB

352

10.5 FUSES AND RELAYS

354

Vehicles Stamped with

355

S/N 8249 and Before

355

Starter Circuit Checks

357

10.6.3 Starter Relay

358

10.7 CHARGING CIRCUIT

360

10.7.1 Alternator

361

10.7.2 Battery

364

10.8.1 Warning Devices

367

10.8.4 Thermo-Start Plug

374

10.8.5 Fuel Run Solenoid

375

10.8.8 Parking Brake Switch

378

10.8.9 Service Brake Switch

379

(Travel Select Lever)

380

10.8.13 Joystick

384

10.8.16 Stabil-TRAK System

388

10.8.17 Steering

391

10.8.18 Steer Select Valve

394

10.8.21 Engine Coolant

397

High Temperature Sender

397

10.8.24 Hourmeter

401

10.9 ELECTRICAL SYSTEM

402

TROUBLESHOOTING

402

Problem Possible Cause Remedy

402

JLG Worldwide Locations

412

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