Skytrak 3606 Service Manual User Manual

Service and Maintenance ManualModel36068990300OCTOBER 1999ANSI

Section 11-41.5 SAFETY INSTRUCTIONSFollowing are general safety statements to consider before performing maintenance procedures on thevehicle. Additio

Section 44-14 Joystick Handle Installation1. Apply Loctite® #272 (red) to the threaded stud on the joystick handle. Position the joystick mounting stu

Cab, Covers and Mirrors4-156. From the outside rear of the cab (Fig. 4–18), remove the four button-head capscrews and plastic washers securing the out

Section 44-16 Figure 4–22. Reach through the logic panel opening and position the joystick wires as shown.11. Use labels, tape or some type of perman

Cab, Covers and Mirrors4-176. Connect all wire leads to the proper connectors on the logic panel. Set the logic panel in its mounting hole, but DO NOT

Section 44-18 Figure 4–28. Slide the boot onto the joystick.17. Install the joystick boot (Fig. 4–28) by pulling the boot over the joystick handle an

Cab, Covers and Mirrors4-19Figure 4–32. For Early Production Vehicles,snap the switch bezel into position in the side console.24. Wipe up any spilled

Section 44-20 Throttle Pedal Installation1. Install the hex jam nut (item E, Fig. 4–34) and SAE flat 1/4" washer (D) onto the end of the throttle

Cab, Covers and Mirrors4-21Keep the mirrors clean for optimal operator performance.Replace any mirror with cracked glass as vehicle use and vibration

Section 44-22 Engine Hood Installation1. Park the vehicle on a firm, level surface. Allow sufficient overhead clearance for engine hood installation (

Cab, Covers and Mirrors4-23Figure 4–37. Covers and guards.1234567891011121314151617181920212223242526273031323334353637383940414243444546474837311121

Safety1-5SOFT SURFACES AND SLOPES: NEVER work on a vehicle parked on soft surfaces or slopes (inclined ground or hills). Vehicle must be on hard, leve

Section 44-24 Model 3606 • Origin 10/99

5-1Section 5Axles, Wheels and TiresContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 55-2 IntroductionLegendThe front (park-brake equipped) and rear (no park brake) Carraro axles are designed for heavy-duty, off-road industrial

Axles, Wheels and Tires5-3General Overview1272823230101114316329282744291621819155131298763433353637271720212223242526PS0200Front of vehicle Model 360

Section 55-4 5.1 GENERAL INFORMATION5.1.1 Axle Serial Number PlateThe front axle serial number plate is located on a mount-ing pad on the inboard port

Axles, Wheels and Tires5-5IMPORTANT: When replacing a fastener, replace it with one of equal or higher grade and quality. Torque fasten-ers to the sp

Section 55-6 Figure 5–2. Axle to frame mounting configuration.1. Self-tapping lube fitting, 1/8"2. Self-align bearing, 1-1/2" ID3. Cylinder

Axles, Wheels and Tires5-7IMPORTANT: Clear the work area of all debris, unnec-essary personnel, etc. Allow sufficient space to raise the vehicle and

Section 55-8 4. Four bushings (Fig. 5–2) help locate the axle supports on the vehicle frame. Insert the bushings into the holes on the front and rear

Axles, Wheels and Tires5-911. Torque the lug nuts to 370 lb/ft (500 Nm) using the alternating pattern depicted in Fig. 5–5.Figure 5–5. Lug nut torque

Section 11-6Safety Decal List – Earlier Models1. No Riders WARNING2. Vehicle Rollaway WARNING3. Electrocution DANGER4. Load Chart Booklet5. Tipover DA

Section 55-10 5.3.1 Removing Wheel and Tire Assemblyfrom Vehicle1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment

Axles, Wheels and Tires5-115.3.2 Wheel CleaningRemove all rust, corrosion, dirt and other foreign material from all metal surfaces. In particular, the

Section 55-12 D. Mounting Tire onto Wheel1. Read, understand and follow the above warning message.2. Clean, inspect and repair the wheel if necessary.

Axles, Wheels and Tires5-13F. Care and Storage of TiresStore unmounted tires vertically, standing on their tread. If stored for an extended period of

Section 55-14 Model 3606 • Origin 10/99

6-1Section 6Transfer Case and Drive ShaftsContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 66-2 IntroductionLegendThe Carraro Model TB 420 transfer case is a single-speed, mechanical unit designed for heavy-duty industrial use. The t

Transfer Case and Drive Shafts6-3General Overview12345678910111213141510101071415722726252423222120191817167373635363537712113433322313029283839404142

Section 66-4 6.1 GENERAL INSTRUCTIONSIMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at th

Transfer Case and Drive Shafts6-56.3.2 Transfer Case MaintenanceInformation regarding checking the transfer case oillevel and/or changing the transfer

Safety1-7Safety Decal List – Later Models1. No Riders WARNING2. Vehicle Rollaway WARNING3. Electrocution DANGER4. Load Chart Booklet5. Tipover DANGER

Section 66-6 6.3.5 Transfer Case InstallationIMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a un

Transfer Case and Drive Shafts6-76.4.3 Drive Shaft RemovalIMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially bal

Section 66-8 6.4.7 Drive Shaft InstallationIMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit

Transfer Case and Drive Shafts6-96.5 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during

Section 66-10 10. Noise when driving. 1. Pinion and crown-wheel wear.2. Gears and bearings loose.3. Gears and bearings worn.4. Excessive eccentricity

7-1Section 7Transmission: Clark-Hurth T 12000ContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 77-2 IntroductionLegendModel 3606 • Origin 10/991. Dipstick Assembly2. Dipstick Tube3. Plug4. O-ring5. Sensor Port Plug6. Oil Level Plug7. Oil

Transmission7-3General Overview43333231342126283029272121261712252435363938161037131211141598776653344214233323125344140211819252433344434422222121212

Section 77-4 7.1 TRANSMISSION SERIAL NUMBERThe transmission serial number plate (Fig. 7–1) is located on the engine side of the transmission at the bo

Transmission7-57.4 TRANSMISSION MAINTENANCE7.4.1 Maintenance IntroductionIMPORTANT: These instructions cover only the routine maintenance of the tran

Section 11-8Copies of Accident Prevention Tags are provided on pages 1-9 and 1-10.Model 3606 • Origin 10/99

Section 77-6 7.5 TRANSMISSION REPLACEMENTIMPORTANT: To help ensure safety and optimum per-formance, replace the transmission if it is damaged. Refer

Transmission7-7IMPORTANT: To help ensure optimum performance, thedrive shaft assemblies are specially balanced as a unit atthe factory. Mark the drive

Section 77-8 23. Remove any external transmission components as required, including the transmission temperature switch (Fig. 7–4).24. Remove the tran

Transmission7-98. Begin securing the transmission to the flywheel housing with M10 lock washers and M10 x 1,5 x 30 mm PC8.8 hex-head capscrews. Remove

Section 77-10 24. Attach the front engine cover plate (Fig. 7–5) to the vehicle frame. Secure with 5/16-18 x 1" hex-head capscrews, 5/16" lo

Transmission7-117.6 TRANSMISSION TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during oper

Section 77-12 Model 3606 • Origin 10/99

8A-1Section 8AEngine: Perkins 1004 SeriesContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8A8A-2 IntroductionLegendDISCLAIMER AND SCOPEThese instructions are written for worldwide use. In territories where legal requirements govern

Perkins Engine8A-3General OverviewFigure 8A–1. Perkins engine general overview.29252628234567891010112720924222120111019181716109151412131MS1000Flang

Safety1-9OS2180Model 3606 • Origin 10/99

Section 8A8A-4 8A.1 SAFETY INFORMATIONGeneral Vehicle OperationPreparationEngine OperationCleaningEngine Coolant (anti-freeze/anti-boilover)Rotating P

Perkins Engine8A-5Engine Repair PartsWARNING: Before beginning any adjustments or repairs, place a DO NOT OPERATE tag in the operator’s compartment a

Section 8A8A-6 8A.2 PERKINS ENGINE SERIAL NUMBERThe Perkins 1004-series engine serial number is stamped on a label which is fastened to the side of th

Perkins Engine8A-78A.5.1 Radiator Pressure CapThe cooling system is designed to use a radiator pres-sure cap to help prevent the coolant from boiling.

Section 8A8A-8 Model 3606 • Origin 10/99Figure 8A–4. Perkins engine radiator and oil cooler.123456789710111213141471513161718192021222324252624192728

Perkins Engine8A-9To remove the radiator and oil cooler:1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), eng

Section 8A8A-10 16. Remove the oil cooler (Fig. 8A–6).Figure 8A–6. Perkins oil cooler hose routings.17. Remove, inspect and replace the seal bulb (1)

Perkins Engine8A-11Figure 8A–7. Perkins engine fuel system.1. Fuel/water separator2. Hex-head capscrew,5/16-18 x 1-1/4"3. Flat narrow washer, 5/

Section 8A8A-12 8A.7.1 Diesel FuelFuel represents a major portion of vehicle operating costs and therefore must be used efficiently. Always use a prem

Perkins Engine8A-135. Refill the fuel tank with water until it overflows. Completely flush the tank with water. Empty the tank and allow it to dry com

Section 11-10OS2180Model 3606 • Origin 10/99

Section 8A8A-14 8A.7.5 Fuel FilterRefer to Section 2 General Information, Specifications, and Maintenance Instructions for information on remov-ing an

Perkins Engine8A-154. Place the new fuel injector and new seat washer into position. DO NOT misalign the fuel injector. Tighten the flange nuts evenly

Section 8A8A-16 8A.9 PERKINS ENGINE REPLACEMENTRemoval and installation of the engine can be done with or without the transmission attached. For infor

Perkins Engine8A-17Figure 8A–12. Perkins air cleaner.10. Disconnect the exhaust pipe (Fig. 8A–9) from the exhaust bellows, secured with a heavy-duty

Section 8A8A-18 14. At the starter, label and disconnect the positive (+) battery cable.15. Label and disconnect the engine water temperature switch l

Perkins Engine8A-19Figure 8A–19. Fuel inlet line to lift pump connection.23. Mark the location of the throttle cable at its engine mount bracket (Fig

Section 8A8A-20 2. Attach a suitable engine hoist to the engine lift plates (Fig. 8A–21).3. Carefully install the engine onto the engine mounts (items

Perkins Engine8A-21Figure 8A–26. Align yokes in the same plane as shown.15. Coat the M12 transmission driveshaft yoke retaining capscrews with Loctit

Section 8A8A-22 37. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hy

Perkins Engine8A-238A.11 TROUBLESHOOTINGItems 1 through 60 in the Key cover both naturally-aspi-rated and turbocharged engines. There are no items tha

2-1Section 2General Information, Specifications, and MaintenanceContentsPAR. TITLE PAGE2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION . . . . . . . .

Section 8A8A-24 Model 3606 • Origin 10/99

8B-1Section 8BEngine: Cummins 4BT3.9ContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8B8B-2 IntroductionLegendDISCLAIMER AND SCOPEThese instructions are written for worldwide use. In territories where legal requirements govern

Cummins Engine8B-3General OverviewFigure 8B–1. Cummins engine general overview.1234567891011121314151617181919202019192526272829301421222324312814141

Section 8B8B-4 8B.1 SAFETY INFORMATIONGeneral Vehicle OperationPreparationEngine OperationCleaningEngine Coolant (anti-freeze/anti-boilover)Rotating P

Cummins Engine8B-5Engine Repair PartsWARNING: Before beginning any adjustments or repairs, place accident prevention tags in the operator’s compartme

Section 8B8B-6 8B.2 CUMMINS ENGINE SERIAL NUMBERThe Cummins 4BT3.9 serial number is stamped on the front of the engine block, near the fan pulley. Inf

Cummins Engine8B-7Model 3606 • Origin 10/998B.5.1 Radiator Pressure CapThe cooling system is designed to use a radiator pres-sure cap to help prevent

Section 8B8B-8 Model 3606 • Origin 10/99Figure 8B–4. Cummins engine radiator and oil cooler.444546474849505152505354555657585059605661626364656667686

Cummins Engine8B-9To replace the radiator and oil cooler:1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), en

Section 22-2 2.11.4 After Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-162.11.5 After Fuel System Service. . . . .

Section 8B8B-10 16. Remove the oil cooler (Fig. 8B–6).Figure 8B–6. Cummins oil cooler hose routings.17. Remove, inspect and replace the seal bulb (it

Cummins Engine8B-11Figure 8B–7. Cummins engine fuel system.8B.7.1 Diesel FuelFuel represents a major portion of vehicle operating costs and therefore

Section 8B8B-12 Inform the owner/operator of the vehicle to use No. 2 D diesel fuel, unless ambient temperatures are below 32° F (0° C). When temperat

Cummins Engine8B-134. Reconnect the fuel hoses and follow the directions in Section 4 Cab, Covers and Mirrors to replace the other fuel system compone

Section 8B8B-14 To test a fuel injector:1. Remove the fuel injector from the cylinder head.2. Invert the fuel injector with the nozzle facing out, the

Cummins Engine8B-1514. Bleed the fuel system in accordance with the instructions in Section 2 General Information, Specifications, and Maintenance Ins

Section 8B8B-16 8B.9 CUMMINS ENGINE REPLACEMENTRemoval and installation of the engine can be done with or without the transmission attached. For infor

Cummins Engine8B-17Figure 8B–13. Cummins air cleaner.8. Disconnect the turbocharger exhaust connection, secured with a stainless steel V-band clamp,

Section 8B8B-18 12. Label and disconnect the positive (+) battery cable at the starter.13. Label and disconnect the engine water temperature switch le

Cummins Engine8B-1917. Label and disconnect the wiring harness at the steer select valve (Fig. 8B–18).Figure 8B–18. Label and disconnect the wiringat

General Information, Specifications, and Maintenance2-32.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONThe replacement of any part with any other than

Section 8B8B-20 25. In four locations, remove the nuts, washers and capscrews securing the engine mounts (Fig. 8B–1) to the hydraulic reservoir/engine

Cummins Engine8B-2118. For priming purposes, pour hydraulic oil into the main hydraulic pump. Connect the hydraulic system inlet and outlet hoses at t

Section 8B8B-22 8B.10 CUMMINS ENGINE STORAGEIf the engine is properly protected and stored according to the following recommendations, no corrosion da

Cummins Engine8B-238B.11 TROUBLESHOOTINGTrouble Possible Causes (see key, below)Low Cranking Power 1, 2, 3, 4Will Not Start 5, 6, 7, 8, 9, 10, 12, 13,

Section 8B8B-24 Model 3606 • Origin 10/99

9-1Section 9Hydraulic SystemContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 99-2 9.10.4 Hoist/Lower Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-979.10.5 Frame Tilt and Stabilizer Cylin

Hydraulic System9-3General OverviewFigure 9–1. Major hydraulic system components.INAU 2STEERCYLINDERPOERSTEERINGUNITLTPRHYDRAULICOIL COOLERETENDCYLI

Section 99-49.1 SAFETY INFORMATIONGeneralPetroleum-based hydraulic fluids are used in this vehicle.Temperature increases occur to hydraulic fluid duri

Hydraulic System9-5Figure 9–4. Flowmeter hydraulic diagnostic kit.9.3.1 Pressure Checks and AdjustmentsWhen diagnosing trouble in the hydraulic system

Section 22-4 6. Hold the fitting in the desired position and tighten to the proper torque according to the following chart:Adjustable Straight-thread

Section 99-6 MS1011IN2aAUX 2STEERCYLINDERPOWERSTEERINGUNITLTPRHYDRAULICOIL COOLEREXTENDCYLINDERHYDRAULIC RESERVOIRMAIN PUMPHOISTCYLINDERRLREPPGAUXILI

Hydraulic System9-7Engine InformationIdle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpmFull Speed . . . . . . . . . . . . .

Section 99-8 9.4 HYDRAULIC FLUIDGeneral information and specifications pertaining to hydraulic fluid are found in Section 2 General Informa-tion, Spec

Hydraulic System9-99.5 HOSES, TUBE LINES, FITTINGS, ETC.There are numerous hydraulic hoses, tube lines, fittings, etc., used on this vehicle. Periodic

Section 99-10 9.6 HYDRAULIC RESERVOIRThe hydraulic reservoir (Fig. 9–5) includes the engine mounting crossmembers. The reservoir is secured to the rig

Hydraulic System9-11Figure 9–5. Hydraulic reservoir/engine mount.MS20101. Hydraulic Reservoir2. Hex-head Capscrew, Grade 8, 1-8 x 2-3/4"3. Harde

Section 99-12 9.7 HYDRAULIC SYSTEM PUMPThe main gear pump (1, Fig. 9–6) is attached to the top of the transmission and driven via the pump main shaft

Hydraulic System9-13Figure 9–6. Pump, unloader valve and cooling circuit.281721924Torque to Maximum 20 lb/ft. (27 Nm)Bypass PortPrimary PortAux. Supp

Section 99-14 9.7.3 Pump Replacementa. Pump Removal1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, ground the att

Hydraulic System9-15Figure 9– 10. Special steel sleeve dimensions.5. A lip seal installation bar, made from round steel bar stock 1-3/4" (44,45m

General Information, Specifications, and Maintenance2-5LENGTH (distance)Millimeters (mm)0,0394 Inches (in)Centimeters (cm)0,394 Inches (in)Meters (m

Section 99-16 Figure 9– 11. Hydraulic system pump.Legend for Pump1. Main Pump2. Washer3. Capscrew4. PEC Housing5. Dowel Pin6. Bushing7. Back-up Seal8

Hydraulic System9-17f. Pump Inspection1. Inspect internal pump components for wear, damage, etc. If inner surfaces of the pump do not display an ultra

Section 99-18 12. Lubricate the gear set (12) with clean hydraulic oil from a filtered source. Slide the gear set into position within the SEC housing

Hydraulic System9-199.8 HYDRAULIC CIRCUITSThis section describes each hydraulic circuit and includes, on the following pages, a circuit schematic and

Section 99-20 9.8.1 Brake CircuitThe brake system circuit (Fig. 9– 12) includes the park brake and the service brake, along with the auxiliary functio

Hydraulic System9-21Figure 9– 12. Brake system circuit schematic.2500 RPM32.5 GPMTSPOOL3500PSI65PSI250PSIINLET25PSI3.0 IN4BYPASS TO TANKRELIEFVALVE5

Section 99-22 Legend for Brake Circuit1. Service Brake Valve2. 90° Elbow, SAE 6 - Str. Thd.ORB x O-ring face seal3. Swivel Run Tee, SAE 6,O-ring face

Hydraulic System9-23Figure 9– 13. Vehicle brake circuit.T12212345667689101112111111121313131313131415151415161718192017171718181820MS1870Front of Veh

Section 99-24 Figure 9– 14. Cross section of service brake valve.Fluid Flow When Brake Pedal is PressedSystem pressure from the main pump flows to th

Hydraulic System9-251. Brake pedal displacement is transmitted to the valve at the plunger (Fig. 9– 14).2. The series spring transmits plunger displac

Section 22-6 2.4 SPECIFICATIONS2.4.1 Vehicle Dimensions (Fig. 2-1)With Standard 12-ply 13.00-24 TiresRef. DescriptionA. Length(without attachment) 22

Section 99-26 9.8.2 Boom Hoist/Lower Circuita. Hoist CircuitWith the joystick in the boom lift position, pilot pressure shifts the hoist/lower spool v

Hydraulic System9-27Figure 9– 16. Boom hoist/lower hydraulic circuit schematic.XXHOIST/LOWERSOLENOID VALVE(Part of Pilot Select Manifold)T1FWD.BACK3A

Section 99-28 Model 3606 • Origin 10/999.8.3 Boom Extend/Retract CircuitHydraulic flow is applied in the boom extend/retract cir-cuit (Fig. 9– 17 and

Hydraulic System9-29Model 3606 • Origin 10/99Figure 9– 18. Extend/retract hydraulic circuit schematic.2500PSI550PSI4000PSI1211RIGHTEXTEND24LEFTT21PPP

Section 99-30 Model 3606 • Origin 10/99Figure 9– 19. Hoist/lower and extend/retract components.PS0690Legend1. Hose, 3/4” I.D. x 21-1/2”2. Hose, 3/4”

Hydraulic System9-31Model 3606 • Origin 10/99d. Extend/Retract Cylinder Counterbalance ValveThe extend/retract cylinder (Fig. 9– 19) includes two coun

Section 99-32 Model 3606 • Origin 10/999.8.4 Frame Tilt Circuita. Frame Tilt LEFTWith the two frame tilt select buttons on the joystick depressed and

Hydraulic System9-33Model 3606 • Origin 10/99Figure 9– 22. Frame tilt and stabilizer hydraulic schematic.LOAD SENSEOUTSHUTTLEINPILOT SELECT MANIFOLD9

Section 99-34 Model 3606 • Origin 10/999.8.5 Stabil-TRAK Hydraulic Circuita. Stabil-TRAK SystemThe patented rear axle lock or Stabil-TRAK system works

Hydraulic System9-35Model 3606 • Origin 10/99Figure 9– 24. Frame tilt and stabilizer components.FTBFTRPH094038244545566785678787899101112131213141516

General Information, Specifications, and Maintenance2-7C. Cylinder Times (with no load, at full throttle)Function Approximate Times, in secondsBoom

Section 99-36 b. Stabil-TRAK ModesThe function of the Stabil-TRAK system varies under dif-ferent operating conditions. The basic modes include the fre

Hydraulic System9-37Figure 9– 25. Free pivot mode hydraulic circuit.FRAME TILTCYLINDERFTRFTB0.60 ORIFICE100 PSICARTRIDGEMAIN CONTROL VALVE(located on

Section 99-38 Final Positioning Mode(Fig. 9– 26)• Rod Oil OUTConditions: Boom angle is above 40°, park brake OFF, and service brake released, and trav

Hydraulic System9-39Figure 9– 26. Final positioning mode hydraulic circuit.FRAME TILTCYLINDERFTRFTB0.60 ORIFICE100 PSICARTRIDGEMAIN CONTROL VALVE(loc

Section 99-40 Locked Mode(Fig. 9– 27)• Rod Oil OUTConditions: Boom angle is above 40°, park brake ON, or service brake applied, or travel select lever

Hydraulic System9-41Figure 9– 27. Stabil-TRAK locked mode hydraulic circuit.FRAME TILTCYLINDERFTRFTB0.60 ORIFICE100 PSICARTRIDGEMAIN CONTROL VALVE(lo

Section 99-42 9.8.6 Steering CircuitVehicle steering modes are two-wheel steer, four wheel steer and crab steer. Fig. 9– 35 shows an exploded view of

Hydraulic System9-43Figure 9– 30. Steering hydraulic circuit schematic.MS0120SPOOL3500PSI65PSI250PSIINLET25PSI3.0 IN0.5 PSI4BYPASS TO TANKRELIEFVALVE

Section 99-44 c. Four-wheel Steer• Left Turn(Fig. 9– 31)With the steer select switch in the four-wheel steer posi-tion, the steering unit control valv

Hydraulic System9-45d. Crab Steer• Left Turn(Fig. 9– 33)With the steer select switch in the crab steer position, the steering control valve spool is s

Section 22-8 Block forks, 2 x 2 x 48 (5 x 5 x 122 cm)quantity: 6... 480 lb (216 kg)Lumber forks, 1.75 x

Section 99-46 Figure 9– 35. Steering circuit.LTRPPPSPSGTPBPPGPP21345678910112122129131415161743423138202939293025272824323554373637353227242326262725

Hydraulic System9-47Steering Circuit Legend1. Steering Unit2. 90° Elbow, SAE 6-4 - str. thd. ORB x o-ring face seal3. Long Connector, SAE 8 - str. thd

Section 99-48 9.8.7 Attachment Tilt and Slave Cylinder CircuitThe attachment tilt functions are dependent on the posi-tion of the attachment tilt mode

Hydraulic System9-49Figure 9– 38. Attachment tilt/slave cylinder schematic.3700PSI3700PSIBYPASS TO RESERVOIRABaLOADSENSE OUTINLET15GPMMAX2178SLAVE CY

Section 99-50 Figure 9– 39. Attachment tilt spool valve circuit.a. Center PositionWhen the joystick is in the center or neutral position, the attachm

Hydraulic System9-51c. DOWN PositionWith the right button depressed and held on the joystick, and the joystick moved to the right, the attachment tilt

Section 99-52 Figure 9– 40. Attachment tilt/slave cylinder circuit.3312345678910111213141516171819202122232425262729111237111415161516171820222222222

Hydraulic System9-53Attachment Tilt/Slave Cylinder Legend1. Hose, 1/2” I.D. x 33-1/2”2. Hose, 1/2” I.D. x 16”3. Hose, 1/2” I.D. x 39”4. Bulkhead Fitti

Section 99-54 9.8.8 Joystick CircuitJoystick hydraulic circuit (Fig. 9– 43) commands are achieved through electric and hydraulic signals via a set of

Hydraulic System9-55Figure 9– 43. Joystick circuit.12345678910112658889456UNDERSIDEFront of VehicleAuxiliary Function ValvePort “ PP”Valve Plate Asse

General Information, Specifications, and Maintenance2-92.5 FLUIDS, LUBRICANTS AND CAPACITIES2.5.1 Axles (Differential Housings) and Transfer CaseA.

Section 99-56 Figure 9– 44. Valve plate assembly (without auxiliary hydraulics).15313429131528303332941728Front Of Vehicle FRAME156158718171139382640

Hydraulic System9-57Valve Plate Assembly Legend(without auxiliary hydraulics)1. Pilot Select Manifold2. Main Control Valve3. Shuttle Valve4. Spacer5.

Section 99-58 Figure 9– 45. Valve plate assembly (with auxiliary hydraulics)NOTE:The Auxiliary Hydraulic System is an option that consists of the par

Hydraulic System9-59Valve Plate Assembly Legend(with auxiliary hydraulics)1. Auxiliary Control Valve2. Auxiliary Control Valve Mounting Bracket3. Lock

Section 99-60 9.8.9 Auxiliary Hydraulics Circuit (optional)The optional auxiliary hydraulic circuit (Fig. 9– 47 andFig. 9– 48) functions can be achiev

Hydraulic System9-61Figure 9– 47. Optional auxiliary hydraulic schematic.BbTP3700PSIaBAP21563700PSI15GPMMAXMANUAL PRESSURERELIEF VALVEAUX 2 (OPTIONAL

Section 99-62 Figure 9– 48. Optional auxiliary hydraulic circuit.192220211811123115153112111371032323382827233825242614217166793514034353236373029481

Hydraulic System9-63Auxiliary Hydraulics Legend1. Shuttle Valve2. Bulkhead Fitting Support Bracket3. Tube Assembly, Outer-Aux. Hydraulics (Rear)4. Tub

Section 99-649.9 VALVES AND MANIFOLDSValves are devices that open or close passageways.Manifolds (derived from the words, “many folds”) containcircuit

Hydraulic System9-65Figure 9– 50. Unloader valve detail.Unloader Valve Legend1. Unloader Valve (includes items 2 through 8)2. Cap3. O-Ring4. Spool Sp

Section 22-10 2.5.4 Hydraulic SystemA. Hydraulic FluidsThe hydraulic system is factory filled with ISO Grade 46 anti-wear hydraulic oil. When filling

Section 99-66 9.9.2 Main Control ValveThe main control valve assembly (2, Fig. 9– 51) is located at the rear of the vehicle, beneath the rear cover, s

Hydraulic System9-67b. Main Control Valve Removal1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, ground the attac

Section 99-68 Figure 9– 51. Main control valve plate assembly (without auxiliary hydraulics).15313429131528303332941728Front Of Vehicle FRAME15615871

Hydraulic System9-69Main Control Valve Plate Assembly Legend(without auxiliary hydraulics)1. Pilot Select Manifold2. Main Control Valve3. Shuttle Valv

Section 99-70 Figure 9– 52. Main control valve plate assembly (with auxiliary hydraulics)NOTE:The Auxiliary Hydraulic Systemis an option that consist

Hydraulic System9-71Main Control Valve Assembly Legend(with auxiliary hydraulics)1. Auxiliary Control Valve2. Auxiliary Control Valve Mounting Bracket

Section 99-72 Outlet SectionRemove the SAE plug (7, Fig. 9– 53) and O-ring (8) from the outlet section assembly (6) to facilitate cleaning and removal

Hydraulic System9-732. Remove the plug (45), poppet (46), back-up rings (47), and jam nut (48). Keep the back-up rings (47) for re-use later during as

Section 99-74 Figure 9– 53. Attachment tilt and frame tilt sections.PS0780123456789101112131415161718192021222324252627282930313233343536371112141316

Hydraulic System9-75Main Control Valve LegendAttachment Tilt and Frame Tilt Sections1. Main Control Valve Assembly(includes items 2 through 37)2. Spec

General Information, Specifications, and Maintenance2-112.5.6 TransmissionA. Transmission FluidVehicle transmissions are factory filled with 10W mot

Section 99-76 f. Main Control Valve ReassemblyNote: Always replace O-rings with new O-rings to help ensure a leak-proof seal and proper vehicle perfo

Hydraulic System9-77Boom Extend/Retract Section1. Install the poppet (24, Fig. 9– 54), spring (25) and shuttle (21) into the boom extend/retract secti

Section 99-78 Figure 9– 54. Hoist/lower and extend/retract sections.312456789101112131415161718192021222324252627282930313233343536373839404142434414

Hydraulic System9-79Main Control Valve LegendHoist/Lower and Extend/Retract Sections1. Main Control Valve Assembly(includes items 2 through 42)2. Spec

Section 99-809.9.3 Auxiliary Function ManifoldThe auxiliary function manifold (Fig. 9–55) is locatednear the battery, secured to a bracket at the hydr

Hydraulic System9-81b. Auxiliary Function Manifold Disassembly, Cleaning, Inspection and Reassembly1. Secure the auxiliary function manifold (Fig. 9–

Section 99-82 9.9.5 Pilot Select ManifoldThe pilot select manifold (Fig. 9– 57) is a precisely-machined block located inside the rear cover, secured a

Hydraulic System9-836. Start the engine and run at approximately 1/3 to 1/2throttle for about one minute without moving thevehicle or operating any hy

Section 99-84 When the solenoid is de-energized, the control spool (4) is returned to its normal condition by the centering springs (5).Figure 9– 60.

Hydraulic System9-85c. Shuttle Valve Installation1. Attach the shuttle valve (Fig. 9– 61) to the brake valve (Fig. 9– 62) with a 90° elbow fitting. Th

Section 22-12 2.5.7 Drive Shaft SplinesIMPORTANT: DO NOT disassemble any of the drive shafts (see Section 6 Transfer Case of this manual for informa

Section 99-86 9.10 CYLINDERSThere are many factors involved with the proper disas-sembly, cleaning, inspection, repair and reassembly of hydraulic cyl

Hydraulic System9-879.10.1 Attachment Tilt CylinderThe attachment tilt cylinder (Fig. 9– 64) is attached at the front of the inner boom inside the goo

Section 99-88 Figure 9– 64. Attachment tilt cylinder.Attachment Tilt Cylinder Legend1. Attachment Tilt Cylinder w/Bushings(includes items 2 through 1

Hydraulic System9-89c. Attachment Tilt Cylinder Cleaning1. Thoroughly clean the inner surface of the attachment tilt cylinder (Fig. 9– 64) with trichl

Section 99-90 2. Install the lower attachment tilt cylinder pin by tapping it out through the bottom of the quick attach (if installed).3. Coat the at

Hydraulic System9-91Figure 9– 65. Slave cylinder exploded view drawing.Slave Cylinder Legend1. Slave Cylinder(includes items 2 through 15)2. Tube3. L

Section 99-92 9. Remove the capped T-seal (4) from the piston (5). Note: The T-seal actually consists of four components; a wide, flexible inner band

Hydraulic System9-936. Install the capped T-seal (4) onto the piston (5). Note: The T-seal actually consists of four components; a wide, flexible inn

Section 99-94 9.10.3 Extend/Retract CylinderThe extend/retract cylinder (Fig. 9– 66) is located within the inner boom.a. Extend/Retract Cylinder Remov

Hydraulic System9-95Figure 9– 66. Extend/retract cylinder.Extend/Retract Cylinder Legend1. Extend/Retract Cylinder(includes items 2 through 19)2. Hyt

General Information, Specifications, and Maintenance2-132.5.10 PaintUnless otherwise specified, paint components as indi-cated in the following sect

Section 99-96 2. Clean parts with trichlorethylene.3. Check that the rod (17) is straight. If it is bent, install a new rod.e. Extend/Retract Cylinder

Hydraulic System9-97Figure 9– 67. Hoist/lower cylinder.Hoist/Lower Cylinder Legend1. Hoist/Lower Cylinder with Bearing(includes items 2 through 18)2.

Section 99-98 4. Attach a sling to the hoist/lower cylinder and to a hoist or an overhead crane. Support the hoist/lower cylinder in the sling, and re

Hydraulic System9-99c. Hoist/Lower Cylinder Cleaning1. Remove all hydraulic fluid, dirt and debris from the inner surface of the cylinder tube (3, Fig

Section 99-100 19. If necessary, install a grease fitting (19) into the tapped hole in the end of the rod weldment (18). Lubricate the self-align bear

Hydraulic System9-101Figure 9– 68. Frame tilt and/or stabilizer cylinder.Frame Tilt and Stabilizer Cylinder Legend1. Frame Tilt/Stabilizer Cylinder(i

Section 99-102 4. Remove the locking insert (13) from its hole in the head gland threads. Pry or drill out the insert as required. DO NOT damage the h

Hydraulic System9-103c. Frame Tilt or Stabilizer Cylinder Internal Cleaning1. Remove all hydraulic fluid, dirt and debris from the inner surface of th

Section 99-104 e. Frame Tilt or Stabilizer Cylinder AssemblyNote: Follow Section 9.12 c. General Assembly Instruc-tions.1. Install the deep Z-seal wi

Hydraulic System9-105f. Frame Tilt or Stabilizer Cylinder Installation1. Lubricate the 1.5" diameter cylinder pins with multi-purpose lithium-bas

iModel 3606 • Origin 10/99ForewordSKY TRAK Model 3606Service ManualThis manual is designed to provide the service techni-cian with complete informatio

Section 22-14 2.6 CLEANINGDirt and abrasive dust reduce the efficient working life of parts and systems, and lead to the costly replacement of compon

Section 99-106 9.10.6 Swing Carriage (optional)The optional swing carriage (1, Fig. 9– 69) provides a way to swing the carriage attachment from side t

Hydraulic System9-107Figure 9– 69. Swing carriage (optional).EERR123456789101112131415161718192021222324252627282930313233343536373839404142PH0560121

Section 99-108 a. Swing Carriage Cylinder Removal1. Level the boom (place the boom in a horizontal boom).2. Swing the carriage to the centered positio

Hydraulic System9-109Figure 9– 72. Swing carriage cylinder (optional).Swing Carriage Cylinder Legend1. Swing Carriage Cylinder (OPTIONAL)(includes it

Section 99-110 5. Using a pin spanner wrench, unscrew the gland (8) from the cylinder tube (2). Slide the gland down along the rod toward the eyelet,

Hydraulic System9-1119. Install new O-rings and backup rings on the counterbalance cartridge (12) and direct-acting relief valve (13). Lubricate the c

Section 99-112 9.10.7 Side Tilt Carriage Cylinder (optional)The optional side tilt carriage cylinder (1, Fig. 9– 75) pro-vides a way to tilt the carri

Hydraulic System9-113Figure 9– 74. Side tilt carriage (optional).PA1592123456789101112131415161718192021222324252627282930313233343536373833313211118

Section 99-114 Figure 9– 75. Side tilt carriage cylinder (optional).Side Tilt Carriage Cylinder Legend1. Side Tilt Carriage Cylinder (OPTIONAL)(inclu

Hydraulic System9-1157. Using a pin spanner wrench, unscrew the gland (5) from the cylinder tube (2).IMPORTANT: Protect the finish on the rod at all

General Information, Specifications, and Maintenance2-152.9.3 Bearing Installation1. Always install bearings carefully to help avoid damaging their

Section 99-116 10. Apply a compression sleeve or other suitable tool to the gland in order to compress the O-ring (11). Carefully insert the rod (6) w

Hydraulic System9-1179.11 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during operation o

Section 99-118 6. Boom hoist or extend function slow or malfunc-tioning.1. External fluid leakage at tubes, hoses or fittings.2. Faulty relief valve s

Hydraulic System9-11910. Frame tilt slow or malfunc-tioning.1. External fluid leakage at tubes, hoses or fittings.2. Faulty relief valve setting.3. In

Section 99-120 17. Park lock brake fails to set. 1. Defective solenoids and/or valves.2. Defective switch.3. Defective or weak springs in park lock as

Hydraulic System9-12122. Steering is “ spongy” or noisy.1. Air in steering lines.2. Faulty steering unit.1. Check and tighten loose connections. Oper

Section 99-122 27. Cylinder movement is jerky.1. Air trapped in cylinder or in hydraulic line. Low oil level in hydraulic oil reservoir.2. Binding of

Hydraulic System9-12331. Directional control valve difficult to shift.1. Broken internal parts.2. Scored valve body bore, producing leakage between sp

Section 99-124

10-1Model 3606 • Origin 10/99Section 10Electrical SystemContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 22-16 2.11.4 After Brake System Service1. Check the oil level in the axle and replenish with SAE 80W90 or SAE 80W140 oil as required.2. Bleed

Section 1010-2 Model 3606 • Origin 10/9910.8.17 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7310

Electrical System10-3Model 3606 • Origin 10/99IntroductionThe electrical system produces, stores and distributes electricity in the operation of the v

Section 1010-4 Model 3606 • Origin 10/991. Cab Harness2. Back-up Alarm3. Hex-lock Elastic Nut, 1/4-204. Flat Washer, 1/4”5. Boom Sensor6. Service Brak

Electrical System10-5Model 3606 • Origin 10/99General Overview (Cab Harness)Figure 10–1. Typical cab harness (S/N 8249 and before; see text).PS079112

Section 1010-6 Model 3606 • Origin 10/99General Overview (Engine Harness)Figure 10–2. Engine harness.Front1PS0801234567893101112131414151516161718191

Electrical System10-7Model 3606 • Origin 10/99Legend for Engine Harness1. Engine Harness2. Conduit, 3/4” diameter x 10” long3. Hex-lock Elastic Nut, 3

Section 1010-8 Model 3606 • Origin 10/9910.2 SPECIFICATIONSElectrical system specifications are listed in Section 2 General Information, Specification

Electrical System10-9Model 3606 • Origin 10/9910.4 WIRING HARNESSESWiring on the vehicle is contained within two separate wiring harnesses, an engine

Section 1010-10 Model 3606 • Origin 10/99Figure 10–5. Cab wiring diagram (S/N 8249 and before), left side.SteerSelectSwitchWHT/PUR25LT BLUBulkheadCon

Electrical System10-11Model 3606 • Origin 10/99Figure 10–6. Cab wiring diagram (S/N 8249 and before), right side.48DK GRN/WHTDK GRN/WHTDK GRN/WHT48A4

General Information, Specifications, and Maintenance2-172.12 MAINTENANCE INSTRUCTIONSMaintenance IntroductionThis section contains a routine equipme

Section 1010-12 Model 3606 • Origin 10/9910.4.1 Cab Harness, S/N 8249 and BeforeUse this chart for vehicles with S/N 8249 and before.WIRE No. COLOR G

Electrical System10-13Model 3606 • Origin 10/99WIRE No. COLOR GAUGE FUNCTION26 WHT/BLU 16 Splice 12 to Second Gear Clutch Solenoid26A WHT/BLU 16 Seco

Section 1010-14 Model 3606 • Origin 10/99Figure 10–7. Cab wiring schematic, S/N 8249 and before.2UJ3BULHEADCONNECTORPIN LOCATIONJ7LT BLUH8RED / GRYRE

Electrical System10-15Model 3606 • Origin 10/99Figure 10– 8. Cab harness relays, bulkhead connector and fuse panel, S/N 8249 and before.CABBULHEADCON

Section 1010-16 Model 3606 • Origin 10/99Figure 10– 9. Cab wiring diagram, S/N 8250-9398, left side (refer to the appropriate wire code chart).WHT/PU

Electrical System10-17Model 3606 • Origin 10/99Figure 10– 10. Cab wiring diagram, S/N 8250-9398, right side (refer to the appropriate wire code chart

Section 1010-18 Model 3606 • Origin 10/9910.4.2 Cab Harness, S/N 8250-9398Use this chart for vehicles with S/N 8250-9398.WIRE No. COLOR GAUGE FUNCTIO

Electrical System10-19Model 3606 • Origin 10/9925A LT BLU 16 First Clutch Shift Control to Transmission Logic26 WHT/BLU 16 Splice 12 to Second G

Section 1010-20 Model 3606 • Origin 10/9976 PNK/BLU 16 4TH Gear (optional--if equipped) Splice to Transmission Relay 2 (Terminal 85)77 PUR 10 Ig

Electrical System10-21Model 3606 • Origin 10/99Figure 10– 11. Cab wiring harness schematic, S/N 8250-9398 (refer to the appropriate wire code chart).

Section 22-18 C. 250 Hour IntervalsFigure 2–6. Two-hundred-fifty hour interval maintenance schedule and checklist.At 250 hour intervals, perform the

Section 1010-22 Model 3606 • Origin 10/99This page is intentionally blank.

Electrical System10-23Model 3606 • Origin 10/99Figure 10– 12. Cab harness relays, bulkhead connector and fuse panel, S/N 8250-9398.247 3712LL59A97470

Section 1010-24 Model 3606 • Origin 10/99Figure 10– 13. Cab wiring harness diagram, S/N 9399 and after, left side (refer to the appropriate wire code

Electrical System10-25Model 3606 • Origin 10/99Figure 10– 14. Cab wiring harness diagram, S/N 9399 and after, right side (refer to the appropriate wi

Section 1010-26 Model 3606 • Origin 10/9910.4.3 Cab Harness, S/N 9399 and AfterUse this chart for vehicles with S/N 9399 and after.WIRE No. COLOR GAU

Electrical System10-27Model 3606 • Origin 10/9925A LT BLU 16 Splice 60 to First Gear Input (Terminal 6/A dash indicator)26 WHT/BLU 16 Diode to Se

Section 1010-28 Model 3606 • Origin 10/9970 BLU/WHT 16 Fuse Panel 7.5-amp Fuse to Transmission Relay 1 (Terminal 30)71 ORN/DK BLU 16 Relay 1 (Te

Electrical System10-29Model 3606 • Origin 10/99Figure 10– 15. Cab wiring harness schematic, S/N 9399 and after (refer to the appropriate wire code ch

Section 1010-30 Model 3606 • Origin 10/99Figure 10– 16. Cab harness relays, bulkhead connector and fuse panel, S/N 9399 and after.FUSE BLOCA

Electrical System10-31Model 3606 • Origin 10/99Figure 10– 17. Engine wiring harness diagram (refer to the appropriate wire code chart on the next pag

General Information, Specifications, and Maintenance2-19E. 1,000 Hour IntervalsFigure 2–9. One-thousand-hour interval maintenance schedule and chec

Section 1010-32 Model 3606 • Origin 10/9910.4.4 Engine HarnessUse the chart below for the engine harness diagram (Fig. 10– 17) and engine harness sch

Electrical System10-33Model 3606 • Origin 10/99Figure 10– 18. Engine wiring harness schematic (refer to the appropriate wire code chart).LT GRN/BLK21

Section 1010-34 Model 3606 • Origin 10/9910.4.5 Closed Cab Harness (Option)A closed cab option was being finalized shortly before completion of this

Electrical System10-35Model 3606 • Origin 10/99Figure 10– 20. Enclosed cab option electrical schematic, right side.#124DK BLU/GRY10#2ABBLK16643JUMPER

Section 1010-36 Model 3606 • Origin 10/9910.5 FUSES AND RELAYSFuses and relays help to protect the electrical system. In general, a blown fuse is a sy

Electrical System10-37Model 3606 • Origin 10/9910.5.1 Fuse and Relay ReplacementShut off the engine and disconnect the negative (-) bat-tery cable at

Section 1010-38 Model 3606 • Origin 10/99Figure 10– 26. Vehicles with serial number 8250 through 9398 use the fuse and relay panel shown here.4. If t

Electrical System10-39Model 3606 • Origin 10/9910.6.1 Testing the Starter on the EngineIf the starter does not engage when the ignition key is turned

Section 1010-40Model 3606 • Origin 10/99Figure 10–29. Disconnect the ground cable (from thechassis ground stud) at the starter mounting bolt(Cummins e

Electrical System10-41Model 3606 • Origin 10/99Figure 10– 31. Cummins starter relay.The relay is internally grounded and is equipped with two large t

Section 22-20 2.12.3 Air CleanerA. Engine Air Filter Restriction Warning IndicatorFigure 2–12. Engine air filter restriction warning indicator.The o

Section 1010-42 Model 3606 • Origin 10/9910.7 CHARGING CIRCUITThe charging circuit consists of the battery and a belt-driven alternator with an intern

Electrical System10-43Model 3606 • Origin 10/9910.7.1 AlternatorThere are two types of 65-amp alternators used. Vehicles equipped with Perkins engine

Section 1010-44 Model 3606 • Origin 10/99Figure 10– 35. Perkins alternator mounting detail.b. Perkins Alternator Installation1. If required, install

Electrical System10-45Model 3606 • Origin 10/99Figure 10– 36. Cummins alternator mounting detail.a. Cummins Engine Bosch Alternator Removal1. Disconn

Section 1010-46 Model 3606 • Origin 10/994. Use a 1/2" square drive ratchet to raise the tensioner bracket (2). Properly route the fan belt (3) o

Electrical System10-47Model 3606 • Origin 10/99Note: The accuracy of this test procedure depends on closely following the load, time and temperature

Section 1010-48Model 3606 • Origin 10/992. Continue with the jump starting instructions foundunder C. Jump Starting in Section 2.12.15 Battery.g. Batt

Electrical System10-49Model 3606 • Origin 10/9910.8 ELECTRICAL SYSTEM COMPONENTSElectrical components include warning devices such as the indicators i

Section 1010-50 Model 3606 • Origin 10/992. Engine Coolant Temperature Warning IndicatorThis indicator (item 2, Fig. 10– 41) is illuminated when the e

Electrical System10-51Model 3606 • Origin 10/99Back-up Alarm Removal1. Disconnect the negative (-) battery cable at the negative battery terminal (Fig

General Information, Specifications, and Maintenance2-21Figure 2–15. Engine air cleaner components.To change elements:1. Unlatch the three retainin

Section 1010-52 Model 3606 • Origin 10/99a. Power-Up LightsWhen the ignition key switch is turned to power up the vehicle, all lights in the display p

Electrical System10-53Model 3606 • Origin 10/99B. Parking Brake IndicatorThis illuminates any time the parking brake switch is applied and the ignitio

Section 1010-54 Model 3606 • Origin 10/99Operators Display Panel TestCheck the following as the key is switched into the "RUN" position (Fig

Electrical System10-55Model 3606 • Origin 10/99If the key binds in the switch, check the key for defects and the switch for foreign objects. Clean or

Section 1010-56 Model 3606 • Origin 10/994. Connect the negative (-) battery cable at the negative battery terminal (Fig. 10– 55).Figure 10– 55. Conn

Electrical System10-57Model 3606 • Origin 10/99a. Thermo-Start Plug Removal1. Label and disconnect the thermo-start wiring lead at the thermo-start pl

Section 1010-58 Model 3606 • Origin 10/99a. Fuel Run Solenoid Removal1. Disconnect the negative (-) battery cable at the negative battery terminal (Fi

Electrical System10-59Model 3606 • Origin 10/99Examine the fluid in the hydraulic oil sight glass(Fig. 10– 61) to check whether there is a sufficient

Section 1010-60 Model 3606 • Origin 10/99a. Hydraulic Oil Temperature Switch Removal1. Disconnect the negative (-) battery cable at the negative batte

Electrical System10-61Model 3606 • Origin 10/99a. Parking Brake Switch Removal1. Disconnect the negative (-) battery cable at the negative battery ter

Section 22-22 Fresh Air Intake FilterPeriodically remove the cab rear panel and inspect the fresh air intake filter (Fig. 2–17). The filter must be c

Section 1010-62 Model 3606 • Origin 10/99Service Brake Switch AdjustmentThe service brake switch may be adjusted as required by loosening the jam nut

Electrical System10-63Model 3606 • Origin 10/9910.8.11 Transmission Solenoid ValvesThe transmission is shifted via spool-type solenoid car-tridge ass

Section 1010-64 Model 3606 • Origin 10/99d. Transmission Solenoid Valve Installation1. Carefully install the four-way cartridge valve assembly with fo

Electrical System10-65Model 3606 • Origin 10/9910.8.12 Attachment Tilt Mode SwitchThe attachment tilt mode switch (Fig. 10– 72) is located on the das

Section 1010-66 Model 3606 • Origin 10/9910.8.13 JoystickThe multi-function joystick (Fig. 10– 74) controls boom movement, attachment tilt, vehicle f

Electrical System10-67Model 3606 • Origin 10/99Figure 10– 75. Logic panel and joystick wiring schematic.38LT BLU/WHT16TOPRIGHTBUTTONFRONTBUTTONTOPLEF

Section 1010-68 Model 3606 • Origin 10/99a. Joystick Button Testing1. Remove the four button-head capscrews (Fig. 10– 76) securing the logic panel to

Electrical System10-69Model 3606 • Origin 10/9910.8.14 Logic Board PanelThe logic board or side console panel (Fig. 10–80; seealso Fig. 10–76 and Fig.

Section 1010-70 Model 3606 • Origin 10/9910.8.16 Stabil-TRAK SystemThe patented Stabil-TRAK system works to stabilize the vehicle under various condi

Electrical System10-71Model 3606 • Origin 10/99Stabil-TRAK System TestIMPORTANT: The operator must know that the Stabil-TRAK system is active and fun

General Information, Specifications, and Maintenance2-23Figure 2–21. Drain coolant from the overflow bottle.4. Place a funnel at the base of the ra

Section 1010-72 Model 3606 • Origin 10/998. Depress the service brake pedal. Disengage the parking brake switch and move the travel select lever to th

Electrical System10-73Model 3606 • Origin 10/9910.8.17 SteeringCertain steering functions are dependent upon electrical operations, described below.

Section 1010-74 Model 3606 • Origin 10/99Figure 10– 88. The steer select switch has three positions.Steering select indicators on the right side of t

Electrical System10-75Model 3606 • Origin 10/99c. Steering Select Switch Removal1. Disconnect the negative (-) battery cable at the negative battery t

Section 1010-76 Model 3606 • Origin 10/9910.8.18 Steer Select ValveThe steer select valve (Fig. 10– 95), is secured to the steer select manifold and

Electrical System10-77Model 3606 • Origin 10/9910.8.19 Engine Low Oil Pressure SenderThe engine oil pressure sender is located on the engine block (C

Section 1010-78 Model 3606 • Origin 10/99Figure 10– 100. Disconnect the negative (-) battery cableat the negative (-) battery terminal.b. Engine Oil

Electrical System10-79Model 3606 • Origin 10/9910.8.20 Transmission High Temperature SenderThe transmission high temperature sender (Cummins, Fig. 10

Section 1010-80 Model 3606 • Origin 10/99Figure 10– 102. Perkins engine/transmission senders.Figure 10– 103. Operators display panel indicators.a. E

Electrical System10-81Model 3606 • Origin 10/9910.8.22 Engine Block Heater (option)Some engines are equipped with an optional engine block heater (Fi

iiSection ContentsSection Subject PageSection 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 22-24 For most climates, use a premium-quality 15W40 motor oil that meets API, CD or CE (severe duty diesel engine) specifications. In cold c

Section 1010-82 Model 3606 • Origin 10/99The fuel level sender (Fig. 10– 107) consists of a resis-tance, float-type fuel level sender mounted in the t

Electrical System10-83Model 3606 • Origin 10/994. If the fuel level indicators do not illuminate, and a faulty or defective fuel sender in the fuel ta

Section 1010-84 Model 3606 • Origin 10/9910.9 ELECTRICAL SYSTEM TROUBLESHOOTINGThis section provides an easy reference guide covering the most common

Electrical System10-85Model 3606 • Origin 10/997. LOSS OF ELECTRICAL POWER for some but not all vehicle operations.1. No voltage at these circuits, ca

Section 1010-86 Model 3606 • Origin 10/9914. Engine turns over but does not start.Note: Refer to the Perkins or Cummins engine trouble-shooting inform

Electrical System10-87Model 3606 • Origin 10/9919. Intake manifold remains abnormally hot duringnormal engine operation.1. Thermo-start plug is ON con

Section 1010-88 Model 3606 • Origin 10/9927. With key in the START posi-tion, engine does not crank.1. Travel select lever is in forward (F) or revers

Electrical System10-89Model 3606 • Origin 10/9933. Backup alarm sounds with travel select in NEUTRAL (N) and FORWARD (F).1. Short circuit in wiring.2.

Section 1010-90 Model 3606 • Origin 10/9940. ENGINECOOLANT TEM-PERATURE SWITCHEngine coolant tempera-ture warning indicator on operators display panel

Electrical System10-91Model 3606 • Origin 10/9944. Transmission temperature warning indicator illumi-nates during vehicle opera-tion when transmission

General Information, Specifications, and Maintenance2-2511. Remove the engine oil fill cap and add oil (refer to the engine manufacturer's manu

Section 1010-92 Model 3606 • Origin 10/99

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

Section 22-26 6. Screw the new canister onto the base. Hand tighten only.7. Remove air from the fuel system. See Venting Air from the Fuel System. (s

General Information, Specifications, and Maintenance2-27IMPORTANT: DO NOT attempt to start the engine until the injection pump has been filled and

Section 22-28 Figure 2–36. Cummins injector and high-pressurefuel line locations.4. Tighten the fitting to 22 lb/ft (30 Nm). Repeat this procedure f

General Information, Specifications, and Maintenance2-29Figure 2–39. Cummins engine fan belt adjustment points.6. Close and lock the engine compart

Section 22-30 Figure 2–43. Hydraulic oil filter restriction warningindicator for early production (top)and current production (bottom) vehicles.1. L

General Information, Specifications, and Maintenance2-3111. Fully install a new hydraulic oil filter element onto the hydraulic oil filter head unti

Section 22-32 Figure 2–49. Location of transmission maintenance items.4. Clean and reinstall the transmission drain plug into the transmission housi

General Information, Specifications, and Maintenance2-335. Clean and reinstall the drain plug. Remove the axle fill/level plug from the axle housing

iiiSection 6 Transfer Case and Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1INTRODUCTION. . . . . . . . . . . . . . .

Section 22-34 2.12.13 Transfer Case OilA. Transfer Case Oil Level CheckFigure 2–58. Every 250 hours of engine operation, check the transfer case oil

General Information, Specifications, and Maintenance2-35minimum for 13.00 - 24, 12-ply tires. Maximum ground pressure with a full load is 93 psi (64

Section 22-36 3. Wear safety glasses and visually inspect the battery. Check terminals for corrosion. Replace the battery if it has a cracked, melted

General Information, Specifications, and Maintenance2-377. Next, remove the negative (-) jumper cable connected to the negative (-) post of the boos

Section 22-38 Figure 2–68. Vehicles with serial number 8249 and before use the fuse and relay panel shown here.Figure 2–69. Vehicles stamped with s

General Information, Specifications, and Maintenance2-39Figure 2–70. Vehicles stamped with serial number 9399 and after use the fuse and relay pane

Section 22-40 Figure 2–74. Prevent the clevis end from turning,and tighten the extend chain locknutat the rear of the outer boom.5. Periodically mea

General Information, Specifications, and Maintenance2-412.13 EMERGENCY OPERATIONS2.13.1 Towing a Disabled VehicleIMPORTANT: After the vehicle has b

Section 22-42 6. For early production vehicles, see Fig. 2–79; for current production vehicles, see Fig. 2–80. Alternately turn the parking brake rel

General Information, Specifications, and Maintenance2-43Figure 2–82. Alternately turn parking brake release bolts A, B and C outward until torque d

ivSection 9 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1INTRODUCTION. . . . . . . . . . .

Section 22-44 Model 3606 • Origin 10/99

1-1ContentsPAR. TITLE PAGE1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.2 OWNERS/OPERA

Section 11-21.1 INTRODUCTIONSky Trak International (hereafter, Sky Trak) products meet all applicable industry safety standards. Sky Trak actively pro

4-1Section 4Cab, Covers and MirrorsContentsPAR. TITLE PAGEINTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 44-2 IntroductionLegendThe welded metal cab features European styling and a modular design, allowing for a relatively quick, simple exchange o

Cab, Covers and Mirrors4-3General OverviewModel 3606 • Origin 10/99PS0330PF078012345645678910661187121314151617181920452122222123203164524252627282929

Safety1-31.3.1 Safety Alert SymbolThe exclamation mark within a triangle is the Safety Alert Symbol.The Safety Alert Symbol means ATTENTION! BECOME AL

Section 44-4 4.1 SERIAL NUMBER DECALThe cab serial number decal (Fig. 4–1) is located along the top right side of the cab, near the mirror. Informatio

Cab, Covers and Mirrors4-56. Route the joystick, power steering and service brake hydraulic hoses out of and away from the cab. Cut and dispose of pla

Section 44-6 9. Remove the front cab-to-cab-mount attaching hardware (refer to items in the General Overview illustration on page three). Front hardwa

Cab, Covers and Mirrors4-715307.57.57.57.57.5 7.57.57.57.5 7.57.57.57.5 7.57.57.51515307.57.57.57.57.57.57.57.57.5 7.57.57.530257.520207.57.5 7.512345

Section 44-8 4.2.2 Cab InstallationIMPORTANT: Transfer and install cab panels and other components as needed after the cab is securely mounted on the

Cab, Covers and Mirrors4-920. Connect the battery negative (-) ground cable(Fig. 4–2).21. Carefully examine all cab components, fasteners, etc., one l

Section 44-10 Figure 4–9. Standard (left) and optional (right) seats.123456789101112131415161234567891011121314967435224811121153MS0900StandardseatOp

Cab, Covers and Mirrors4-11Standard Seat Installation1. Install the seat belt assembly (4, Fig. 4–9) and tethers (2) on the seat with the seat out of

Section 44-12 Note: Early production cabs included a threaded hole for tether mounting. In Fig. 4–9, items 11 through 14 are not used on early produc

Cab, Covers and Mirrors4-13Steering Wheel Removal1. Carefully pry the horn cover button out of its recess in the steering wheel. Disconnect the horn w