SkyTrak 3606 Service Manual

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Service and Maintenance Manual

Model

3606

8990300

OCTOBER 1999

ANSI

Foreword

SKY TRAK Model 3606

Service Manual

This manual is designed to provide the service technician with complete information on the maintenance and repair of the Sky Trak International SKY TRAK Model 3606 rough-terrain 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 that 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.

There are many variations in service environments and skill levels of repair technicians, as well as procedures, techniques, tools, and service parts. A ser vice manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, any departure from the instructions in this manual must take into consideration both personal safety as well as vehicle integrity.

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. 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. All references to the right side, left side, front, and rear are given from the perspective of the operator's position, facing forward (see figure below).

Section Contents

The

allows the user to quickly locate any desired section. Each section begins with its own table of contents, and, where applicable, an informative introduction and exploded-view illustration appears, to show the location of major section components.

Provision for supplementary information is made by Trak International in the form of Service Bulletins, Service Campaigns, Service Training Schools, the OmniQuip web site, other literature, and through updates to the manual itself. Comments and suggestions for improvement are welcomed 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. Trak 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. When additional information is desired to satisfy a situation not covered sufficiently, consult the nearest Sky Trak International distributor, or the Sky Trak International Service Department at 1-414-268-8959.

LEFT

All references to direction are as viewed from the operator’s position, facing forward.

Model 3606 • Origin 10/99

FRONT

TOP

RIGHT

FRONT REAR

BOTTOM

MS2240

REAR

Section Cont ents

Section Subject Page

Section 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 OWNERS/OPERATORS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 ACCIDENT PREVENTION TAGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.6 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section 2 General Information, Specifications, and Maintenance . . . . . . . . . . . 2-1

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION. . . . . . . . . . 2-3

2.2 SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5 FLUIDS, LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.6 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.7 REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.8 HOSES AND TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.9 BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.10 PRESSURE TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 2-15

2.11 AFTER SERVICE STARTUP AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 2-15

2.12 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.13 EMERGENCY OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Section 3 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2 BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 QUICK-ATTACH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Section 4 Cab, Covers and Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.1 SERIAL NUMBER DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2 CAB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 CAB COVERS AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Section 5 Axles, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2 AXLE ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Model 3606 • Origin 10/99

Section 6 Transfer Case and Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.1 GENERAL INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4 DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Section 7 Transmission: Clark-Hurth T 12000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.1 TRANSMISSION SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.2 TRANSMISSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 TOWING A DISABLED VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.5 TRANSMISSION REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.6 TRANSMISSION TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Section 8A Engine: Perkins 1004 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2

8A.1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A4

8A.2 PERKINS ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . 8A6

8A.3 PERKINS SPECIFICA TIONSAND MAINTENANCE INFORMATION. . . . 8A6

8A.4 PERKINS ENGINE STANDARD PRACTICES . . . . . . . . . . . . . . . . . . . . . 8A6

8A.5 PERKINS ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8A6

8A.6 PERKINS ENGINEELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 8A10

8A.7 PERKINS ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A10

8A.8 PERKINS ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8A15

8A.9 PERKINS ENGINE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A16

8A.10 PERKINS ENGINE STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A22

8A.11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A24

Section 8B Engine: Cummins 4BT3.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2

8B.1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-4

8B.2 CUMMINS ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-6

8B.3 CUMMINS SPECIFICATIONS AND MAINTENANCE INFORMATION. . . 8B-6

8B.4 CUMMINS ENGINE STANDARD PRACTICES . . . . . . . . . . . . . . . . . . . . 8B-6

8B.5 CUMMINS ENGINE COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 8B-6

8B.6 CUMMINS ENGINE ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . 8B-10

8B.7 CUMMINS ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10

8B.8 CUMMINS ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 8B-15

8B.9 CUMMINS ENGINE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-16

8B.10 CUMMINS ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-22

8B.11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-23

Model 3606 • Origin 10/99

iii

Section 9 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.3 HYDRAULIC PRESSURE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.4 HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.5 HOSES, TUBE LINES, FITTINGS, ETC. . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.6 HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9.7 HYDRAULIC SYSTEM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9.8 HYDRAULIC CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

9.9 VALVES AND MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64

9.10 CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-86

9.11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-117

Section 10 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10.1 SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10.3 EFFECTIVE GROUND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10.4 WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

10.5 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36

10.6 ENGINE START CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37

10.7 CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42

10.8 ELECTRICAL SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . 10-49

10.9 ELECTRICAL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . 10-84

Model 3606 • Origin 10/99

Section 1

Safety

Contents

PAR. TITLE PAGE

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 OWNERS/OPERATORS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.1 Safety Alert Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3.2 Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 ACCIDENT PREVENTION TAGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.6 SAFETY DECALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Model 3606 • Origin 10/99

1-1

Section 1

1.1 INTRODUCTION

Sky Trak International (hereafter, Sky Trak) products meet all applicable industry safety standards. Sky Trak 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 involv ed in engineering, design, manufacture, marketing and service.

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.

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 Sky Trak distributor or the Sky Trak Service Department at 1-800-439-8959.

1.2 OWNERS/OPERATORS MANUAL

The vehicle must be driven and operated a s a consequence of, or when performing, service, maintenance and test procedures. The service technician must, therefore, thoroughly read, understand, and follow the

Owners/Operators Manual

An owners/operators manual is supplied with each vehicle and must be kept in the holder or storage compartment located to the left and below the operators seat (for vehicles without the closed cab option, see Fig. 1–1; for vehicles with the closed cab option, see Fig. 1–2).

In the event that the owners/operators manual is missing, consult the local Sky Trak distributor or the Sky Trak Service Department before proceeding.

Sky Trak 3606

WITHOUT CLOSED CAB

Seat Base (ref.)

Owners/Operators Manual Holder

FRONT

Figure 1–1. The Owners/Operators Manual holder is

located beneath the seat (

FRONT

Seat Base

(ref.)

Owners/Operators Manual Holder

Figure 1–2. The Owners/Operators Manual holder is

located at the left side of the seat base (

without

closed cab option).

WITH CLOSED CAB

closed cab option

MS2630

MS2620

1.3 SAFETY INFORMATION

The following information provides general safety instructions, inclu ding signal words, hazard stat ement defin itions, notification of hazards, methods to help avoid hazards, and the consequences of failing to follow the safety information. For safe maintenance of the vehicle, read, understand and follow all DANGER, WARNING, and CAUTION information.

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.

1-2

Model 3606 • Origin 10/99

Safety

DANGER

1.3.1 Safety Alert Symbol

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The symbol is used to attract attention to safety hazards found on vehicle safety decals and throughout this manual.

The message that follows the symbol contains important information about Safety. To avoid possible death or injury, carefully read and follow all safety messages. Fully understand the potential ca use s of death or inju ry.

Also, know where to obtain medical assistance, how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire and police departments, ambulance, rescue squad or paramedics, etc.) nearby. If working alone, routinely check with another person to help assure personal safety.

1.3.2 Signal Words

Three types of hazard statements are used in this manual. Each signal word indicates the existence and degree of relative risk of the hazard described within the statement that follows the signal word. The three types of hazard statements use the following signal words:

DANGER

1.4 ACCIDENT PREVENTION TAGS

OS2180

Figure 1–3. Accident Prevention Tag.

Before beginning any maintenance or service, place an Accident Prevention Tag on both the ignition switch and the steering wheel (Fig. 1–4), stating that the vehicle should not be operated. Copies of Accident Prevention Tags are provided on pages 1-9 and 1-10.

DANGER:

The signal word

DANGER

denotes an extremely hazardous situation exists on or near the vehicle which would result in a high probability of death or irreparable injury if proper precautions are not taken.

WARNING

WARNING:

The signal word

WARNING

denotes a hazard exists on or near the vehicle which can result in injury or death if the proper precautions are not taken.

CAUTION

CAUTION:

The signal word practices or directs attention to unsafe practices on or near the vehicle which could result in personal injury if

CAUTION

denotes a reminder of safety

the proper precautions are not taken.

OS1520

Figure 1–4. Place Accident Prevention Tags on both

the ignition switch and the steering wheel.

Model 3606 • Origin 10/99

1-3

Section 1

1.5 SAFETY INSTRUCTIONS

Following are general safety statements to consider

before

vehicle. 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

1.5.1 Personal Hazards

HAIR and CLOTHING: 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.

BREA T HING PROTECTION: Wear respiratory protection when grinding or painting.

HEARING PRO TECTION: Alw ays wear he aring protection in a high-noise area.

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

LIFTING: least one assistant or a suitable sling and hoist.

1.5.2 Equipment Hazards

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

performing maintenance procedures on the

NEVER

before

lift a heavy object without the help of at

proceeding.

DO NOT

wear loose clothing or

DO NOT

equipment. Always support equipment with propercapacity blocks or approved stands. Hoist or jack failure can allow the equipment to tip or to fall.

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.

use a hoist, jack, or jack stands only to support

1.5.3 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 resulting in bleeding or opened skin (cuts, abrasions, burns, etc.), no matter how minor. Know where the First Aid Kit is, and 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.

1.5.4 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.

OPERATIONAL PROTECTION: Before operating the vehicle or returning it for operational use, check that the cab and all roll-over protection systems and falling-object protection system s (R OPS /FOP S) are inta ct, un da ma ged and secure. Replace any component as required.

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,

properly attached.

and

NEVER

suspended load or under raised equipment. The load or equipment could fall or tip.

1-4

stand or otherwise become positioned under a

DANGEROUS START: Place a warning sign on vehicles that are dangerous to start. Disconnect battery leads if leaving the vehicle unattended. Place Accident Prevention Tags on the steering wheel and ignition key switch before attempting to perform any service or maintenance.

VENTILATION: Avoid prolonged engine operation in enclosed areas with inadequate 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.

Model 3606 • Origin 10/99

Safety

SOFT SURFACES AND SLOPES : vehicle parked on soft surfaces or slopes (inclined ground or hills). Vehicle must be on hard, level surface with wheels blocked when necessary before performing any service. Obtain assistance, block all wheels, and add supports if necessary before beginning any work.

SUPPORT S AND ST RAPS : I nst a ll s afe, stable supports, slings or straps beneath or around a component or structural member before beginning any work.

FLUID PRESSURE: Before loosening any hydrau lic or diesel component, hoses or tubes, turn engine OFF. Wear heavy, protective gloves and eye protection. check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, see a doctor immediately. Diesel fuel leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause 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 applyi ng pressure, use components, parts, hoses and pipes that are in good condition, connected and tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.

NEVER

work on a

NEVER

1.6 SAFETY DECALS

Locations of vehicle safety and other decals are shown on the following pages. As part of routine maintenance, check that ALL safety and informational decals on the vehicle are present and readable. Keep the safety decals clean. 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 Parts Worldwide directly at:

1-888-872-5123

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.

Model 3606 • Origin 10/99

1-5

Section 1

Safety Decal List –

1. No Riders WARNING

2. Vehicle Rollaway WARNING

3. Electrocution DAN GER

4. Load Chart Booklet

5. Tipover DANGER – Operating

6. Tipover DANGER – Tire Pressure

DANGER

CONTACTING ELECTRIC POWER LINES can result in electrocution.

NEVER operate vehicle within 10 feet (3m) of electric power lines.

Earlier

Models

DANGER

LOW TIRE PRESSURE can result in tipover.

MAINTAIN proper tire pressure at all times.

7. Safety Instructions

8. Moving Parts WARNING

9. Explosive Gases WARNING

10. Carrying Personnel WARNING

11. Boom Extend Stripes

12. Boom Angle Indicator

SAFETY INSTRUCTIONS

Note:

1. Read operators manual before operating.

2. Fasten seat belt.

Many of these hazard related decals are available free of charge by calling

3. Allow no riders.

4. Use an approved work platform to lift or lower personnel.

OS1511

OmniQuip Parts Worldwide at 1-888-872-5123.

OS1256

1-6

Model 3606 • Origin 10/99

Safety

Safety Decal List –

1. No Riders WARNING

2. Vehicle Rollaway WARNING

3. Electrocution DANGER

4. Load Chart Booklet

5. Tipover DANGER – Operating

6. Tipover DANGER – Tire Pressure

CONTACTING ELECTRIC POWER LINES can result in electrocution.

DANGER

NEVER operate vehicle within 10 feet (3m) of electric power lines.

DANGER

LOW TIRE PRESSURE can result in tipover.

MAINTAIN proper tire pressure at all times.

Later

VEHICLE TIPOVER can result in death or serious injury.

Models

DANGER

DO NOT travel with the boom raised.

SAFETY INSTRUCTIONS

1. Read operators manual before operating.

2. Fasten seat belt.

DO NOT raise boom while on a slope unless load is level.

3. Allow no riders.

4. Use an approved work platform to lift or lower personnel.

7. Safety Instructions

8. Moving Parts WARNING

9. Explosive Gases WARNING

10. Carrying Personnel WARNING

11. Boom Extend Stripes

12. Boom Angle Indicator

WARNING

VEHICLE ROLLAWAY can cause death or serious injury.

WARNING

Allow no riders.

ALWAYS engage parking brake before dismounting.

OS1241

Note:

Many of these hazard related decals are available free of charge by calling

OmniQuip Parts Worldwide at 1-888-872-5123.

OS1255

Model 3606 • Origin 10/99

1-7

Section 1

Copies of Accident Prevention Tags are provided on pages 1-9 and 1-10.

1-8

Model 3606 • Origin 10/99

Safety

OS2180

Model 3606 • Origin 10/99

1-9

Section 1

1-10

OS2180

Model 3606 • Origin 10/99

Section 2

General Information, Specifications, and Maintenance

Contents

PAR. TITLE PAGE

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION. . . . . . . . . . 2-3

2.2 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.1 Fastener Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.2 Straight Thread O-ring Fitting (non-adjustable). . . . . . . . . . . . . 2-3

2.3.3 Straight Thread O-ring Fitting (adjustable) . . . . . . . . . . . . . . . . 2-3

2.3.4 Metric Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.4.1 Vehicle Dimensions (Fig. 2-1) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.4.2 Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.4.3 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.4.4 Miscellaneous Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.5 FLUIDS, LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.5.1 Axles (Differential Housings) and Transfer Case. . . . . . . . . . . . 2-9

2.5.2 Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.5.3 Lubrication Points (grease fittings) . . . . . . . . . . . . . . . . . . . . . . 2-9

2.5.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.5.5 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.5.6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.5.7 Drive Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.5.8 General Anti-corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.5.9 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.5.10 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.5.11 Thread Locking Compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.6 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.7 REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.8 HOSES AND TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.8.1 Hose and Tube Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.8.2 Hose and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.9 BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.9.1 Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.9.2 Bearing Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.9.3 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.10 PRESSURE TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 2-15

2.11 AFTER SERVICE STARTUP AND CHECKS . . . . . . . . . . . . . . . . . . . . . . 2-15

2.11.1 After Service Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.11.2 After Electrical/Electronic Component Service . . . . . . . . . . . . . 2-15

2.11.3 After Hydraulic Component Service . . . . . . . . . . . . . . . . . . . . . 2-15

Model 3606 • Origin 10/99

2-1

Section 2

2.11.4 After Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.11.5 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.11.6 After Transmission Service or Replacement . . . . . . . . . . . . . . . 2-16

2.11.7 After Tire and Wheel Service . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.11.8 After Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.11.9 After Boom Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.11.10 After Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.12 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.12.1 Maintenance Schedule and Checklist. . . . . . . . . . . . . . . . . . . . 2-17

2.12.2 Boom Wear Pad Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.12.3 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.12.4 Optional Closed Cab Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.12.5 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2.12.6 Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.12.7 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2.12.8 Engine Fan Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2.12.9 Hydraulic System Oil And Filter. . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.12.10 Transmission Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.12.11 Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.12.13 Transfer Case Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

2.12.14 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

2.12.15 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.12.16 Fuse and Relay Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

2.12.17 Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

2.12.18 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2.12.19 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2.13 EMERGENCY OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.13.1 Towing a Disabled Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2-2

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

The replacement of any part with any other than a Sky Trak authorized replacement part can adversely affect the safety, performance, or durability of the vehicle, and may void the warranty. Sky Trak International assumes no liability whatsoever for unauthorized replacement parts.

A warranty registration form must be filled out by the Sky Trak distributor, signed by the purchaser, and returned to Sky Trak when the vehi cle 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 Sky Trak.

2.2 SERIAL NUMBER LOCATIONS

When ordering replacement parts or making service inquiries about the vehicle, various serial numbers are required to help assure the provision of correct parts and information. Before ordering parts or initiating service inquiries, make note of the pertinent serial numbers.

2.3.2 Straight Thread O-ring Fitting (non-adjustable)

When the vehicle leaves the factory, it is equipped only with straight thread O-ring fittings. Customer-added accessories may differ; therefore, consult the manufacturer's product literature for information.

1. V erify that both threads and sealing surfaces are free of burrs, nicks, scratches, and any foreign material.

2. Lubricate the new O-ring with a light coating of hydraulic oil.

3. Tighten fitting to the proper torque according to the following chart:

SAE Size

4 22-26 30-35 6 46-54 62-73

8 95-105 129-142 10 125-135 170-183 12 165-175 224-237 16 245-255 332-346 20 270-290 366-393 24 365-385 495-522

lb/ft Nm

Torque

2.3 TORQUE VALUES

2.3.1 Fastener Rating

All fasteners (nuts, bolts, washers, etc.) are equal to SAE Grade 5 (PC8.8) and are plated, u nless otherwis e specified.

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

Size Torque Size Torque

Inch lb/ft Nm mm Nm lb/ft

1/4 9 12 6.0 10 7

5/16 18 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 7/8 380 515 22.0 510 372

1.0 585 793 24.0 650 475

2.3.3 Straight Thread O-ring Fitting (adjustable)

1. Verify that both mating parts are free of burrs, nicks, scratches, and any foreign material.

2. Lubricate the new O-ring with a light coat of hydraulic oil.

3. Back off the locknut as far as possible.

4. Screw the fitting into the port by hand until the backup washer contacts the face of the port and is pushed all the way towards the locknut.

5. To position the fitting, unscrew by the required amount, but not more than one full turn.

Model 3606 • Origin 10/99

2-3

Section 2

6. Hold the fitting in the desired position and tighten to the proper torque according to the following chart:

Adjustable Straight-thread O-ring Fitting Torque Chart

SAE Size

lb/ft Nm

Torque

4 14.5-17.5 20-24 6 37-43 50-58

8 75-85 102-115 10 115-125 156-170 12 155-165 210-224 16 225-235 305-319 20 260-280 353-380 24 340-360 461-488

2.3.4 Metric Conversion Factors

A. 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)

FUEL CONSUMPTION

Miles per gallon, US (mpg)

[Miles per gallon values are commonly converted to liters/100 kilometers; mpg (Imperial x l/100 km = 282; US mpg x l/100 m = 235)]

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

1.609 Kilometers per hour (km/hr; kph)

0.425 Kilometers per liter (km/l)

) 6.5 Square centimeters (cm2)

) 0.09 Square meters (m2)

) 0.8 Square meters (m2)

) 2.6 Square kilometers (km2)

Acres 0.4 Hectares (ha) MASS (weight) Ounces (oz) 28 Grams (g)

Pounds (lb) 0.4536 Kilograms (kg) Short tons (2000 lb) 0.9 Metric ton (t)

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 (l) Pints (pt) 0.47 Liters (l) Quarts (qt) 0.95 Liters (l) Gallons (gal) 3.8 Liters (l) Cubic feet (ft Cubic yards (yd

) 0.03 Cubic meters (m3)

) 0.76 Cubic meters (m3)

AIR PRESSURE

Pounds per square

6.895 Kilopascals (kPa)

inch (psi)

HYDRAULIC PRESSURE

Pounds per square

0.069 Bars

inch (psi) TEMPERATURE (exact)

C), subtract 32, then

To determi ne degree s Celsius ( multiply by 0.56; (°

F - 32) x 0.56 = °C.

B. 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

0,621 Miles per hour (mph)

(km/hr; kph)

FUEL CO NSUMPTION

Kilometers per liter

2,352 Miles per gallon, US (mpg)

(km/l) [Miles per gallon values are commonly converted to liters/

100 kilometers; mpg (Imperial x l/100 km = 282; US mpg z l/100 km = 235)]

2-4

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

LENGTH (distance)

Millimeters (mm) Centimeters (cm) Meters (m) Meters (m) Kilometers (km)

AREA

Square centimeters

(cm

) Square meters (m Square kilometers

)

(km Hectares (10000 m MASS (weight)

Grams (g) 0,035 Ounces (oz) Kilograms (kg) 2,2 Pounds (lb) Metric ton (1000 kg)

(t)

VOLUME

0,0394 In che s (in) 0,394 Inches (in) 3,281 Feet (ft) 1,1 Yards (yd) 0,621 Miles (mi)

0,4 Square inches (in

) 1,1 Square yards (yd2)

0,6 Square miles (mi

)2,5 Acres

1,1 Short tons

)

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

Milliliters (ml) 0,06 Cubic inches (in

) Liters (l) 2,1 P ints (pt ) Liters (l) 1,06 Quarts (qt) Liters (l) 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

Bars 14,5 Pounds per square inch

(psi) TEMPERATURE (exact) To deter mine degree s Fahrenheit (

Celsius (

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

°F), multiply degrees

Model 3606 • Origin 10/99

2-5

Section 2

2.4 SPECIFICATIONS

2.4.1 Vehicle Dimensions

(Fig. 2-1)

With Standard 12-ply 13.00-24 Tir es

Ref. Description

A. Length

(without attachment) 221.0" (5613 mm) B. Wi dth 98.0" (2489 mm) C. Height (boom lowered) 91.75" (2330 mm) D. Wheelbase 122.0" (3099 mm) E. Tread 84.0" (2 134 mm) F. Ground Clearance 17.0" (432 mm) G. Turning radius, curb to curb 138.0" (3505,2 mm) H. Turning radius, clearance 180.5" (4584,7 mm) I. Maximum lift height,

boom extended 36' 2" (11023,6 mm) J. Maximum lift height,

boom retracted 18' 6" (5638,8 mm) K. Maximum below grade depth,

boom extended 2' 5" (736,6 mm) L. Maximum reach,

from front of front tires 24' 8" (7518,4 mm) M. Maximum reach at maximum lift angle,

boom extended 67.2" (1707 mm) N. Maximum reach at maximum lift angle,

boom retracted -26.2" (-665,48 mm) O. Maximum reach at minimum lift angle,

boom extended 24' 2" (7366 mm) P. Maximum boom lift angle 68 Q. Minimum boom lift angle -3.8

R. Angle of approach N/A S. Angle of departure 33

Fork tilt angle:

T. At minimum boom angle up 8.1

U. At minimum boom angle down -10 8.3° V. At maximum boom angle up 80.8° W. At maximum boom angle down -21.8

0.0

Figure 2–1. Vehicle dimensions with standard tires.

2.4.2 Performance Specifications

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

A. Travel Speed (standard tires, no load)

4-SPEED 3-SPEED

First gear 4.3 mph 4.2 mph

(6,9 km/hr) (6,8 km/hr)

Second gear 9.1 mph 9.2 mph

(14,6 km/hr) (14,8 km/hr)

Third gear 15.3 mph 17.7 mph

(24,6 km/hr) (28,5 km/hr)

Fourth gear 20.8 mph N/A

(33,5 km/hr)

MS2110

Frame tilt angle

(not shown)

Right 10.0

Left 10.0°

2-6

B. Braking Distance (standard tires, no l oad)

4-SPEED 3-SPEED

From road speed to stop 29.0 ft (8,8 m) 21.4 ft (6,5 m)

Model 3606

•

Origin 10/99

General Information, Specifications, and Maintenance

C. Cylinder Times (with no load, at full throttle) Function Approximate Times, in seconds

Boom extend 12.00 Boom retract 7.00 Boom lift retracted 12.75 Boom lower retracted 10.75 Fork tilt up 4.20 Fork tilt down 3.75 Frame tilt left to right

with boom down 8.50

and emergency

Fr ame tilt le ft to right with boom abo v e 40

brake engaged 24.0 to 30.0 Frame tilt right to left

with boom down 13.50

and emergency

Frame tilt right to left with boom above 40

brake engaged 24.0 to 30.0

D. Draw Bar Pull

Per SAE drawbar test, 200 ft (61 m) track

4-SPEED 3-SPEED

Peak drawbar in 1st gear at converter stall (no load) 15,000 lb 13,250 lb

(6.810,0 kg), slip (6.015,5 kg), no slip

Peak drawbar in 1st gear at converter stall (rated load) 16,750 lb 13,250 lb

(7.604,5 kg), no slip (6.015,5 kg), no slip

E. Engine Performance

Low idle setting for all engines = 1050 +/- 50 RPM

Engine Model

Perkins Turbo

Perkins Natural/ EPA

Cummins Turbo

1004.4T 243 CID 2600 +/-

1004.42 258 CID 2600 +/-

4BT3.9 239 CID 2700 +/-

Displace-

ment

High Idle

100

Horse-

power

108 HP @ 2400 rpm

86 HP @ 2400 rpm

110 HP @ 2500 rpm

Peak

Torqu e

277 lb/ft @ 1600 rpm

221 lb/ft @ 1600 rpm

293 lb/ft @ 1500 rpm

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

F. Fuel Consumption

Average, depending on load/duty:

2 gal/hr (1,67 Imp gal/hr, or 7,57 l/hr)

G. Steering Wheel

Maximum number of turns, lock to lock

3.80 turns

Minimum number of turns, lock to lock

3.20 turns

H. Breakout Force

Utility bucket (calculated at -24

lip angle, max moment)

15,100 lb (6.855,4 kg).

2.4.3 Weights

A. Basic Vehicle

Curb Weight 20,195 lbs (9.160 kg) Operating Load 6,600 lbs (3.000 kg)

B. Working Weight

Machine working weight is figured with 48" carriage, two 48" pallet forks, 25%-full fuel tank, and standard bias ply tires (no hydrofill):

Front Axle Rear Axle TOTAL

Open Cab 8,390 lb 12,540 lb 20,930 lb

(3,8 kg) (5,6 kg) (950 kg)

Closed Cab N/A N/A N/A

C. Attachments

Std 48" carriage with shaft ....................... 456 lb (205 kg)

Std 60" carriage with shaft .................... 526 lb (236,7 kg)

Std 72" carriage with shaft .................... 677 lb (304,6 kg)

48" side tilt carriage

with shaft and cylinder.............................. 640 lb (288 kg)

60" side tilt carriage

with shaft and cylinder.............................. 700 lb (315 kg)

72" side tilt carriage

with shaft & cylinder.............................. 770 lb (346,5 kg)

52" swing carriage

with shaft & cylinders ............................ 950 lb (427,5 kg)

72" swing carriage

with shaft and cylinder...................... 1,135 lb (510,75 kg)

Bucket, 1.125 yd

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

Pallet forks, 2.25 x 4 x 48 (5,7 x 10 x 122 cm),

quantity: 2 ............................................. 312 lb (140,4 kg)

(0,855 m3)................... 760 lb (342 kg)

Model 3606 • Origin 10/99

2-7

Section 2

Block forks, 2 x 2 x 48 (5 x 5 x 122 cm)

quantity: 6................................................. 480 lb (216 kg)

Lumber forks, 1.75 x 7 x 60 (4 x 17,8 152,4 cm)

quantity: 2.............................................. 466 lb (209,7 kg)

Auger drive unit..................................... 285 lb (128,2 kg)

Auger mounting frame................................ 180 lb (81 kg)

Auger (various sizes available)............................... Varies

Auger extension (various sizes available).............. Varies

2.4.4 Miscellaneous Specifications

A. Wheels and Tires

Wheel lug nut torque............................370 lb/ft (500 Nm)

Air Pressure

13.00-24, 12-ply (minimum) tires ........... 65 psi (448 kPa)

Tire Footprint Area

(area is established under max tip load)

13.00-24, 12-ply tires @ 65 psi (448 kPa),

Vehicle with no load: ............................ 140 in

13.00-24, 12-ply tires @ 65 psi (448 kPa),

Vehicle with rated load: ...................165 in

Maximum Ground Pressure

Vehicle with no load,

13.00-24 12-ply tires @ 65 psi (448 kPa):

............................................................ 75 psi (516,6 kPa)

Vehicle with 6,600 lb (2.994 kg) load,

13.00-24 12-ply tires @ 65 psi (448 kPa):

............................................................ 85 psi (585,4 kPa)

Note: Maximum ground pressure at tip = (machine weight + load) / (foot print area x 2)

B. Valve Relief Settings

Main system relief .............3,500 +/- 100 psi (241,5 Bars)

Port relief boom hoist ........3,700 +/- 100 psi (255,3 Bars)

Port relief boom extend..........3,175 +/- 75 psi (219 Bars)

Port relief boom retract......3,750 +/- 100 psi (258,8 Bars)

Port relief fork tilt

(both sides) .......................3,700 +/- 100 psi (255,3 Bars)

Pressure-reducing/rel ieving valve,

stabilizer cylinder........................100 +/- 25 psi (6,9 Bars)

Power steering relief..........2,500 +/- 100 psi (172,5 Bars)

Park brake relief......................... 550 +/- 50 psi (38 Bars)

(910 cm2)

(1072,5 cm2)

C. Tamper Proofing

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

• Hoist cylinder counterbalance valves (1)

• Main valve port relief valves (5)

• Extend cylinder counterbalance valves (2)

• Steering relief valve (1)

• Fork cylinder counterbalance valves (2)

• Pilot relief valve (1)

• Main system relief valve (1)

• Park brake relief (1)

D. Fork Ratings

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

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

Since forks are always used in multiples, the total rating of any combination of forks is the sum of their rated capacity.

Other than block forks, use all forks in matched pairs. Use block forks in matched sets.

Stamped Fork Rating

24 in.

Load Center

Figure 2–2. The stamped fork rating specifies the

maximum load capacity that the individual fork can

safely carry at a maximum load center of 24" (610 mm).

(610mm)

4000 x 24

OS0390

2-8

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

2.5 FLUIDS, LUBRICANTS AND CAPACITIES

2.5.1 Axles (Differential Housings) and Transfer Case

A. Axle and Transfer Case Lubricants

In general, use gear oil that meets the requirements of U.S. ordinance specification MIL-L-2105C with an API classification of GL-5. The oil should be a multi-grade 80W90 with EP properties.

Products known to meet these requirements include:

• AMOCO GEAR LUBE 80W90

• ARCO HD 90W GEAR LUBE

• BP TRANS GEAR 80W90

• CATERPILLAR 80W90 EP GL-5

• CHEVRON ULTRA GEAR LUBE 80W90

• CITGO PREMIUM GEAR LUBE 80W90

• CONOCO UGL 80W90

• EXXON GEAR OIL GX80W90

• FRANKLIN GEAREX AGMA 5 EP GEAR OIL

• KENDALL NS-MP 80W90

• MOBIL MOBILUBE HD 80W90

• MP GEAR LUBE GL-5 80W90

• PENNZOIL 409L 80W90

• QUAKER STATE HIGH PERFORMANCE 80W90

• QUAKER STATE SYNTHETIC 80W90

• SHELL SPIRAX HD 80W90

• STUART M2C-105A 80W90

• SUNOCO DURO GEAR GL-5, SYNTHETIC

• SUNOCO MULTI-PURPOSE GL-5

• TEXACO DIFFERENTIAL GEAR LUBE 80W90

• TEXACO MULTIGEAR EP 80W90

• UNICAL 76 MP GEAR LUBE-LS

•VALVOLINE HIGH PERFORMANCE GEAR LUBE 80W90

Note: Use of a premium grade 80W140 gear oil is recommended for operation where the ambient (outside air) temperature is consistently above 80°F (27°C).

B. Axle and Transfer Case Capacities

Axles (differential housings) ......... ....... ...... ...... 18 qt (17 l)

Transfer case.................................................1.5 qt (1,4 l)

2.5.2 Wheel Ends

A. Wheel-end Lubricants

In general, use gear oil with an API classification of GL-5 that meets the requirements of U.S. ordinance specification MIL-L-2105 and MIL-L-2105D, respectively. The oil should be a 90W, a multi-grade 80W -90, or 80W -140 with EP properties (80W-90 EP). Products known to meet these requirements include:

• BP TRANS GEAR 80W90

• CHEVRON ULTRA GEAR LUBE 80W90

• CITGO PREMIUM GEAR LUBE 80W90

• MOBIL MOBILUBE HD 80W90

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

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

B. Wheel-end Capacity

Wheel end capacity.............. 1.4 qt (44.8 oz, or 1,324 ml)

2.5.3 Lubrication Points (grease fittings)

Lubricants

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

• AMOCO AMOLITH EP2

•ARCO LITHOLINE EP2

• BENZ MOLY-SERVICE EP2

• CHEVRON DUROLITH EP2

• CITGO H EP2

• GULF GULFCROWN EP2

• MOBILE MOBILUX EP2

• SHELL ALVANIA EP2

• SUN PRESTIGE 742EP

• TEXACO MULTIFAX EP2

Note: Refer to section

and Checklist

locations.

for lubrication intervals and grease fitting

2.12.2 Maintenance Schedule

Model 3606 • Origin 10/99

2-9

Section 2

2.5.4 Hydraulic System

A. Hydraulic Fluids

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

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

• AMOCO RYKON 46

• ARCO DURO AW S-215

• BENZ PETRAULIC 46-7C

• CASTROL AGRICASTROL HDD

• CASTROL/DEUSOL CRD

• CHEVRON AW HYDRAULIC OIL 46

• CITGO PACEMAKER XD-46

• ESSO ESSOLUBE D-3HP

• ESSO ESSOLUBE XD-3

• GULF HARMONY 46 AW

• ISO-46 HYDRAULIC OIL

• MOBIL DTE-25

• SAE 10W MOTOR OIL

• SHELL RIMULA CT

• SHELL RIMULA TX

• SHELL RIMULA X

• SHELL TULLUS 46

• SUN SUNVIS 821 WR

• TEXACO RANDO HD 46

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

B. Hydraulic System Capacity

System capacity ................................... 59.5 gal (225,2 l)

Reservoir capacity ................................ 32.2 gal (121,9 l)

2.5.5 Engine

A. Engine Fluids and Lubricants

1. Engine oil:

Diesel Engine Oil, SAE 10W-30, or 15W40 In general, use a premium-quality 10W-30 diesel engine

(motor) oil. Add itives ar e not necessary. For most cli mates, use 15W40 motor oil that meets API, CD or CE (severe duty diesel engine) specifications. In cold climates where ambient (outside air) temperatures are consistently below 32°F (0°C), 10W30 motor oil can be used; however, continuous use of low viscosity oil may cause premature engine wear.

2. Cooling system (engine coolant):

In general, use a 50/50-mix of premium-quality ethylene glycol (commonly referred to as “anti-freez e/anti-b oilo v er”) and water. Additives are not necessary.

3. Fuel: In general, use No. 2 diesel fuel. From November 15 to

March 15 when operating in cooler climates where ambient (outside air) temperatures are consistently at or below 32°F (0°C), use a 50/50 mix of #1 and #2 diesel fuels. Use good quality diesel fuel and change the fuel filter regularly. Additives are not necessary.

B. Engine Capacities

1. Engine oil capacity:

TOTAL CAPACITY FILTER

WITH FILTER CHANGE CAPACITY

Cummins Turbo......... 11.6 qt (11,0 l)............1.3 qt (1,2 l)

Perkins Turbo ............ 9.0 qt (8,5 l)............... 1.5 qt (1,5 l)

Perkins Natural.......... 9.0 qt (8,5 l)............... 1.5 qt (1,5 l)

2. Cooling system capacity (w/o heater):

Cummins Turbo......... 5.0 gal (18,9 l)

Perkins Turbo ............ 5.0 gal (18,9 l)

Perkins Natural.......... 5.0 gal (18,9 l)

Coolant system overflow bottle capacity:

CAPACITY CAPACITY W/O HEATER W/ HEATER

Overflow bottle.......... 3.0 qt (2,8 l)............... 3.0 qt (2,8 l)

3. Fuel tank capacity:

Total capacity ............ 35.1 gal (132,8 l)

Usable capacity......... 33.6 gal (127,2 l)

2-10

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

2.5.6 Transmission

A. Transmission Fluid

Vehicle transmissions are factory filled with 10W motor oil. Any suitable 10W motor oil, which meets the requirements of U.S. ordinance specification MIL-L-2104C, can be used. Products known to meet these requirements include:

• ARCO TRACTOR FLUID or equivalent

• CASTROL AGRICASTROL HDD

• CASTROL/DEUSOL CRD

• ESSO ESSOLUBE D-3HP

• ESSO ESSOLUBE XD-3

• SAE 10W MOTOR OIL

• SHELL RIMULA CT

• SHELL RIMULA TX

• SHELL RIMULA X

In general, use any approved 10W or 5W20 motor oil (depending on ambient temperatures; see information below), Dexron* or Dexron II D*, or an anti-wear hydraulic oil meeting ISO Grade 46 specifications with a -40°F (-40°C) pour point/ASTM viscosity SUS 215 at 100°F

(38°C) For -30°F to +120°F (-34°C to 49°C), Dexron* II transmis-

sion fluid with a -50°F pour point may be substituted. 5W20 motor oil may be substitute d for use with tempera-

ture conditions of -30 Products known to m eet the se r e qui reme nts include:

• AMOCO RYKON 46

• ARCO DURO AW S-215

• BENZ PETRAULIC 46-7C

• CHEVRON AW HYDRAULIC OIL 46

• CITGO PACEMAKER XD-46 or equivalent

• GULF HARMONY 46

• ISO-46 HYDRAULIC OIL

• MOBIL DTE-25

• SHELL TULLUS 46

• SUN SUNVIS 821 WR

• TEXACO RANDO HD 46

If anti-wear h ydr aulic oil as specifi ed above is not av ailab le , a suitable tractor fluid may be substituted which meets the requirements of any of the following specifications:

• ARCO TRACTOR FLUID or equivalent

• DETROIT DIESEL C-3

• FORD TRACTOR M2C134B

• JOHN DEERE J20A

•TEXACO TDH OIL

• WHITE FARM Q1826

F to 70°F (-34°C to 21°C) only.

RECOMMENDED LUBRICANTS FOR CLARK-HURTH

T12000 POWER SHIFTED TRANSMISSION

150 140 130 120 110 100

-10

-20

-30

-40

-50

-60

Farenheit

90 80

70 60

50 40 30 20 10

-10

-20

-30

-40

-50

Celsius

Te mpe rature Range "3"

If using Dexron*, Use ONLY Dexron* or Dexron II D* See NOTE Below

Chart 2-1. Transmission fluid temperature range. PREFERRED OIL VISCOSITY: Select the highest vis-

cosity compatible with prevailing ambient temperatures and the oil application information listed under

2.5.6 A. Transmission Fluid

Section

The Clark Hurth T12000 modulated shift transmission used in this vehicle should use ONLY C-3 or Temperature Range 3 transmission fluids, Dexron* or Dexron II D*.

Note: Dexron II D* is not compatible with graphitic clutch plate friction material UNLESS IT MEETS THE APPROVED C-3 SPECIFICATIONS.

*Dexron and Dexron II D are registered trademarks of General Motors Corporation.

B. Transmission Capacity

Capacity w/ filter change ................. 3.4 gal (12,9 l)

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

Model 3606 • Origin 10/99

2-11

Section 2

2.5.7 Drive Shaft Splines

IMPORTANT: DO NOT disassemble any of the drive

shafts (see

Section 6 Transfer Case

of this manual for information covering drive shafts and U-joints). To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly. Refer to the parts manual for ordering information.

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

Aldrich Chemical Co., Inc.

Product name:

Aldrich MOLYBDENUM (IV) SULFIDE,

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

Contact:

Aldrich Chemical Co., Inc. P.O. B ox 3 3 5 Milwaukee, Wisconsin 53201 USA Telephone: (414) 273-3850

DOW CORNING INC.

Product name:

MOLYKOTE

77 Paste

Contact:

Dow Corning Corporate Center P.O. B ox 9 9 4 Midland, MI 48686-0994 Telephone: (517) 496-4400

2.5.8 General Anti-corrosion

A. Anti-corrosion Compound

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

LPS 3

. It is marketed by:

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

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

B. Anti-corrosion Need Areas

Coat all unplated pins and all bores f o r cylinder pins, attachment pivot pins, chain sheave pins, the quick-attach lock pin, and all quick-attach lock pin bores. On the boom, coat the fork shaft and unpainted boom slide pathways.

2.5.9 Electrical

A. Basic Ratings

Battery Type................ 12Vdc, Negative (-) ground/earth,

Maintenance Free

Battery Rating..........................1,000 cold cranking amps

@ 0°F (-18°C)

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

Alternator Rating.................................................65 amps

B. Fuse Ratings, amps

• Main (S/N 8249 and Before) ..................................... 40

(S/N 8250 and After) ........................................ 30

• Cold Start (Optional) ................................................. 15

• Logic Panel .............................................................. 7.5

• Display Panel ........................................................... 7.5

• Fuel Shutoff ............................................................. 7.5

• Neutral Sense .......................................................... 7.5

• Neutral Relay/Starter ............................................... 7.5

• Hourmeter ................................................................ 7.5

• Horn ......................................................................... 7.5

• Stabil-TRAK ............................................................. 7.5

• Stabilizer Lock Relay ................................................ 7.5

• Steering Solenoids ................................................... 7.5

• Park Brake Sense Relay .......................................... 7.5

• Transmission Solenoids ........................................... 7.5

• Transmission Relay (without Closed Cab Option)..... 7.5

• Transmission Relay (with Closed Cab Option)........... 15

• Switch Lamps (Optional) .......................................... 7.5

• Closed Cab Option - Front Wiper Motor .................. 7.5

• Closed Cab Option - Skylight Wiper Motor .............. 7.5

• Closed Cab Option - Rear Wiper Motor ................... 7.5

• Closed Cab Option - Blower Motor ........................... 25

• Closed Cab Option - Power WIndow Motor .............. 30

• Closed Cab Option - Power Accessories Relay ........ 40

• Closed Cab Option - Power Window Motor Relay .... 40

• Light Package Option - Circuit A ............................... 20

• Light Package Option - Circuit B ............................... 20

2-12

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

2.5.10 Paint

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

A. Orange Paint

Durable, premium Sky Trak orange paint is available in both a convenient 16-ounce (480 ml) spray can for touchups, and in a production-sized one gallon (3,8 l) container for extensive repainting. Consult the current

Model 3606 PARTS MANUAL

for the applicable part number and ordering information. Use orange paint on all vehicle components except as specified in paragraphs

2.5.10

A, B, C

and D.

B. Black Paint

Durable, premium black paint is available in both a convenient 16-ounce (480 ml) spray can for touch-ups, and in a production-sized one gallon (3,8 l) container for extensive repainting. Consult the current

PARTS MANUAL

for the applicable part number and

Sky Trak Model 3606

ordering information.

• Boom Angle Indicator Pointer

• Wheels (some models )

• Brake Pedal

•Radiator

• Seat Adapter Plate

• Radiator Shroud

• Transmission Oi l Cool er

•Axles

• Drive Shafts

• Drop Box

•Forks

• Mirrors and Mirror Brackets

• Air Cleaner

• Steering Column

Sky Trak

C. White Paint

Durable, premium white paint is available in both a convenient 16-ounce (480 ml) spray can for touch-ups, and in a production-sized one gallon (3,8 l) container for extensive repainting. Consult the current

3606 PARTS MANUAL

for the applicable part number

Sky Trak Model

and ordering information.

• Boom Extend Cylinder

• Extend Cylinder Mount Bracket (some models)

D. Gray Paint

The following parts must be painted dark gray (Ref.: Sky Trak Color Chip 8528102):

• Wheels

• Engine mount/Hyd. tank

• Counterweight

•Cab Mount

Durable, premium gray paint is available in both a convenient 16-ounce (480 ml) spray can for touch-ups, and in a production-sized one gallon (3,8 l) container for extensive repainting. Consult the current

PARTS MANUAL

for the applicable part number and

Sky Trak Model 3606

ordering information.

• Wheels (some models)

• Fuel Tank Cradle

• Hydraulic Fluid Reservoir

• Battery Cover Panel

2.5.11 Thread Locking Compound

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

Contact:

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

Loctite

is a registered trademark of Loctite Corporation.

Model 3606 • Origin 10/99

2-13

Section 2

2.6 CLEANING

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

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

Servicing the hydraulic system in particular requires cleanliness.

Follow these precautions before attempting to service any hydraulic component:

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

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

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

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

5. Use clean, filtered oil whe n filling th e system. Maint ain the hydraulic system at a minimum cleanliness level of ISO code 18/15-particle ration count.

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

3. Replace if any of the foll owing conditions exis t:

• Ballooning (replace hose immediately!)

• Kinking, crushing, stretching or deforming

• Concealed corrosion of wire reinforcement

• Chafed outer cover

2.8.2 Hose and Tube Installation

1. When installing a new hose, loosely connect each end and verify that the hose takes up the designed position before tightening the connection completely. Tighten clamps sufficiently to hold the hose without crushing it, and to prevent movement and chafing.

2. If a hose is replaced on a moving part, move the part through its entire range of motion to verify that the hose will not incur damage. Adjust as necessary.

3. When installing any hose, verify that it does not become kinked or twisted.

4. NEVER allow freely-moving or unsupported hoses to contact each other or a related work surface. Such contact causes chafing and reduces hose life.

2.9 BEARINGS

2.9.1 Bearing Removal

2.7 REPLACEMENT

ALWAYS use the correct tool when removing or replac-

ing any part or performing any service. Replace O-rings, seals, and gaskets whenever they are

disturbed. NEVER mix new and old seals or O-rings, regardless of apparent visual condition. Always lubricate new seals and O-rings with hydraulic oil before installation.

2.8 HOSES AND TUBES

2.8.1 Hose and Tube Inspection

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

1. NEVER remove bearings unless absolutely necessary! Always use the recommended puller to reduce the risk of beari ng or rela ted co mpo nent damage.

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

2.9.2 Bearing Cleaning

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

2-14

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

2.9.3 Bearing Installation

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

2. Install bearings using one of the following methods:

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

• PUSH FIT into static locations such as reduction gear housings.

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

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

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

2.10 PRESSURE TESTING AND ADJUSTMENT

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

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

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

Verify that the hydraulic oil is at proper operating temperature, 80°-120°F (27°-49°C), before adjusting the pressure reducing valve, or relief valves. If necessary, operate the vehicle to raise the oil temperature. In the absence of a temperature gauge, the oil temperature can be checked by placing a hand against the side or the bottom of the reservoir; if the tank is too hot to keep the hand in contact with it, the oil temperature should be within the proper range.

2.11 AFTER SERVICE STARTUP AND CHECKS

2.11.1 After Service Startup

Note: Refer to the owners/operators manual for engine

cold-start procedures.

1. Check fluid levels.

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

3. Start and idle engine. Check for leaks from hydraulic components, engine, axles, transmission, brakes and reservoirs or tanks. Check the levels of all fluids and lubricants.

4. Purge the hydraulic system of air by operating all vehicle functions through their entire range of motion several times.

5. Check for proper operation of all components.

6. Retract all cylinders fully. Turn the engine OFF and check the hydraulic reservoir level. Recheck the level when the hydraulic oil is cold.

7. Replace the hydraulic filter if required.

2.11.2 After Electrical/Electronic Component Service

1. Check the torque of all fasteners securing replaced electrical/elec tr oni c co mpo nent s.

2. Check wiring connections to components.

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

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

5. Check for brittle or frayed wire shielding.

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

7. Start the engine and ble ed the hydraulic system of air.

8. Recalibrate sensors as required.

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

2.11.3 After Hydraulic Component Service

1. Check torque of fasteners on replaced components.

2. Check that hoses and tubes are properly attached, positioned, and tightly connected.

3. If a hydraulic component failed and contaminated the system, flush the system, clean the hydraulic oil reservoir (tank), and replace the hydraulic oil filter.

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

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

6. Recalibrate sensors as required.

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

Model 3606 • Origin 10/99

2-15

Section 2

2.11.4 After Brake System Service

1. Check the oil level in the axle and replenish with SAE 80W90 or SAE 80W140 o il a s re quire d.

2. Bleed the brakes.

3. Check brake pressure.

4. Check brake operation.

2.11.5 After Fuel System Service

1. Drain and flush fuel tank; if it was contaminated.

2. Bleed fuel system.

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

2.11.6 After Transmission Service or Replacement

1. Check transmission oil level and add 10W motor oil as required. In general, use an anti-wear hydraulic oil meeting ISO Grade 46 with -40°F (-40°C) pour point/ ASTM viscosity SUS 215 at 100°F (38°C) or other lubricant that meets these specifications (refer to

Section 2.5.6 Transmission

transmission lubricants).

2. Replace transmission filter.

3. Check torque on drive shaft yoke retaining bolts. Tighten these M12 bolts to 156 lb/ft (212 Nm).

4. Refer to the Clark-Hurth 12000 transmission maintenance manual for servicing the transmission after overhaul or repair.

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

6. Drain and flush the entire system.

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

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

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

10. Reassemble all components and fill the transmission with clean, fresh anti-wear ISO Grade 46 or 10W motor oil through the filler opening until oil comes up to the FULL port on the transmission housing.

11. Remove UPPER check plug, fill until oil runs from UPPER oil hole. Replace filler and level plug.

for information on

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

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

14. Add ISO 46 10W motor oil as necessary to bring the fluid level up until it begins to run freely from the UPPER oil level check plug hole. Install the oil level plug. Recheck the oil level when it reaches operating temperature (180-200°F, or 83-94°C).

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

2.11.7 After Tire and Wheel Service

1. Check air pressure.

2. Check wheel nut torque. Tighten to 370 lb/ft (500 Nm).

2.11.8 After Engine Service

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

2.11.9 After Boom Service

1. Check wear pads.

2. Check chain tension adjustment.

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

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

2.11.10 After Axle Service

1. Check fluid levels.

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

3. Check wheel nut torque. Tighten to 370 lb/ft (500 Nm).

4. Check toe-in if required.

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

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

2-16

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

Change

Transmission

Filter

Change Engine

Oil and Filter

Change

Hydraulic

Filter

Change Transfer

Case Oil

Change Axle Oil

Change

Wheel End Oil

2.12 MAINTENANCE INSTRUCTIONS

Maintenance Introduction

WARNING: DO NOT perform service or main-

tenance on the vehicle with the engine running. Contact with moving parts can cause serious injury or death.

This section contains a routine equipment checklist and a maintenance schedule and checklist with references to pertinent procedures and instructions. To help prevent problems before they occur, follow the maintenance schedule.

Note: Lubrication and Maintenance Chart decals are located inside the engine compartment cover (Fig. 2–3). These decals contain a general maintenance schedule that should be followed to maintain the vehicle in good operating condition. The same schedule information is presented in this manual, except that it contains a more detailed account of how to perform these specific maintenance operations.

Lubrication chart

Maintenance chart

2.12.1 Maintenance Schedule and Checklist

A. 10 Hour Intervals

Figure 2–4. Ten-hour interval maintenance schedule

At ten hour intervals, perform the following:

• Drain the fuel/water separator (see 2.12.7).

• Check the engine coolant level (see 2.12.5).

• Check the engine oil level (see 2.12.6).

• Check the hydraulic reservoir oil level (see 2.12.9).

• Check the transmission oil level (see 2.12.10).

• Check the air pressure in the tires (see 2.12.14).

• Check boom wear pad thickness (see 2.12.2).

Drain

Fuel/Water

Separator

Check

Transmission

Oil

Level

Check Engine

Coolant

Level

Check

Tire

Pressure

Check

Engine

Level

and checklist .

Oil

Check

Boom Wear

Pads

Check

Hydraulic

Oil

Level

MS0530

Figure 2–3. Lubrication and maintenance charts are

located inside the engine cover.

B. At First 50 Hours of Use

OS1170

MS1340

Figure 2–5. First 50 hour interval

maintenance schedule and checklist.

When the vehicle completes its first 50 hours of use, perform the following:

• Change the engine oil and filter (see 2.12.6 C).

• Change the transmission filter (see 2.12.10).

• Change the hydraulic filter (see 2.12.9).

• Change the transfer case oil (see 2.12.13).

• Change the axle oil (see 2.12.11).

• Change the wheel end oil (see 2.12.12).

Model 3606 • Origin 10/99

2-17

Section 2

C. 250 Hour Intervals

250

Change Engine

Oil and Filter

(Cummins)

Check

Wheel End

Oil Level

Figure 2–6. Two-hundred-fifty hour interval maintenance

schedule and checklist.

At 250 hour intervals, perform the following:

• On a unit equipped with a Cummins engine, change the engine oil and filter (see 2.12.6).

• Check the transfer case oil level (see 2.12.13).

• Check the axle oil level (see 2.12.11).

• Check the wheel end oil level (see 2.12.12).

• Apply multi-purpose grease at all lubrication points (Fig. 2–7). Lubricate the following components via the grease fittings with a multi-purpose, lithiumbased grease every 250 hours (remove all excess grease):

A. Hydraulic cylinder pins ..................................7 points

B. Drive shaft slip joints and universal joints......9 points

C. Boom pivot pin ..............................................2 points

D. Carriage Quick Attach pivot pin.....................2 points

E. Axle trunnion pivot pins.................................4 points

F. Boom attachments.......................................All points

G. Axle steering knuckles..................................8 points

H. Tilt cylinder pivot pins....................................2 points

Note: Shorten the lubrication interval on all lubrication points when operating under severe conditions.

Check

Transfer Case

Oil Level

Apply Multi-Purpose

Grease (MPG) At

All Lubrication Points

Check

Axle

Oil Level

MS1350

(2)

PLACES

(2)

PLACES

BBB B

VIEW IN DIRECTION OF ARROW

VIEW IN DIRECTION OF ARROWS

Figure 2–7. Sky Trak Model 3606

lubrication points.

D. 500 Hour Intervals

500

Change

Air

Filter

Change

Fuel

Filter

VIEW IN DIRECTION

OF ARROW

Change Engine

Oil and Filter

(Perkins)

D E

OS0561

MS1360

2-18

Figure 2–8. Five-hundred hour interval maintenance

schedule and checklist.

At 500 hour intervals, perform the following:

• Change the air filter (see 2.12.3).

• Change the fuel filter (see 2.12.7).

• On a unit equipped with a Perkins engine, change the engine oil and filter (see 2.12.6).

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

E. 1,000 Hour Intervals

0001

Check

Boom Chain

Tension

Change Transfer Case Oil

Figure 2–9. One-thousand-hour interval maintenance

schedule and checklist.

Check

Fan Belt

Change Axle Oil

Change Transmission Oil and Filter

Wheel End Oil

Change

Hydraulic

Oil and Filter

MS1370

At 1,000 hour intervals, perform the following:

• Check boom chain tension (see 2.12.17).

• Check the fan belt (see 2.12.8).

• Change the transmission oil and filter (see 2.12.10).

• Change the hydraulic oil and filter (see 2.12.9).

• Change the transfer case oil (see 2.12.13).

• Change the axle oil (see 2.12.11).

• Change the wheel end oil (see 2.12.12).

F. 2,000 Hour Intervals

0002

Change

Engine

Coolant

MS1380

Figure 2–10. Two-thousand hour interval maintenance

schedule and checklist.

At 2,000 hour intervals, perform the following:

• Change the engine coolant (see 2.12 .5) .

2.12.2 Boom Wear Pad Maintenance

A. Boom Wear Pad Check

Daily, and every 10 hours of engine operation, visually inspect the boom wear pads between the boom sections at the rear and front of the boom for excessive wear (Fig. 2–11).

The average expected service life of boom wear pads varies depending on the particular location of each wear pad within the boom, vehicle use, operating conditions, and the load weight.

If load weights are at or near maximum capacity, or if the vehicle is operating in very dirty or dusty conditions, the boom wear pads will wear at a much faster rate.

Angled-cut

Wear Pad

Indicator

0.25"

0.625"

(15,9 mm)

Figure 2–11. Inspect boom wear pads for excessive wear.

(6,4 mm)

Wear Pad

Spacer

Metal

Insert

Boom

Plate

Wear

Pad

OS1230

The boom wear pads that are under the most stress from weight of the load will also wear faster than other pads. For example, the lower pads at the front of the boom are under much more stress than the pads attached at the top front or sides of the boom. Consequently, the lower pads will require service more often.

B. Boom Wear Pad Replacement

Each boom wear pad is manufactured with a convenient wear pad indicator. This is the angled cut at each end of all boom wear pads (Fig. 2–11). The total thickness of a new boom wear pad is 0.625 inch (15,9 mm). The angled cut will provide a total w ear thic kness of 0.25 inch (6,4 mm). This will leave approximately 0.375 inch (9,5 mm) of total unused base material.

The pads must NEVER be worn past the angled cut indicator, or the metal pad insert that holds the pads in place will begin to wear into the boom pad sliding surfaces. Pads worn past this point will gouge the boom surfaces, resulting in premature wear of any new boom wear pads installed, and requiring eventual, expensive replacement of the boom. Replacement of boom wear pads must be performed when the boom wear pads indicate.

C. Boom Wear Pad Lubrication IMPORTANT: The boom has been factory lubricated for

proper wear pad break-in and will normally not require further lubrication. However, after replacing any wear pad(s), or after prolonged periods of inoperation, light lubrication of the boom wear surfac es wit h a rus t inhi bit o r/ lubricant such a s

LPS 3

or equivalent is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surf aces is also recomme nded in salt air climates, and when the vehicle is stored, to help prevent rusting.

LPS 3

is marketed by:

LPS Laboratories, Inc.

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

Model 3606 • Origin 10/99

2-19

Section 2

500

2.12.3 Air Cleaner

A. Engine Air Filter Restriction Warning Indicator

Early Production

Current Production

Figure 2–12. Engine air filter restriction warning indicator.

The operator’s display panel includes an indicator light (Fig. 2–13) that illuminates to alert the operator when restricted air flow to the engine is sensed. This indicates that the air filter needs servicing. NEVER operate the vehicle without the air cleaner assembly and both filters in place.

Air Cleaner Cover

F N R

Engine Air Filter Restriction Warning Indicator

Engine Air Filter Restriction Warning Indic ator

Air Cleaner

Retaining Clips

Vactuator Valve

OS0222

B. Air Cleaner Element: Change or Clean

MS2180

Figure 2–14. Change or clean the air filter element.

OS0790

As indicated by the air cleaner restriction indicator, and/or every 500 hours, change or clean the air cleaner element.

Outer Primary Element

All air cleaner manufacturers agree that attempting to clean or wash an element increases the chance for element damage. Consider the value of cleaning an element against the risks that could lead to engine damage. Adopt the policy that all elements should be replaced with new and not cleaned.

Careful cleaning or washing, if done correctly, can extend the life of an element. Each time an element is cleaned, the dirt-holding capacity is reduced and the risk of dirt reaching the clean side of the filter is increased. Filters should NEVER be washed more than six times or retained for more than one year's service, whichever comes first.

If an element is washed, use a non-sudsing detergent that disso lve s comb ustion residue s without damagi ng the filter media. One such detergent that is specifically formulated for this purpose is

FM 1400

. This cleaner contains biodegradable synthetic detergents and is environmentally safe.

FM 1400

is marketed by:

Filter Service Corp.

2105 W. Apache Farmington, New Mexico 87401 Telephone: (505) 326-1127

Inner Safety Element

An inner safety element (Fig. 2–15) should NEVER be washed or reused. ALWAYS install a new element.

Replace safety elements after every third primary element change. DO NOT remove a safety element until the inside of the air cleaner canister is thoroughly cleaned. This will help prevent dirt that could damage the engine from entering the induction manifold.

IMPORTANT: NEVER run the engine with only the safety element installed.

2-20

OS0440

Figure 2–13. Location of engine air cleaner components.

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

4. Rinse the filter from the inside out with a gentle

Air Cleaner Cover

Primary Element

Safety Element

Air Cleaner Element

stream of water [less than 40 psi (2,8 kPa), without nozzle] to remove all dirt and suds. If the inside of the element has been contaminated with dirty water from the soaking, rinse both sides.

5. Dry the filter before re-using. Circulate warm air at less than 160°F (57°C). DO NOT use a light bulb to dry the filter.

6. Inspect for holes or tears by looking through the filter toward a bright light. Check for damaged gaskets or metal parts. DO NOT re-use a damaged filter.

Vactuator Valve (ref.)

OS0450

Figure 2–15. Engine air cleaner components.

To change elements :

1. Unlatch the three retaining clips (Fig. 2–13) and remove the air cleaner cover (Fig. 2–15).

2. Remove the wing nut and the primary element. Inspect the element for damage. DO NOT clean or reuse a damaged element.

3. Thoroughly clean the interior of the air filter canister and vactuator valve.

4. If replacing the safety element, carefully slide it out. Always discard this element and replace it with a new element.

5. Slide the new primary element over the safety element, making sure the sealing edge is flush with the base of the air cleaner. Install and tighten the wing nut secu rely.

6. Position the canister cover in place and secure it by latching the three retaining clips.

Sky Trak recommends changing filters. If a replacement filter is not available, carefully follow these procedures to clean a primary element:

1. Remove loose particles from the filter with compressed air [maximum 30 psi (2,1 kPa)] or water hose [maximum 40 psi (2,8 kPa) without nozzle]. Rotate and apply pressure from the inside of the element.

2. Soak the filter in non-sudsing detergent (such as

FM 1400

) for at least 15 minutes. NEVER soak

longer than 24 hours.

3. Swish the filter around in the solution to remove loosened dirt particles.

C. Air Intake System-Inspection

Inspect the intake piping for cracked hoses, loose clamps, or punctures that can allow dirt or debris to enter the combustion chamber. If dirt or debris is allowed to enter the combustion chamber, it can severely damage the engine. If necessary, tighten or replace parts to help prevent air intake system leakage.

2.12.4 Optional Closed Cab Air Filters

The optional closed cab has two air filters, the recirculation air filter (Fig. 2–16) and the fresh air intake filter (Fig. 2–17). Both of these filters require periodic inspection and maintenance.

Recirculation Air Filter

Periodically remove and inspect the recirculation air filter (Fig. 2–16) located directly below the seat. Gently hand wash with water, a mild detergent may also be used if the filter is saturated with dirt.

Recirculation Air Filter

Vent Cover

Truss-head Bolt

OS1810

Figure 2–16. Periodically remove and inspect

the recirculation air filter.

Model 3606 • Origin 10/99

2-21

Section 2

Fresh Air Intake Filter

Periodically remove the cab rear panel and inspect the fresh air intake filter (Fig. 2–17). The filter must be cleaned sometimes as often as twice a day, depending on the operating environment. This is done by removing the filter and shaking it. Pressurized air can also be used to blow out dust. The filter will clean outside air when pressurizing the cab. The filter should be replaced when required.

Note: Correctly position the filter so the air flow is directed into the cab.

Filter Latch

Radiator Cap

Radiator

Coolant Overflow Bottle

Radiator Drain Plug

OS0481

Figure 2–19. Check the coo lant level in the overflow bottle.

B. Drain and Flush the Radiator

Note Direction of Air Flow

OS1790

REAR OF CAB with REAR PANEL REMOVED

Figure 2–17. Periodically remove and inspect

the recirculation air filter.

2.12.5 Engine Cooling System

A. Engine Coolant Level Check (10 Hour Intervals)

MS2140

Figure 2–18. Check the engine coolant level every

10 hours of engine operation.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine.

2. Unlatch, unlock and open the engine cover.

3. Check the coolant level in the overflo w bottle (Fig. 2–19). When the coolant is hot, the bottle should be half to three-quarters full. When the coolant is cool, the bottle should be one-quarter to half full. Add coolant (use a 50/50 mixture of ethylene glycol and water) as required through the overflow bottle.

OS0800

0002

OS0810MS3000

Figure 2–20. Drain and flush the radiator

every 2,000 hours of engine operation.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine.

WARNING: DO NOT attempt this procedure when the engine is hot. Wait for the engine, muffler, and tailpipes to cool down before proceeding. Failure to do so could result in severe burns.

2. Unlatch, unlock and open the engine cover . Allo w the engine to cool before proceeding. Draining and flushing the cooling system while the engine is hot can cause cracks in the engine block.

WARNING: NEVER remove the radiator cap while the engine is hot. The cooling system is under pressure. Hot coolant can cause severe burns or eye injury. Wear protective clothing and safety glasses.

3. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap.

2-22

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

8. Transfer the coolant into a properly labeled container.

Radiator Cap

Fitting on Neck of Radiator Fill Tube

Coolant

Overflow

Bottle

Hose from

Bottom of

Overflow

Bottle

Radiator

Drain

Funnel

OS0472

Figure 2–21. Drain coolant from the overflow bottle.

4. Place a funnel at the base of the radiator (Fig. 2–22) to channel the drained coolant into a container. Unscrew the radiator drain plug and allow the coolant to drain into the funnel.

5. Detach the hose from the fitting on the neck of the radiator fill tube and drain any coolant from the overflow bottle into the funnel.

6. Flush the radiator with clean water, and drain again.

7. Remove the engine block drain plug (Fig. 2–23) and drain any coolant from the engine block. Replace the engine block plug.

Dispose of properly.

9. Reconnect the hose to the fitting on the neck of the radiator fill tube. Close the radiator drain plug or petcock.

10. Fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap. Add coolant to the overflow bottle until the bottle is half to three-quarters full. This “overfilling” will compensate for any air in the cooling system.

11. Clean dirt and debris from the radiator core.

12. Start and run the engine until normal engine operating temperature is reached, then turn the engine OFF. Check for leaks while the engine is cooling.

13. Allow the engine to cool. Check the radiator coolant level again and top off as needed with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap.

14. The overflow bottle should be one-quarter to half full. If not, fill as necessary with a 50/50 mixture of ethylene glycol and water.

2.12.6 Engine Oil and Filter

A. Engine Oil Recommendations

The use of quality engine oil combined with the appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability. Refer to the engine manufacturer’s manual for recommended oil types for various operating conditions).

Engine oil capacity, with filter change, is:

Perkins Engines............................ 9.0 quarts (8,5 liters)

Cummins Engine ......................11.6 quarts (11,0 liters)

Coolant Drain

Cummins Engine

Figure 2–22. Remove the engine block coolant drain plug.

Model 3606 • Origin 10/99

Coolant Drain

Perkins Engines

OS0580

2-23

Section 2

For most climates, use a premium-quality 15W40 motor oil that meets API, CD or CE (severe duty diesel engine) specifications. In cold climates where ambient (outside air) temperatures are consistently below 32° F (0° C), 10W30 motor oil can be used; however, continuous use of low viscosity oil may cause premature engine wear.

B. Oil Level Check

Oil Filter

Oil Fill

Cap

(PERKINS ENGINE)

Oil Fill Cap

Oil Drain

Plug

Dipstick

Oil Fill

Cap

MS2140

Figure 2–23. Check the oil level

every 10 hours of engine operation.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine.

2. Unlock and open the engine cover.

3. Remove the engine dipstick (Fig. 2–24). Check the oil mark on the dipstick. The oil should be between the full and add marks. On Cummins engines, the oil mark should be within the crosshatched area of the dipstick.

FULL

ADD

Perkins Engines

Figure 2–24. Check the oil level mark on the dipstick.

Cummins Engine

4. Add oil as required. Replace the dipstick.

C. Oil and Filter Change

OS0820

OS0521

250

Cummins

MS2150

Figure 2–25. Change the engine oil and engine oil filter.

MS2170

500

Perkins

MS2180

OS0830

Dipstick

Oil

Filter

Oil

Drain Plug

(CUMMINS ENGINE) S/N 9179 and Before

Figure 2–26. Location of items relevant to checking the

engine oil level and changing the oil and filter.

Oil Filter

(Opposite

Side of

Engine)

Dipstick

Oil

Drain Plug

(CUMMINS ENGINE)

S/N 9180 and After

OS0462

Change the oil and filter after the first 50 hours of vehicle operation, at 250-hour intervals for Cummins engines, and 500-hour intervals for P erkins engines. To change the oil and filter:

1. Operate the engine until it reaches operating temperature (approximately five minutes).

2. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine.

3. Unlock and open the engine cover.

4. Place an oil drain pan under the engine's oil drain plug. For Cummins engines, fabricate a V-shaped piece of cardboard to serve as a funnel trough for draining oil from the oil pan to the oil drain pan.

5. Remove the drain plug from the engine oil pan.

6. Allow the oil to drain completely into the receptacle. Transfer the oil to a container with a cover and label the container as used motor oil. Dispose of properly.

7. Remove the oil filter and clean the filter sealing surface.

8. Apply a thin coat of clean engine oil to the new filter mating surface.

9. Install the new oil filter and hand tighten. Use an oil filter wrench or strap to tighten the filter down an additional one-quarter to half turn. DO NOT overtighten.

10. Clean and reinstall the oil drain plug into the engine oil pan.

2-24

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

PERKINS ENGINE

11. Remove the engine oil fill cap and add oil (refer to the engine manufacturer's manual for recommended oil types for various operating conditions). Engine oil capacity with filter change is:

Perkins Engine . . . . . . . .9.0 quarts (8,5 liters)

Cummins Engine . . . . 11.6 quarts (11,0 liters)

12. Reinstall the oil fill cap. Start the engine and allow it to run for several minutes.

13. Shut off the engine. Wait several minutes, then check the oil level again on the dipstick. Add oil as required. DO NOT overfill.

14. Look for oil leaks at the filter and drain plug. Tighten as required.

2.12.7 Engine Fuel System

A. Drain Water from Fuel Water Separator/Filter

MS2140

Figure 2–27. Drain water from the fuel-water

separator/filter every 10 hours of engine operation.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine. Allow the engine to cool.

2. Unlock and open the engine compartment cover.

3. Position a suitable glass container beneath the fuel filter drain cock (Fig. 2–28), located on the underside of the fuel filter.

OS0851

4. Loosen the fuel filter drain cock. Allow the water to drain into the glass container until clear fuel is visible. After draining is complete, tighten the drain cock. Dispose of drainage properly.

5. Close and lock the engine compartment cover.

B. Change Fuel Filter

500

MS2180

Figure 2–29. Change the fuel filter every

500 hours of engine operation.

Change the fuel filter every 500 hours of engine operation, or at shorter intervals with water evidence of contaminated fuel.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine. Allow engine to cool.

2. Unlock and open the engine cover. Clean the outside surfaces of the filter assembly.

3. Loosen the drain cock at the bottom of the canister (Fig. 2–30) to remove it and allow the fuel-water to drain into a suitable container. Dispose of properly.

Canister

OS0870

OS1730

(PERKINS ENGINE SHOWN)

Figure 2–28. Position a suitable glass container

Model 3606 • Origin 10/99

Fuel Water

Separator

Drain Cock

beneath the fuel filter drain cock.

OS1740

(CUMMINS ENGINE SHOWN)

Fuel Filter

Drain Cock

OS0731

Figure 2–30. Perkins drain cock location.

4. Unscrew the canister to remove it from the base. Clean the base. Properly dispose of the canister.

5. Lightly lubricate the new fuel filter gasket with clean No. 2 diesel fuel. If the engine has been completely run out of fuel, prefill the canister with clean fuel.

2-25

Section 2

6. Screw the new canister onto the base. Hand tighten only.

7. Remove air from the fuel system. See

from the Fuel System

. (see 2.12.7 D)

Venting Air

8. Close, latch and lock the engine cover.

CUMMINS ENGINE

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine. Allow engine to cool.

2. Unlock and open the engine cover. Clean around the fuel-filter head (Fig. 2–31).

Filter Head

Gasket

C. In-line Fuel Strainer

(Every 500 hours of engine operation)

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine. Allow engine to cool.

2. Unlock and open the engine cover.

3. On both Perkins and Cummins engines, the in-line fuel strainer is located down line from the engine lift pump (Fig. 2–32). Loosen the two hose clamps securing the strainer in place.

In-line

Fuel Strainer

In-line

Fuel Strainer

Fuel Filter

OS1450

Figure 2–31. Cummins fuel filter location.

3. Clean the filter head gasket surface and replace the O-ring.

4. Fill the new fuel filter with clean No. 2 diesel fuel.

5. Lubricate the O-ring seal with clean lubricating oil.

6. Install the fuel-filled filter and tighten by hand. DO

NOT over tighten.

Note: DO NOT overtighten. DO NOT tighten with

mechanical means (tools, etc.). Mechanical over-tightenin g may distort the threads or damage the O-ring seal.

Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by changing the fuel filter element will be vented automatically as long as the element was filled with fuel prior to installation.

OS0590

Lift Pump

Perkins Engines

Figure 2–32. In-line fuel strainer and lift pump locations.

Lift Pump

Cummins Engine

4. Remove and properly dispose of the old strainer.

5. Install the new strainer with the arrow pointing toward the lift pump.

6. Assemble the hoses to the strainer and tighten the hose clamps.

7. Remove air from the fuel system. See

from the Fuel System

. (see 2.12.7 D)

Venting Air

8. Close and lock the engine cover.

D. Venting Air from the Fuel System

WARNING: DO NOT vent air from the fuel sys-

tem of a hot engine. Allow the engine to cool before attempting to purge air from the fuel system. Failure to do so could create a fire hazard.

Air must be vented from the fuel system whenever any component between the fuel tank and the injection pump has been disconnected, or when the system has been emptied, or has run out of fuel.

2-26

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

CUMMINS ENGINE

IMPORTANT: DO NOT attempt to start the engine until

the injection pump has been filled and primed with fuel. Serious damage to the lift pump will result due to lack of proper lubrication.

PERKINS ENGINE

Vent Screw

Vent Plug

Figure 2–33. Perkins vent plug and filter head locations.

Filter Head

OS0731

1. To vent a ir from the low pressure fuel lines, loosen the vent plug until fuel, free of air, comes out of the vent plug. Tighten the vent plug.

Note: If the lift pump drive cam is at the point of maximum lift, it will not be possible to operate the priming lever. In this situation, the crankshaft must be turned one revolution.

2. Loosen the high pressure connections at the injectors. Verify that the manual stop control is in the RUN position. Operate the starter motor until fuel, free of air, comes out of the pipe connections. Tighten the connections to 16 lb/ft (22 Nm).

High Pressure Line

Injector

Hand Plunger

Lift

Pump

Figure 2–35. Cummins vent screw, hand plunger

and lift pump locations.

OS1450

1. To vent the low pressure lines and fuel filter, open the vent screw located on the filter head. Operate the hand plunger on the lift pump until fuel flowing from the fitting is free of air. Tighten the vent screw and torque to 7 lb/ft (9 Nm).

IMPORTANT: When cranking the engine with the starter motor to vent air from the fuel system, DO NOT energize the starter solenoid or crank the engine for more than 15 seconds at a time. Wait two minutes between each 15-second cranking interval.

2. Operate the starter motor for no more than 15 second s. The process of venting the high pressure fuel lines involves energizing the starter motor, which rotates the crankshaft, which, in turn, operates the fuel pump to purge air from the high pressure fuel lines.

WARNING: KEEP CLEAR of spraying fuel. Diesel fuel will spray when venting high pressure lines. The fuel pressure is sufficient to penetrate the skin and cause serious bodily injury. Wear protective clothing and safety glasses.

Model 3606 • Origin 10/99

3. Loosen one fitting at the injector (Fig. 2–36). Operate the starter motor for 15 seconds. Wait two minutes. Operate the starter motor again for 15 seconds. Repeat this process until fuel, free of air, comes out of the injector fitting.

OS0731

Figure 2–34. Perkins high pressure line

and injector locations.

2-27

Section 2

High-pressure Fuel Lines

Injector

OS0990

Figure 2–36. Cummins injector and high-pressure

fuel line locations.

4. Tighten the fitting to 22 lb/ft (30 Nm). Repeat this procedure for each fitting until the engine runs smoothly. With the engine running, visually check for leaks. Turn the ignition switch OFF.

Alternator

Pulley

1/4" to 3/8"

(6,4 to 9,4mm)

Deflection

Figure 2–38. Perkins engine fan belt adjustment points.

Fan Pulley

Crankshaft Pulley

0A0362

5. If the fan belt needs adjustment, loosen both alternator mounting bo lt s an d us e a fan-belt tensioner to carefully pry the alternator to tighten the belt. DO NOT overtighten. Retighten the alternator mounting bolts.

6. Recheck fan belt deflection. Adjust as necessary.

7. Close and lock the engine compartment cover.

2.12.8 Engine Fan Belt

0001

MS2190

Figure 2–37. Inspect the engine fan belt

every 1,000 hours of engine operation.

PERKINS ENGINE

1. Ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine. Allow engine to cool.

2. Unlock and open the engine cover.

3. Inspect the fan belt. Replace if cracked or frayed.

4. Check fan belt tension midway between the crankshaft and alternator pulleys (Fig. 2–38). Deflection should be 1/4" to 3/8" (6,4 to 9,4 mm) with an applied force of 13 to 15 pounds (6 to 7 kg).

OS0880

CUMMINS ENGINE

1. Ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut off the engine. Allow engine to cool.

2. Unlock and open the engine cover.

3. The Cummins engine is equipped with an automatic belt tensioner (Fig. 2–39). Rotate the tensioner up and remove the fan belt. Inspect the fan belt and tensioner bearing. Inspect the fan belt. Replace if cracked or frayed. Spin the bearing, and check for resistance or rough spots in bearing travel.

4. Spin the fan and check for wobble or excessive play. Maximum play should be 0.006 inch (0,15 mm).

5. To install the fan belt, position the belt over the grooved pulleys. While holding the tensioner up, slide the belt over the water pump pulley.

2-28

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

Automatic

Belt Tensioner

Alternator

Pulley

Water Pump

Pulley

Figure 2–39. Cummins engine fan belt adjustment points.

Crankshaft Pulley

OS0770

6. Close and lock the engine compartment cover.

2.12.9 Hydraulic System Oil And Filter

A. Hydraulic Oil Level Check

MS2140

Figure 2–40. Check the hydraulic oil le v el

every 10 hours of engine operation.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), and engage the parking brake switch.

2. Fully retract all hydraulic cylinders and shut off the engine.

3. Allow the hydraulic oil to cool.

4. Unlock and open the engine co ver. Locate the hydraul ic oil sight glass along the vertical wall of the hydraulic oil tank (Fig. 2–41). Check the level of the hydraulic oil in the tank. The hydraulic oil level should be visible at the lower end of the sight glass. If hydraulic oil is not visible, remove the hydraulic oil fill cap and add ISO Grade 46 hydraulic oil until the hydraulic oil level is visible at the lower end of the sight glass. DO NOT overfill.

OS0660

Hydraulic Oil

Sight Glass

OS1590

Figure 2–41. Check the hydraulic oil level

via the sight glass.

5. Reinstall the hydraulic oil fill cap. Close and lock the engine cover.

B. Hydraulic Oil and Hydraulic Oil Filter Change

0001

MS2190

Figure 2–42. Change the h ydraulic oil filter after the fi rst 50

hours of engine, and every 1,000 hours thereafter.

Change the hydraulic oil filter after the first 50 hours of engine operation, and every 1,000 hours of operation thereafter.

Also, the hydraulic oil filter must be changed anytime the hydraulic oil filter restriction warning indicator light on the operator's instrument panel begins to flicker ON and OFF at high idle (Fig. 2–43).

OS0840

Model 3606 • Origin 10/99

2-29

Section 2

F N R

Hydraulic Oil Filter Restriction

Warning Indicator

Hydraulic Oil Filter Restriction

Warning Indicator

Early Production

Current Production

OS0222

Figure 2–43. Hydraulic oil filter restriction warning

indicator for early production (top)

and current production (bottom) vehicles.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), and engage the parking brake switch.

WARNING: DO NOT change the hydraulic oil or the hydraulic oil filter with the engine running. Contact with moving parts can cause serious injury or death.

Hydraulic Oil Filter Head

OS1040

Figure 2–44. Clean around the hydraulic oil filter head.

7. Remove the hydraulic oil filter element (Fig. 2–45) from the hydraulic oil filter head. Dispose of properly.

8. Clean the filter head sealing surface.

Filter Head

Element

Seal

Sight Glass

2. Fully retract all hydraulic cylinders and shut off the engine.

3. Unlock and open the e ngin e co v e r. Allow the hyd r aulic oil to cool.

4. Clean around the hydraulic oil filter head (Fig. 2–44). Loosen, but DO NOT remove, the nuts that secure the hydraulic oil filter head to the hydraulic oil tank.

5. Place a suitable container under the h y dr aulic reserv oir drain plug . Th e co nt ai ne r m us t be la rge eno ugh to hold 32 gallons (1 21, 9 lit e rs) of hydraulic oil .

6. To facilitate removal of the hydraulic oil filter head and filter, the hydraulic oil return line may need to be swiveled out of the way, and the indicator wiring unplugged. DO NOT crimp the hydraulic oil return line or indicator wiring. Rotate and remove the hydraulic oil filter head; be prepared for a large amount of oil to be displaced.

2-30

Hydraulic Reservoir

Drain Plug

OS1600

Figure 2–45. Replace the hydraulic filter element and add

hydraulic oil as required.

9. Remove the magnetic drain plug and allow the hydraulic oil to drain into the container. Clean loose particles from the magnetic drain plug. Transfer the used hydraulic oil to a container with a cover and label the container as used hydraulic oil. Dispose of properly.

10. Reinstall the magnetic drain plug into the hydraulic oil reservoir.

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

11. Fully install a new hydraulic oil filter element onto the hydraulic oil filter head until the filter seats. Slide the filter assembly into the reservoir. Secure the filter head by tightening the nuts loosened earlier.

12. If the hydraulic oil return line was swiveled out of the way, reposition the line. If the indicator wiring was unplugged, reconnect it.

13. Remove the fill cap and fill with ISO Grade 46 hydraulic oil until the oil level is visible within the lower end of the sight glass. Reservoir capacity is 32 gallons (121,9 liters). Reinstall the fill cap. Thoroughly clean or wipe up any spilled hydraulic oil.

14. Close and lock the engine compartment cover.

15. Operate all hydraulic functions through their full range of motion several times. Cycle all control modes to help purge air from the hydraulic system.

WARNING: DO NOT use your hand or any part of your body to check for hydraulic leaks. Hydraulic oil leaking under pressure can penetrate the skin and cause severe personal injury. When checking for hydraulic leaks, wear safety glasses and gloves to help provide protection from spraying hydraulic oil. Use a piece of cardboard or paper to search for leaks.

3. Remove the transmission dipstick (Fig. 2–46). Check the transmission oil level.

Hose, Hydraulic Reservoir to Main Pump

Transmission Oil Filter

Breather (ref.)

Transmission Dipstick

OS0680

Figure 2–47. Transmission oil level dipstick location.

4. As required, add a premium grade of transmission fluid (see

Section 2.5.6 A. Transmission

for a list of approved fluids) to the transmission to bring the level up to the full mark.

B. Transmission Oil and Filter Change

16. Check for leaks.

2.12.10 Transmission Oil And Filter

A. Transmission Oil Level Check

MS2140

Figure 2–46. Every 10 hours of engine operation,

check the transmiss ion oil le v el.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), and engage the parking brake switch.

2. Check the transmission oil level with the engine at idle and the oil at normal operatin g tempe rature.

OS0890

0001

MS2190

Figure 2–48. Every 1,000 hours of engine operation,

change the transmission oil and transmission oil filter.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), and engage the parking brake switch.

2. Unlock and open the engine compartment cover. Allow the engine and transmission to cool.

3. Place a suitable receptacle under the transmission drain plug (Fig. 2–49). Remove the drain plug and allow the transmission oil to drain into the receptacle. Transfer the used transmission oil into a suitable covered container and label the container as used oil. Dispose of properly.

OS0950

Model 3606 • Origin 10/99

2-31

Section 2

250

Transmission

Drain Plug

Transmission Filter

Transmission Dipstick

OS1010

2.12.11 Axle Oil

A. Axle Oil Level Check

MS2170

Figure 2–51. Every 250 hours of engine operation, check

the axle oil level in both the front and rear axles.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut the engine off.

OS0920

Figure 2–49. Location of transmission maintenance items.

4. Clean and reinstall the transmission drain plug into the transmission housing.

5. Remove the transmission oil filter and dispose of properly. Clean the mating surface where the filter mounts.

Note: 10W motor oil is recommended in most climates; however, 5W20 motor oil may be substituted for use under

temperature conditions of -30 only. Refer to

Section 2.5.6. A. Transmission Fluid

F to 70°F (-34°C to 21°C)

6. Apply a thin film of clean 10W motor oil (that meets ISO 46 standards) to the new filter gasket. Install the new filter and torque 20-25 lb/ft (27-34 Nm).

7. Transmission oil may be added through either the fill plug (Fig. 2–50) or dipstick. Remove the fill plug or dipstick and fill with approximately 3.4 gallons (12,9 liters) of 10W motor oil. Check the level by taking intermittent dipstick readings as outlined in

Transmission Oil Level Check

. DO NOT overfill.

Reinstall the fill plug or dipstick when finished.

Transmission Filter

Fill Plug

Breather (ref.)

T ransmission Dipstick

OS0690

Figure 2–50. Fill the transmission through the fill plug or

dipstick opening.

8. Close and lock the engine compartment cover.

Axle Fill/

Level Plug

Drain Plug

Figure 2–52. Axle fill/level plug

(front axle shown; rear axle similar).

OS1581

2. Clean the area around the a xle fill/le vel plug (Fig. 2–52), then remove the plug from the axle housing.

3. Add a premium grade of SAE 80W90 or SAE 80W140 axle oil to bring the oil level up, even with the bottom of the plug hole.

4. Reinstall the axle fill/level plug.

B. Axle Oil Change

0001

MS2190

Figure 2–53. Every 1,000 hours of engine operation,

change the axle oil.

1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut the engine off.

2. Clean the area around both the axle fill/level plug (Fig. 2–52) and the axle drain plug.

3. Place a suitable receptacle under the axle drain plug. Remove the plug from the axle housing and allow the axle oil to drain completely.

4. Transfer the oil to a container with a cover and label the container as used axle oil. Dispose of properly.

OS0970

2-32

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

5. Clean and reinstall the drain plug. Remove the axle fill/level plug from the axle housing.

6. Fill the axle with a premium grade of SAE 80W90 or SAE 80W140 axle oil. Filling is accomplished through the axle fill/level hole. Fill until the axle oil level is even with the plug hole. The axle capacity is three gallons (11,5 liters).

7. Reinstall the axle fill/level plug into the axle housing.

2.12.12 Wheel End Oil

WARNING: DO NOT perform service or main-

tenance on this vehicle with the engine running. Contact with moving parts can cause serious injury or death.

A. Wheel End Oil Level Check

250

MS2170

Figure 2–54. Every 250 hours of engine operation, check

the wheel-end oil level for all four wheel-ends.

1. With the vehicle on level ground, move forward or backward enough to align the oil level line (Fig. 2–55) horizontally.

2. Ground the carriage, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut the engine off.

3. Clean the area around the wheel end fill/drain plug. Slowly remove the plug; pressure may be present. Check the oil level. It should be even with the bottom edge of the hole.

Wheel End

Oil Level Line

Figure 2–55. Wheel-end oil should be e ven wi th the bottom

edge of the fill/drain plug hole.

4. As required, add a premium grade of SAE 80W90 or SAE 80W140 axle oil to bring the level up and even with the plug hole.

5. Clean and reinstall the wheel end fill/drain plug.

OS0930

Wheel End Fill/Drain Plug

OS0710

B. Wheel End Oil Change

0001

MS2190

Figure 2–56. Every 1,000 hours of engine operation,

change the wheel-end oil level at all four wheel-ends.

1. Position the vehicle on level ground and move the vehicle forward or backward to place the wheel end fill/drain plug in the six o'clock position (Fig. 2–57).

Wheel End

Fill/Drain Plug

Figure 2–57. Drain each wheel-end every 1,00 0 hours of

engine operation.

2. Ground the carriage, place the travel select lever in the NEUTRAL (N) position, engage the parking brake switch and shut the engine off.

3. Clean the area around the wheel end fill/drain plug. Slowly loosen the plug. Hold a receptacle under the wheel end and remove the plug from the wheel end.

4. Allow the axle oil to drain completely into the receptacle. Transfer the axle oil to a container with a cover and label the container as used oil. Dispose of properly.

5. Reposition the vehicle so the oil level line is placed horizontally.

6. Fill the wheel end with a premium grade of SAE 80W90 or SAE 80W140 axle oil. The wheel end is full when the oil is level with the bottom of the plug hole. Wheel end oil capacity is approximately 1.4 quarts (1,3 liters).

7. Clean and reinstall the wheel end fill/drain plug.

OS0980

OS1020

Model 3606 • Origin 10/99

2-33

Section 2

2.12.13 Transfer Case Oil

A. Tr ansfer Case Oil Level Check

250

MS2170

Figure 2–58. Every 250 hours of engine operation, check

the transfer case oil level.

1. Level the vehicle, ground the carriage, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut the engine OFF.

2. Clean the area around the transfer case oil level plug and oil fill/vent cap (Fig. 2–59).

Vent Cap

Oil Drain Plug

Figure 2–59. Clean the area around the

transfer case oil level plug.

Oil Level Plug

Oil Fill Plug

3. Remove the oil level plug from the transfer case and check the oil level.

4. Add a premium grade of SAE 80W90 or SAE 80W140 gear oil as required through the oil level hole or oil fill/ vent cap. Bring the oil level up and even with the oil level plug hole.

5. Clean and reinstall the oil level plug and oil fill/vent plug.

B. Transfer Case Oil Change

OS0910

OS0722

0001

MS2190

Figure 2–60. Every 1,000 hours of engine operation,

change the transfer case oil.

1. Level the vehicle, ground the carriage, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut the engine OFF.

OS0960

2. Clean the area around the transfer case oil level plug, oil drain plugs and the oil fill/vent cap (Fig. 2–61).

Vent Cap

Oil Drain Plug

Figure 2–61. Remove the oil drain plug from the transfer

case to drain the oil.

Oil Level Plug

Oil Fill Plug

OS0722

3. Place a receptacle beneath the transfer case drain plugs.

4. Remove the drain plugs from the transfer case.

5. Allow the oil to drain completely into the receptacle. Transfer the oil into a container with a cover and label as used oil. Dispose of properly.

6. Clean and reinstall the transfer case drain plugs.

7. Remove the oil fill/vent cap and oil level plug.

8. Fill the transfer case with SAE 80W90 or SAE 80W140 gear oil. The transfer case is full when oil is level with the bottom of the oil level plug hole. Total transfer case gear oil capacity is 1.5 qt (1,4 l).

9. Replace the oil fill/vent cap and oil level plug. Wipe up any spilled gear oil.

2.12.14 Wheels and Tires

A. Tire Pressure Check

MS2140

Figure 2–62. Every ten hours of engine operation, check

the air pressure in all four tires.

DANGER: LOW TIRE PRESSURE can result

in vehicle tipover. MAINTAIN proper tire pressure at all times.

Check all four tires:

1. Remove the valve stem cap.

2. Check tire pressure using a premium-quality gauge. Proper inflation pressure cannot be determined visually. Pressure should be 65 psi (448 kPa)

OS0900

2-34

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

F N R

minimum for 13.00 - 24, 12-ply tires. Maximum ground pressure with a full load is 93 psi (641 kPa).

3. Add air as required. DO NOT overinflate.

4. Replace the valve stem cap.

B. Wheel Lug Nut Check

Every ten hours of engine operation, check the torque on all lug nuts. Tighten as required.

1. Wire brush the area around the lugs if necessary. Foreign material such as dirt, concrete, mud, etc. can prevent an accurate torque reading.

2. Use the torque sequence diagram below (Fig. 2–63), to alternately check the torque of each of the ten lug nuts. The recommended torque is 370 lb/ft (500 Nm).

panel (Fig. 2–64) illuminates when the alternator is no longer able to charge the battery.

Early Production

Current Production

Figure 2–64. Typical alternator charging warning indicator.

Alternator Charging Warning Indic ator

Alternator Charging Warning Indicator

OS0222

To service the battery:

1. Level the vehicle, ground the carriage, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut the engine off.

2. Unlock and open the engine cover. The battery is

Figure 2–63. Lug nut torque sequence.

2.12.15 BATTERY

OS0740

located directly underneath the radiator assembly (Fig. 2–65).

Radiator

Battery

A. Battery Inspection, Testing and Service

W ARNING: A lead-acid battery produces flam-

mable and potentially explosive gases. To he lp avoid personal injury w hen ch ecking, testing o r charging the battery:

• DO NOT use smoking materials near a battery.

• Keep arcs, sparks and open flames away from the battery.

W ARNING: • Provide adequate ventilation and

OS1040

Figure 2–65. The battery is located beneath the radiator.

wear safety glasses

The battery is of maintenance-free design. The battery is filled with electrolyte and charged when shipped with the vehicl e. A w arning indi cator li ght on th e operat or's di spla y

Model 3606 • Origin 10/99

2-35

Section 2

3. Wear safety glasses and visually inspect the battery. Check terminals for corrosion. Replace the battery if it has a cracked, melted or damaged case.

WARNING: Fluid (electrolyte) in electric storage batteries contains sulfuric acid, a POISON that can cause SEVERE CHEMICAL BURNS. Avoid all contact of fluid with eyes, skin or clothing. Use proper protective gear when handling

batteries. DO NOT tip a battery beyond a 45 angle in any direction. If contact with battery fluid does occur, follow the First Aid suggestions in the “Battery Fluid (electrolyte) First Aid” box below.

Battery Fluid (electrolyte) Firs t Aid

• External Contact: Flush with water.

• Eyes: Flush with water for at least 15 minutes and get medical attention immediately.

• Internal Contact: Drink large quantities of water. Follow with Milk of Magnesia, a beaten egg or vegetable oil and get medical attention immediately. DO NOT take fluids that induce vomiting.

IMPORTANT: In case of internal contact DO NOT take fluids that induce vomiting!

B. Battery Charging

WARNING: DO NOT charge a frozen battery.

A frozen battery could explode and cause serious personal injury. Allow the battery to thaw before “jump starting” the vehicle or connecting a battery charger.

Under normal operating conditions, the alternator will keep the battery charged. The alternator may not be able to charge a battery that has been completely discharged for an extended period of time. Under this condition, a battery charger or a “jump start” is required to recharge the battery.

An attempt to “jump start” the vehicle and let the engine run so the alternator charges the battery can be made before using a battery charger.

C. Jump Starting

WARNING: NEVER jump start the vehicle

directly at the starter motor or starter solenoid. Serious personal injury or death could result from the vehicle lurching forward or backward and running over personnel attempting to jump start the vehicle.

WARNING: To help avoid personal injury when jump star ting with another vehicle, DO NOT allow the vehicles to contact each other. NEVER jump start a frozen battery. A frozen battery could explode and cause serious personal injury . K eep arcs, sparks, lighted smoking materials and open flames away from the battery. A lead-acid battery produces flammable and potentially explosive gases. Wear safety glasses when working near a battery.

The jumper or booster battery must be a 12-volt type. A vehicle used for jump starting must also have a negative ground electrical system. When handling and connecting jumper cables, DO NOT allow premature or unintended contact with any part of the vehicle.

To jump start the vehicle:

1. Connect the positive (+) jumper cable to the positive (+) post of the discharged battery.

2. Connect the other end of the positive (+) jumper cable to the positive (+) post of the booster battery.

3. Connect one end of the negative (-) jumper cable to the negative (-) post of the booster battery.

4. Make the final cable connection to the engine block ground or to the ground point furthest away from the battery.

5. From the operator’s seat with the seat belt fastened, check that the parking brake switch is engaged. Place the travel select lever in NEUTRAL (N). Turn the ignition switch to the START position (fully clockwise) to crank the engine. Release the key when the e ngi ne s tarts. DO NO T energize the starter solenoid or crank the engine for more than 15 seconds at a time. Wait two minutes between each 15-second cranking interval. If the engine fails to start on the first try, wait until the engine and starter come to a complete stop before engaging the starter again.

6. After the engine starts, remove the jumper cables in reverse order of their connection. First, remove the final cable connection that was made at the engine block ground or at the ground point furthest away from the battery.

2-36

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

7. Next, remove the negative (-) jumper cable connected to the negative (-) post of the booster battery.

8. Remove the other end of the positive (+) jumper cable connected to the positive (+) post of the booster battery.

9. Remove the positive (+) jumper cable connected to the positive (+) post of the discharged, but now charging, batter y.

10. Run the engine at partial throttle for 30 to 60 seconds before attempting to operate the vehicle. Allow the engine to return to idle RPM before engaging the travel- or range-select levers.

2.12.16 Fuse and Relay Replacement

Note: There are

currently in use on the Sky Trak Model 3606. Vehicles with serial number relay panel shown in Fig. 2–68. Mid-pro duc ti on vehicles with serial number relay panel shown in Fig. 2–69. Current production vehicles with serial numbers 9399 relay panel shown in Fig. 2–70.

IMPORTANT: Shut off the engine and disconnect the negative battery cable before checking the electrical system. Use an ohmmeter to check the resistance of wires and components.

Fuses and relays help to protect the electrical system. In general, a blown fuse is symptomatic of another electrical problem. Simply replacing the fuse often will not solve the problem. Blown fuses usually are due to simple causes, including loose or corroded connections, or a defective relay. The main causes of blown fuses include a shorted or grounded wire in the applicable circuit, or a defective electrical component. Visually check the condition of the fuse, wires, connections and components in the involved circuit before replacing a fuse. Check the circuit for shorts, grounding or defective electrical components.

To gain access to the fuses and relays, remove the three screws securing the lower dash panel to the cab (Fig. 2–

66). The fuses and relays are conveniently mounted

under the lower left side of the operator’s console (Fig. 2–

66). Remove the four screws securing the panel to gain

access to the fuses.

three

(3) types of fuse and relay panels

8249 and before

8250 through 9398

use the fuse and

and after

use the fuse and

Electrical Fuse and Relay Panel

Lower Dash Panel

Figure 2–66. Remove the lower dash panel

to gain access to the fuses and relays.

Fuse and Relay Panel

Figure 2–67. Location of fuses and relays.

Before checking a malfunctioning electrical circuit, examine the applicable wiring diagram (see

trical System

) to help identify the components involved.

Section 10: Elec-

Problems can often be identified by noting whether other components related to the circuit are functioning properly. When several components or circuits fail at one time, the problem is probably related to a poor ground connection, because several circuits share that same connection.

Section 10 Electrical System

See

for further information.

OS1093

OS1092

Model 3606 • Origin 10/99

2-37

Section 2

Vehicles Stamped with S/N 8249

and Before

Hourmeter

Neutral Relay/Starter

Fuel Shut-off

Display Panel

Main Fuse

Switch Lamps

Stabil-TRAK Solenoid

Stabilizer Lock Relay

Trans-

mission

Solenoids

Neutral Relay

Forward Relay

Reverse Relay

Trans. Relay 1

Trans. Relay 2

Trans. Relay 3

Boom Switch Relay

Stabilizer Lock Relay

Figure 2–68. Vehicles with serial number

use the fuse and relay panel shown here.

Perkins Cold

Start (optional)

Neutral Sense

Logic

Panel Transmission Relay

Horn

Steer Solenoids

Park Brake Sense

OS1113

8249 and before

Vehicles Stamped with S/N 8250

Neutral

Relay/Starter

Display

Panel

Logic Panel

*Cold Start

7.5

Main

Hourmeter

Fuel Shut-Off

Trans. Relay Park Brake

7.5

7.5 7.5

7.5

Sense Relay

Transmission

Solenoids

Neutral Relay

Trans. Relay #3 T rans. Relay #2

Trans. Relay #1

*Optional

Figure 2–69. Vehicles stamped with serial number

through 9398

use the fuse and relay panel shown here.

through 9398

Neutral Sense

*Switch Lamps

Horn

*Aux. Detent Mode

Steer Solenoids

Stabil-TRAK Solenoid

Stabilizer Lock Relay

Reverse Relay

Forward Relay Stabilizer Lock

Relay Boom Switch Relay

OS1770

8250

2-38

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

2. Measure the distance between the inner boom and

Vehicles Stamped with S/N 9399

Neutral

Relay/Starter

*Cold Start

Main

Display

Panel

Fuel

Shut-Off

*Blower Motor

Stabil-TRAK

Solenoid

Park Brake

*Window

Motor

7.5

Logic Panel

7.5

7.5 7.5

7.5

7.5 7.5

7.5

and After

*Light Pkg (B)

*Light Pkg

(A)

7.5

Neutral

Sense

Hourmeter

*Skylight Wiper/Washer

*Rear Wiper Horn

Sense Relay

Trans.

Solenoids

*Aux. Detent Mode

Steer Solenoids

*Power Accessory

Relay (40 Amp)

Neutral Relay

Stabilizer Lock Relay

*Power Window

Motor Relay (40 Amp)

Reverse Relay Forward Relay

Trans. Relay #3

Trans. Relay #2 Trans. Relay #1

Stabilizer Lock Relay

Boom Switch Relay

*Optional

Figure 2–70. Vehicles stamped with serial number

and after

use the fuse and relay panel shown here.

*Front Wiper

*Switch Lamps

Trans. Relay

OS2190

9399

the intermediate boom (Fig. 2–72). The inner boom should extend 2.25 inches (57 mm) to 2.75 inches (70 mm) beyond the end of the intermediate boom. If the measurement is less than 2.25 inches (57 mm), the chains require adjustment.

2.25"-2.75" (57-70 mm)

Inner Boom

Figure 2–72. Measure the distance between the inner

boom and the intermediate boom.

B. Boom Chain Adjustment

1. Park the vehicle on level ground. Place the travel select lever in NEUTRAL (N), engage the parking brake switch and raise the boom to a horizontal boom. Retract the boom completely and shut the engine off.

2. Loosen the retract chain locknut (Fig. 2–73) located on the bottom at the front of the outer boom.

Intermediate Boom

OS1060

2.12.17 Boom Chains

A. Boom Chain Tension Check

0001

MS2190

Figure 2–71. Every 1,000 hours of en gine oper ation, c hec k

both boom chains for proper tension.

Model 3606 • Origin 10/99

OS0940

Retract

Chain

Locknut

Outer Boom

OS1070

Figure 2–73. Turn the retract chain locknut at the front of

the outer boom.

3. Unlock and open the rear cover.

4. While preventing the clevis end from turning, tighten the extend chain locknut (Fig. 2–74) located at the rear of the outer boom.

2-39

Section 2

Retract

Chain

Locknut

Figure 2–74. Prevent the clevis end from turning,

and tighten the extend chain locknut

at the rear of the outer boom.

Clevis End

OS1440

5. Periodically measure the distance between the inner boom and the intermediate boom. Repeat Step 4 until a distance of 2.5 inches (63,5 mm) is obtained between the inner boom and the intermediate boom (Fig. 2–72).

6. Tighten the retract chain locknut (Fig. 2–73) to 35-40 lb/ft (47,5-54,2 Nm).

7. Close and lock the rear cover.

2.12.18 Storage

1. Install a properly charged battery. Secure the holddown strip and attach the cables.

2. Change the engine oil and filter to remove condensation or other residua ls.

3. If the vehicle has been stored for two years or more, drain the coolant from the engine block and radiator and refill with a 50/50 mixture of fresh anti-freeze and water.

4. Wipe off any

LPS 3

(or equivalent) applied to

exposed cylinder rods prior to storage.

5. Perform all recommended 10 hour maintenance procedures.

2.12.19 Transport

When transporting the vehicle, make use of all four tiedowns (Fig. 2–75).

Vehicle Frame

(S/N 8084 and After)

VIEW IN DIRECTION OF ARROW A

A. Before Storing a Vehicle

Perform the following steps prior to placing the vehicle in storage:

1. Clean the entire vehicle.

2. Lubricate all grease fittings.

3. Prepare the engine for storage (refer to the engine manual).

4. Apply

LPS 3

(or equivalent) to all exposed hydraulic

cylinder rods.

5. Disconnect the battery cables. Remove the battery from the vehicle and store it in a dry place not subject to temperatures near or below freezing.

6. Preferably, store the vehicle inside where it will remain dry. If it must be stored outside, park it on lumber laid on flat, level ground, or on a concrete slap. Cover the vehicle with a tarp.

B. Removing Vehicle From Storage

After removing the vehicle from storage and before operating it, perform the following steps:

VIEW IN DIRECTION OF ARROW B

OS2150

Figure 2–75. When transporting the vehicle,

make use of all four tiedowns.

2-40

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

2.13 EMERGENCY OPERATIONS

2.13.1 Towing a Disabled Vehicle

IMPORTANT: After the vehicle has been towed to a

secure location, reactivate the parking brake. Carefully follow these procedures from start to finish. Consult your local Sky Trak Distributor or the Sky Trak Service Department if you are unsure about any part of this procedure, or for specific instructions for your particular situation.

Towing a disabled vehicle should only be attempted as a last resort, after exhausting all other options. Make ev ery effort to repair the vehicle, and move it under its own power, cedures.

To prepare the vehicle for towing, the parking brake mechanisms at the front axle must be disabled. This will allow the front wheels to rotate freely during emergency towing.

2.13.2 Disabling the P arking Brakes

before

using the following emergency towing pro-

WARNING: BLOCK ALL FOUR WHEELS.

Failure to do so could result in death or serious injury from vehicle roll away.

4. An 8 mm Allen

-head socket and torque wrench are needed to properly disable the parking brakes. Scribe a line on the socket to aid in accurately counting the number of turns each bolt makes during the procedure.

5. At the base of the front axle, locate the six parking brake release bolts (three bolts per side; for early production vehicles, see Fig. 2–77; for current production vehicles, see Fig. 2–78). Thoroughly clean all dirt and debris from the six bolt recesses.

EARLY PRODUCTION

1. Place an Accident Prevention Tag on both the ignition key and the steering wheel (Fig. 2–76) stating that the vehicle should not be operated. If a tag is not available, tape over the ignition switch.

DANGER

OS1520

Figure 2–76. Place an Acc ident Pre ven tion Tag on both the

ignition switch and the steering wheel.

2. Block all four wheels to help prevent the vehicle from moving after the parking brake is disabled.

3. Position the towing vehicle in place. Attach any chains needed to secure the disabled vehicle.

One of Six Parking Brake Release Bolts

OS1581

Figure 2–77. Clean all dirt and debris from the six parking

brake release bolt recesses (

CURRENT PRODUCTION

One of Six Parking Brake Release Bolts

Figure 2–78. Clean all dirt and debris from the six parking

brake release bolt recesses (

early production vehicles

MS2590

current production vehicles

Model 3606 • Origin 10/99

2-41

Section 2

6. For early production vehicles, see Fig. 2–79; for current production vehicles, see Fig. 2–80. Alternately turn the parking brake release bolts A, B and C inward (clockwise) two to three complete turns until resistance is felt.

EARLY PRODUCTION

Turn Clockwise to

Release Brake

Steering Cylinder (ref.)

Brake Release Bolt

FRONT

Left Side, Cross-section of Front Axle

Figure 2–79.

bolts A, B and C inward until resistance is felt

Alternately turn parking brake release

early production vehicles

(

CURRENT PRODUCTION

OS0500

7. Use a torque wrench to alternately turn parking brake release bolts A, B and C (Fig. 2–79 or Fig. 2–80) inward (clockwise) until a torque of 22 lb/ft (30 Nm) is reached. This will take approximately a half-turn. DO NOT exceed 50 lb/ft (68 Nm).

8. Continue using a torque wrench to alternately turn parking brake release bolts A, B and C inward (clockwise) until a minimum torque of 30 lb/ft (41 Nm) is reached. This will take approximately a half-turn. DO NOT exceed 50 lb/ft (68 Nm).

9. Clear the area of any unnecessary personnel.

10. Car ef ull y remove the wheel blocks from each of the four tires. Tow the vehicle to a secure location.

2.13.3 Reactivating the Parking Brakes

WARNING: BLOCK ALL FOUR WHEELS.

Fa il ure to do so could r es ul t in de ath or s erio us injury from vehicle ro ll away.

Upon arriving at a secure location with the towed vehicle, block all four wheels and continue following these procedures.

1. Block all four wheels to help prevent the vehicle from moving. Clear the area of any unnecessary personnel.

2. For early production vehicles, see Fig. 2–81; for current production vehicles, see Fig. 2–82. Use a torque wrench to alternately turn parking brake release bolts A, B and C outward (counter-clockwise) a half-turn until the torque drops to 22 lb/ft (30 Nm).

Turn Clockwise to

Release Brake

Steering Cylinder (ref.)

Brake Release Bolt

FRONT

Left Side, Cross-section of Front Axle

Figure 2–80.

bolts A, B and C inward until resistance is felt

Alternately turn parking brake release

current production vehic les

(

MS2600

EARLY PRODUCTION

Turn

Counter-clockwise

to Activate Brake

Steering Cylinder (ref.)

FRONT

Brake Release Bolt

Figure 2–81.

Snap Ring

Alternately turn parking brake release

Left Side, Cross-section of Front Axle

bolts A, B and C outward until torque decreases

early production vehicles

(

OS0510

2-42

Model 3606 • Origin 10/99

General Information, Specifications, and Maintenance

CURRENT PRODUCTION

Turn

Counter-clockwise

to Activate Brake

Steering Cylinder (ref.)

FRONT

Brake Release Bolt

Figure 2–82.

Snap Ring

Left Side, Cross-section of Front Axle

Alternately turn parking brake release

bolts A, B and C outward until torque decreases

current production vehic les

(

MS2610

3. Use a torque wrench to alternately turn parking brake release bolts A, B and C outward (counter-clockwise) until the torque decreases sharply.

4. For early production vehicles, see Fig. 2–81; for current production vehicles, see Fig. 2–82. Alternately turn parking brake release bolts A, B and C outward (counter-clockwise) until the bolt flanges begin to press against the snap ring. Then, turn each bolt inward (clockwise) one-quarter turn.

5. The parking brak es should now be re-activated and the front wheels locked. Carefully remove the blocking from the four tires.

6. Verify that the parking brake w orks.

7. Remove the Accident Prevention Tags from the ignition switch and steering wheel.

Model 3606 • Origin 10/99

2-43

Section 2

2-44

Model 3606 • Origin 10/99

Section 4

Cab, Covers and Mirrors

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

General Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.1 SERIAL NUMBER DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2 CAB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2.1 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2.2 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.2.3 Operator’s Seat and Seat Belt. . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.2.4 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.2.5 Steering Wheel, Column and Shifter. . . . . . . . . . . . . . . . . . . . . 4-12

4.2.6 Joystick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.2.7 Service Brake Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . 4-19

4.2.8 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.2.9 Mirror Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4.2.10 Cab Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.3 CAB COVERS AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.3.1 Cover and Guard Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.3.2 Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Model 3606 • Origin 10/99

4-1

Section 4

Introduction

The welded metal cab features European styling and a modular design, allowing for a relatively quick, simple exchan ge of the entir e cab and/or component parts . The cab is bolted to the cab mount, which in turn is bolted to the frame.

The operator’s cab is a protective structure. The cab itself contains roll-over protective and falling object protective structures (ROPS/FOPS) for the operator.

WARNING: The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, torqued to their specified value.

DO NOT weld, grind, drill, repair or modify the cab in any way. Any modification or damage to cab structural components requires cab replacement. The lives of the operator and others are potentially at stake.

To help ensure optimum safety, protection and performance, replace the cab if it is damaged. Refer to the

SKY TRAK Model 3606 Parts Manual

for ordering infor-

mation. The cab contains the seat, operating controls, numer-

ous panels, steering and brake components, and more. Covers and mirrors on the vehicle exist for safety, pro-

tection and appearance. They are relatively simple to remove and replace.

Legend

1. Operator’s Protective Structure ROPS/FOPS

2. Headliner

3. Cab rear panel

4. Button-head capscrew, 5/16-18 x 1

5. Flat plastic washer, 5/16"

6. Retaining nut, 5/16-18

7. Hex-head capscrew, 5/16-18 x 1

8. Lock washer, 5/16"

9. Rebound washer

10. Cab panel, rear LH

11. Flat washer, 5/16"

12. Hex-lock elastic nut, 3/4-10

13. Button-head capscrew, 1/4-20 x 3/4

14. Owners/Operators Manual holder

15. Flat washer, 1/4"

16. Hex-lock elastic nut, 1/4-20

17. Floor mat

18. Self-drilling screw, #12-14 x 1

19. Cab panel, front LH

20. Cab isolator

21. Rebound washer

22. Hex-head capscrew, 3/4-10 x 3-3/4", Grade 8

23. Lock washer, 3/4"

24. Cab panel, front

25. Window spacer

26. Window edge seal bulb

27. *Right side window

28. Window clip, w/offset

29. Screw

30. Window clip

31. Spray adhesive, 10 ounce spray can (for item 17)

32. *Steel mesh window (option), glued in

4-2

Model 3606 • Origin 10/99

Cab, Covers and Mirrors

General Overview

26 25

Frame (ref.)

15 16

5 4

4 5

Model 3606 • Origin 10/99

Torque to 280 lb/ft (380 Nm)

Cab mount (ref.)

Torque to 280 lb/ft (380 Nm)

MS1530

PF0780

PS0330

4-3

Section 4

4.1 SERIAL NUMBER DECAL

The cab serial number decal (Fig. 4–1) is located along the top right side of the cab, near the mirror. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.

Serial

Number Decal

Mirror

MS0840

Figure 4–1. Location of the cab serial number decal.

4.2 CAB REPLACEMENT

WARNING: Risk of death or severe personal injury. NEVER modify, weld or drill the cab.

4.2.1 Cab Removal

WARNING: Wear protective footwear with

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

WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in serious personal injury.

IMPORTANT: Remove and label cab panels and other components as needed vehicle. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab replacement cab is securely mounted on the vehicle.

1. Park the vehicle on a firm, level surface. Allow sufficient overhead and side clearance for cab removal. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), engage the parking brake switch and shut the engine OFF. Open the engine hood. Allow the engine and hydraulic fluid to cool.

2. Disconnect the battery negative (-) ground cable at the battery negative (-) terminal (Fig. 4–2).

before

removing the cab from the

after

the

IMPORTANT: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the

SKY TRAK Model 3606 Parts Manual

for ordering infor-

mation. Before performing any inspection, maintenance or ser-

vice operation, thoroughly clean the vehicle. DO NOT spray water or cleaning solution in, on, near or around the operator’s dash panels and electrical components.

Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact Sky Trak or the local Sky Trak distributor with any questions about the suitability or condition of a cab.

Battery negative

(-) terminal

OS1040

Figure 4–2. Disconnect the battery negative (-) cable.

3. Remove the joystick assembly (

Replacement

). Label, disconnect and cap the six

see 4.2.6 Joystick

hydraulic hoses mounted at the base of the joystick assembly.

4. Remove the logic board panel, mounted in the front dash, just forward of the joystick mounting location (see. Fig. 4–3). Disconnect the wiring connector.

5. Remove the front dash (1, Fig. 4–3), console support (12) and rear tool bin (19). Label and disconnect wiring leads as applicable.

4-4

Model 3606 • Origin 10/99

Cab, Covers and Mirrors

Cab (ref.)

Figure 4–3. Operator’s cab inner console and dash panel components.

1. Front dash

2. Retaining nut, 5/16-18

3. Lower dash cover

4. Self-drilling sc rew, #12-14 x 1"

5. Slotted hex-head capscrew, #10-24 x 1"

6. Spacer

7. Fender washer

8. Hex-lock elastic nut, #10-24

Logic board

panel (ref.)

13 16 17

16 17

9. Well nut, #10-32

10. Button-head capscrew, #10-32 x 3/4"

11. Load chart holder

12. Console support

13. Rebound washer

14. Hex-lock elastic nut, 5/16-18

15. Flat washer, 5/16"

16. Lock washer, 5/16"

16 13

6 7

14 15

MS0850

17. Hex-head capscrew, 5/16-18 x 1-1/4"

18. Armrest

19. Rear tool bin

20. Hex-head capscrew, 5/16-18 x 2"

21. Retaining ring

22. Flat washer, 1/2"

23. Conduit, 1/4" x 5" long

24. Conduit, 1/4" x 9" long

6. Route the joystick, power steering and service brake hydraulic hoses out of and away from the cab. Cut and dispose of plastic wire ties as needed. Wipe up any spilled hydraulic fluid.

WARNING: Explosion and fire hazard. Cap or safely cover the fuel tank and beaded hose tee openings.

7. Remove the cab rear panel (item 3 in the

Overview

illustration on page three). From behind the

General

cab, loosen the lower clamp (Fig. 4–3) securing the fuel hose to the fuel tank. Remove the lower end of the fuel hose from the fuel tank. Cap or safely cover the fuel tank opening.

8. Loosen the clamp securing the fuel breather hose (Fig. 4–3) to the top of the beaded hose tee. Remove the low er en d of t he fue l br eat her hos e fr om t he hose tee. Cap or safely cover the hose tee opening.

Model 3606 • Origin 10/99

LH Rear cab panel (ref.)

Fuel filler

Fuel breather hose

Clamp

Beaded hose tee

Upper clamp

Vehicle

frame

(ref.)

Fuel hose Lower clamp

Fuel tank

Cab mount

MS0860

Figure 4–3. Loosen the clamps and remove the fuel tank

hoses from their fittings. Cap or safely cover the openings.

4-5

Section 4

9. Remove the front cab-to-cab-mount attaching hardware (refer to items in the

General Overview

illustration on page three). Front hardware includes 3/4-10 hex-lock elastic nuts (12), 3/4-10 x 3-1/2" Grade 8 hex-head capscrews (22), 3/4" lock washers (23) and rebound washers (21). Rear hardware includes 3/4-10 hex-lock elastic nuts (12), 3/4-10 x 3-1/2" Grade 8 hex-head capscrews (22), and rebound washers (21).

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

10. Remove two 3/4-10 hex-lock elastic nuts (item 12 in

General Overview

the

illustration on page three), two 3/4-10 x 3-3/4" Grade 8 hex-head capscrews (22) and two rebound washers (21). Tap the capscrews out of the cab isolators (20) from above, as required.

11. Disconnect the throttle cable at the engine bracket (Fig. 4–4). Route the cable out of the engine compartment, then close the engine hood. Allow the cable to hang beneath the cab mount for now.

Slotted pan-head

Throttle cable

#10 lock washer

#10-24

hex nut

screw

Cable clamp

Rod end

12. Route the wiring harness out of the cab. Cut and dispose of plastic wire ties as needed. Secure the wiring harness against the frame, safely away from the cab.

13. Remove the mirrors and all other cab components, as needed, if not previously removed.

14. Use a hoist or overhead crane and sling attached to the cab. Carefully

begin

to lift the cab. Stop and check that all wiring, fuel tank components, hydraulic hoses and fasteners are disconnected or removed. If the throttle cable is still attached to the cab, reposition or remove the throttle cable as necessary.

15. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the cab mount. Readjust the position of the sling as needed to help balance the cab during removal.

16. When the cab is completely clear of the vehicle, carefully lower it to the ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter the cab while it is dismounted from the vehicle.

17. Ins pe ct the condi tion of the fuel tank, fuel hose s, fittings, clamps, hydraulic hoses, cab isolators, etc. Replace parts as indicated by their condition.

18. Inspect and replace other vehicle parts that are exposed with the cab removed. Repair or replace as required.

Bracket

1/4-28 NF hex-lock elastic nut

Cummins Engine

Bracket

Cable

clamp

#10 lock washer

#10-24

hex nut

Perkins Engine

Figure 4–4. Throttle cable to engine bracket mounting.

Throttle

lever

extension

Throttle lever extension

Slotted

pan-head

screw

Rod end Washer

1/4-28 NF hex-lock elastic nut

MS0870

4-6

Model 3606 • Origin 10/99

Cab, Covers and Mirrors

S/N 8249 - 9398*

S/N 9399 and After*

7.5

7.5 7.5

7.5

7.5 7.5

7.5

7.5 7.5

7.5

7.5 7.5

7.5

7.5 7.5

7.5

Section 2

*See for fuse and relay

panel information.

29 28

Before S/N 8249*

1. Cab harness

2. Back-up alarm

3. Hex-lock elast ic nut, 1/4-20

4. Flat washer, 1/4"

5. Boom sensor

6. Service brake switch

7. Side console (logic board) panel

8. Button-head capscrew, #10-32 x 3/4"

9. Well nut, #10-32

10. Steer select switc h

11. Switch bezel

12. Auxiliary detent switch (optional)

13. Front console dash

Figure 4–6. Label and disconnect wiring harnesses and wire leads at their connectors.

14. Park brake switch

15. Round-head wood screw, #6 x 1/2"

16. Hourmeter

17. Machine bushing washer, 0.63" ID

18. Ignition switch (includes item 19)

19. Ignition key (set of two)

20. Fuse, 7.5 amp

21. Fuse, 40 amp

22. Fuse, 15 amp (Perkins cold start only)

23. Sealed relay, 12V, 40A

24. Slotted pan-head screw, #10-24 x 3/4"

25. Narrow flat washer, #10

26. Slotted pan-head screw, #10-24 x 5/8"

27. Hex-lock elastic nut, #10-24

28. Flat washer, 1/4"

29. Lock washer, 1/4"

30. Hex nut, 1/4-20

31. Plastic tie

32. Hex jam nut, M6-1 CI4

33. Lock washer, M6

34. Signal horn

35. Tube clip

36. Hex lock nut, 1/2-13

37. Attachment tilt mode switch

38. Attachment tilt direction harness

MS0880

Model 3606 • Origin 10/99

4-7

Section 4

4.2.2 Cab Installation

WARNING: Explosion and fire hazard. Cap or

safely cover the fuel tank and beaded hose tee openings.

WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot injury from falling objects or other bodily injury from slipping or falling.

WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in serious personal injury.

IMPORTANT: Transfer and install cab panels and other components as needed mounted on the vehicle.

1. Cap or safely cover any fuel-tank or fuel-fitting openings. Inspect vehicle parts that are exposed with the cab removed. Repair or replace as required.

2. Block all four wheels from moving. Assure that there is sufficient overhead and side clearance for cab installation.

3. Disconnect the cable at the battery negative (-) terminal (Fig. 4–2) as required.

4. Install cab isolators (item 20 in the illustration on page three) into the mounting holes on the cab mount.

5. Use a hoist or overhead crane and sling attached to the cab (1). Carefully begin to lower the cab onto the cab mount. Stop and check that wiring, fuel tank components, hydraulic hoses, etc., will not be pinched or damaged as the cab is lowered.

6. Route the throttle cable (Fig. 4–4) from beneath the cab to the engine compartment by simply positioning the cable under the frame, then up between the transmission and engine. Bring the cable across the side of engine to the throttle cable bracket. DO NOT attach the cable to the throttle lever extension on the engine at this time.

7. Carefully and slowly lower the cab (item 1 in the

General Overview

Align the cab with the cab isolators (20) as the cab is lowered. Readjust the position of the sling as needed to help balance the cab during installation.

8. Install the cab-to-cab-mount attaching hardware (items 12, 21, 22 and 23). At the rear of the cab, install but DO NOT tighten the two 3/4-10 hex-lock elastic nuts (12), two rebound washers (21) and two

after

the cab is securely

to help prevent the vehicle

General Ov erview

illustration) onto the cab mount.

3/4-10 x 3-3/4" Grade 8 hex-head capscrews (22) that secure the cab (1) to the cab mount (ref.). Tap the capscrews into the cab isolators (20) from below, as required, but DO NOT distort or damage the cab isolators.

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

9. At the front of the cab (1), install but DO NOT tighten the two 3/4-10 hex-lock elastic nuts, two 3/4" lock washers (23), two rebound washers (21) and two 3/410 x 3-1/2" Grade 8 hex-head capscrews (22). Tap the capscrews into the cab isolators (20) from below, as required, but DO NOT distort or damage the cab isolators.

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

10. From behind the cab, position the lower clamp (Fig. 4–3) on the fuel hose. Remove any cap or safety cover from the fuel tank opening. If needed, secure the fuel filler to the cab and the top end of the fuel hose to the fuel filler.

11. Slip the lower end of the fuel hose onto the fuel hose neck on the fuel tank and tighten the lower clamp.

12. Position a clamp on the fuel breather hose (Fig. 4–3). Remove any cap or safety cov e r from the beaded hose tee. If needed, secure the top end of the fuel breather hose to the fuel filler with another clamp.

13. Secure the bottom end of the fuel breather hose to the beaded hose tee.

14. From beneath the cab, route and connect the cab wiring harness (Fig. 4–6). Install plastic conduit as required to protect the wiring as it passes through metal openings. Secure wiring with plastic wire ties as needed.

15. Route the joystick, power steering and service brake hydraulic hoses from the frame into the cab. Using the hose labels made and attached earlier, connect the hoses at the joystick, power steering valve and brake control valve. Wipe up any spilled hydraulic fluid.

16. Check that the cab is not distorting, pinching, crushing or damaging the throttle cable, wiring or hydraulic hoses. Make adjustments as necessary.

17. Tighten the cab-to-cab-mount hardware (refer to the

General Overview

illustration). Torque the 3/4-10 hex-lock elastic nuts (12) and 3/4-10 x 3-1/2" Grade 8 hex-head capscrews (22) to 280 lb/ft (380 Nm).

18. After the cab is securely mounted to the vehicle, install all parts in the cab as required.

19. Connect the throttle cable at the engine (Fig. 4–4) and, if necessary, to the throttle pedal.

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Model 3606 • Origin 10/99

Cab, Covers and Mirrors

20. Connect the battery negative (-) ground cable (Fig. 4–2).

21. Carefully examine all cab components, fasteners, etc., one last time before engine start-up. Rectify any faulty conditions.

22. Start the engine and check the operation of all controls. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

4.2.3 Operator’s Seat and Seat Belt

Three types of operator’s seats are used. These include the standard operator’s seat (Fig. 4–7), and two optional seats that include a headrest and are covered in either deluxe vinyl or deluxe cloth material and include headrests. The seat belt is attached to the seat assembly.

An optional three-inch wide seat belt is available for those locations that require a three-inch seat belt.

A. Seat Replacement

The seat can be removed from the cab by removing the fasteners, including two tether cables, which secure the seat to the cab. The seat belt is also easily removed by removing the nuts, spacers, washers and capscrews securing it to the seat frame. The seat tethers are secured to the seat with the seat belt capscrews.

The seat and seat slides may be removed from the suspension unit and mounting plate by removing four lock nuts and flat washers that attach the seat slides to the suspension unit.

Standard Seat Removal

Working from the outside rear of the cab, remove the rear cab panel (item 3 in the

General Overview

illustration) to gain access to the seat tether mounting hardware. The rear cab panel is secured to the cab with 5/16-18 buttonhead capscrews (4), 5/16" flat plastic washers (5) and 5/16-18 retaining nuts (6).

Note: Early production operator’s cabs included a threaded hole for tether mounting. In Fig. 4–9, items 13 through 16 are

not

used on early production cabs.

Standard

seat

Figure 4–7. Seat styles include standard and optional.

Optional

seats

MS0890

The seat assembly consists of upper (backrest) and lower (bottom) cushions mounted on an adjustable suspension unit (Fig. 4–8). Three seat adjustments can be made: fore and aft position, suspension stiffness and backrest angle. Seat adjustment information is contained in the owners/operators manual.

Backrest angle adjustment lever

Suspension

adjustment

knob

Fore & aft

adjustment

handle

Figure 4–8. Seat positions and stiffness can be adjusted.

Seat belt

OS0200

1. Remove the 3/8-16 hex-lock elastic nuts (16, Fig. 4–9) and rebound washers (15) securing the tethers (2) to the rear of the cab.

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

2. Access to the right-side tether is restricted due to the close proximity of the seat to the cab wall. Move the seat all the way forward, and tip the seat back all the way forward to gain access as needed to the tether mounting hardware from inside the cab. If necessary, remove the seat base mounting hardware before removing the right-side tether.

Note: Early production operator’s cabs included a threaded hole for tether mounting. In Fig. 4–9, items 13 through 16 are

not

used on early production cabs.

3. Remove four 5/16-18 hex-lock elastic nuts (12, Fig. 4–9) and four 5/16 flat narrow washers securing the seat (1) to the seat support (9).

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

4. Carefully remove the seat (Fig. 4–9) from the cab. Remove the seat belt assembly and tethers (or transfer these parts to the replacement seat) with the seat out of the cab.

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4-9

Section 4

Standard

10 11

seat

Optional seats

11 12

Figure 4–9. Standard (left) and optional (right) seats.

Standard Operator’s Seat Parts Legend

1. Seat

2. Tether

3. Spacer

4. Retractabl e seat bel t asse mb ly (in clude s items 5 through 8)

5. Washer

6. Hex-head capscrew

7. Hex-head capscrew

8. Hex nut

9. Seat support

10. Hex-head capscrew, 5/16-18 x 1", Grade 5

11. Narrow flat washer, 5/16"

12. Hex-lock elastic nut, 5/16-18

13. Hex jam nut, 3/8-16

14. Flat washer, 3/8"

15. Rebound washer

16. Hex-lock elastic nut, 3/8-16

MS0900

Optional Operator’s Seat Parts Legend

1. Deluxe seat (covered with CLOTH or VINYL), with suspension

2. Tether

3. Spacer

4. Retractable seat belt a ss em bly (includes items 5 th rough 8)

5. Hex nut

6. Hex-head capscrew

7. Flat washer

8. Hex-head capscrew, 5/16-18 x 1", Grade 5

9. Narrow flat washer, 5/16"

10. Hex-lock elastic nut, 5/16-18

11. Hex jam nut, 3/8-16

12. Flat washer, 3/8"

13. Rebound washer

14. Hex-lock elastic nut, 3/8-16

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Standard Seat Installation

1. Install the seat belt assembly (4, Fig. 4–9) and tethers (2) on the seat with the seat out of the cab.

2. Within the cab, access to the right-side tether (Fig. 4–10) is restricted due to the closeness of the seat to the cab wall. Move the seat all the way forward, and tip the seat back all the way forward to gain access as needed to the tether mounting hardware from inside the cab. If necessary, install the right-side tether before securing the seat base mounting hardware.

Note: Early production cabs included a threaded hole for tether mounting. In Fig. 4–9, items 13 through 16 are

not

used on early production cabs.

Cab

Hex-lock elastic nut

Rebound washer

Tether

Right-side

seat belt

hardware

MS0910

Figure 4–10. Typical late-model seatbelt tether attachment.

3. Position the seat on the seat support (9, Fig. 4–9). Align the seat bracket mounting holes with the holes in the seat support. Secure the seat to the seat support with four 5/16-18 hex-lock elastic nuts (12) and four 5/16 flat narrow washers securing the seat (1) to the seat support (9). T orque to 18 lb/ft (24 Nm).

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

4. Working at the outside rear of the cab with the rear cab panel removed (refer to the

General Overview

illustration on page three), secure the tethers (2, Fig. 4–9) to the cab with 3/8-16 hex-lock elastic nuts (16) and rebound washers (15).

Note: Early production cabs included a threaded hole for tether mounting. In Fig. 4–9, items 13 through 16 are

not

used on early production cabs. Note: ALWAYS replace elastic-lined nuts with new

elastic-lined nuts to help ensure proper fastening.

5. Attach the rear cab panel (refer to the

Overview

illustration) to the cab with 5/16-18 button-

General

head capscrews, 5/16 plastic washers and 5/16-18 retaining nuts.

Optional Seat Removal

1. Working from the outside rear of the cab, remove the rear cab panel (refer to the

General Overview

illustration on page three) to gain access to the seat tether mounting hardware. The rear cab panel is secured to the cab with 5/16-18 button-head capscrews, 5/16 plastic washers and 5/16-18 retaining nuts.

Note: Early production cabs included a threaded hole for tether mounting. In Fig. 4–9, items 11 through 14 are used on early production cabs.

2. Remove the 3/8-16 hex-lock elastic nuts (optional seat item 14, Fig. 4–9) and rebound washers (13) securing the tethers (2) to the rear of the cab.

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

3. Access to the right-side tether (Fig. 4–10) is restricted due to the close proximity of the seat to the cab wall. Move the seat all the way forward, and tip the seat back all the way forward to gain access as needed to the tether mounting hardware from inside the cab. If necessary, remove seat base mounting hardware before removing the right-side tether.

4. Remove four 5/16-18 hex-lock elastic nuts (10, Fig. 4–9), eight 5/16 flat narrow washers (9), and four 5/16-18 x 1" Grade 5 hex-head capscrews (8) securing the seat (1) to the cab seat platform.

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

5. Remove the seat from the cab. Remov e the seat belt assembly and tethers (or transfer these parts to the replacement seat) with the seat out of the cab.

Optional Seat Installation

1. Install the seat belt assembly (4, Fig. 4–9) and tethers (2) on the replacement seat with the seat out of the cab.

2. Access to the right-side tether (Fig. 4–10) is restricted due to the closeness of the seat to the cab wall. Move the seat assembly all the way forward, and tip the seat backrest all the way forw ard to gain access as needed to the tether mounting hardware from inside the cab. If necessary, install the right-side tether before securing the seat base mounting hardware.

not

Model 3606 • Origin 10/99

4-11

Section 4

Note: Early production cabs included a threaded hole for

tether mounting. In Fig. 4–9, items 11 through 14 are

not

used on early production cabs.

3. Position the seat on the seat base. Align the seat bracket mounting holes with the holes in the cab seat platform. Secure the seat to the seat base with four 5/16-18 hex-lock elastic nuts (10, Fig. 4–9), eight 5/16 flat narrow washers (9), and four 5/16-18 x 1" Grade 5 hex-head capscrews (8) securing the seat (1) to the seat support. Torque to 18 lb/ft (24 Nm).

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

4. Working from the outside rear of the cab with the rear cab panel removed (refer to the

General Overview

illustration on page three), secure the tethers (2, Fig. 4–9) to the rear of the cab with rebound washers (13) and 3/8-16 hex-lock elastic nuts (14).

Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening.

5. Attach the rear cab panel (refer to the

Overview

illustration on page 4-3) to the cab with

General

5/16-18 button-head capscrews, 5/16 plastic washers and 5/16-18 retaining nuts.

4.2.4 Controls

Operator’s cab controls (Fig. 4–11) include the steering wheel, horn button, ignition switch, transmission shifter, service brake pedal, throttle pedal and joystick.

Steering

Transmission shifter

Ignition

switch

Service brake

pedal

Figure 4–11. Operator’s cab controls.

wheel

Throttle

pedal

Horn

button

Joystick

OS0091

Figure 4–12. Steering column, steering wheel and shifter.

Service brake pedal

Power steering valve

Steering Column Parts Legend

1. Horn button cover

2. Thin nut, M18-1,5

3. Steering wheel

4. Hex socket-head screw, #10-32 x 1-1/2"

5. Steering column bottom cover

6. Steering column

7. Lock washer, #10

8. Hex nut, #10-32

9. Transmission shift control switch

10. Transmission shifter spacer

11. Lock washer, 3/8"

12. Hex socket-head screw, 3/8-16 x 1"

13. J-nut, #10-24

14. Button-head screw, #10-24 x 5/8"

15. Steering column top cover

Horn switch lead

PS0540

4.2.5 Steering Wheel, Column and Shifter

The steering wheel and transmission shift control switch are components of the steering column (Fig. 4–11).

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Model 3606 • Origin 10/99

Cab, Covers and Mirrors

Steering Wheel Removal

1. Carefully pry the horn cover button out of its recess in the steering wheel. Disconnect the horn wire lead.

2. Remove the thin M18-1,5 nut securing the steering wheel to the splined steering column shaft.

3. Use a steering wheel puller to remove the steering wheel from the splined shaft.

Steering Wheel Installation

1. Install the steering wheel (Fig. 4–12) onto the splined steering colum n shaf t.

2. Secure the steering wheel with a thin M18-1,5 nut. Torque the nut to 50 lb/ft (68 Nm).

3. Connect the horn wire lead, then press the horn cover button into its recess in the steering wheel.

Transmission Shift Control Switch Removal

1. Remove four #10-24 x 5/8" button head screws (item 14, Fig. 4–11) and four #10-24 J-nuts (13) securing the steering column bottom (5) and top (15) covers onto the steering column (6).

2. Remove the two #10-32 x 1-1/2" hex socket-head screws (item 4, Fig. 4–12), #10-32 hex nuts (8) and #10 lock washers (7) securing the transmission shift control switch (9) to the steering column (6).

3. Disconnect the electrical connector and remove the transmission shift control switch (9).

Transmission Shift Control Switch Installation

1. Position the transmission shift control switch (item 9, Fig. 4–12) onto the steering column (6).

2. Plug the electric al conne cto r in to its harness lead.

3. Attach the transmission shift control switch with two #10-32 x 1-1/2" hex socket-head screws (4), #10-32 hex nuts (8) and #10 lock washers (7). Tighten the screws and nuts securely but DO NOT overtighten. Overtightening will cause the shift control switch to break.

4. Install the steering column bottom (5) and top (15) covers onto the steering column. Secure with four #10-24 x 5/8" button-head screws (14) and #10-24 J-nuts (13). DO NOT overtighten.

Steering Column Removal

3. Remove the four 3/8-16 x 1" hex socket-head screws (12) and 3/8 lock washers (11) securing the steering column (6) to the steering valve.

4. Remove the steering column from the cab.

Steering Column Instal la tio n

1. Position the steering column (item 6, Fig. 4–12) within the cab and engage the splined lower end of the steering shaft with the power steering valve. Press the steering column shaft down into the power steering valve. Fully engage the splines.

2. Align the four steering column mounting holes with the dash panel and power steering valve mounting holes. Secure the steering column with four 3/8-16 x 1" hex socket-head screws (12) and 3/8 lock washers (11). Torque to 31 lb/ft (42 Nm).

3. Connect the transmission shift switch (9) and horn switch leads to the wiring harness.

4. Install the steering column bottom (5) and top (15) covers onto the steering column. Secure with four #10-24 x 5/8" button-head screws (14) and #10-24 J-nuts (13).

4.2.6 Joystick Replacement

A. Joystick Handle Replacement

Joystick Handle Removal

1. Remove the rubber boot (Fig. 4–13) from the joystick. Slide the boot up and over the joystick to reveal wiring, a threaded shaft and mounting nut (jam nut).

2. Disconnect the wiring and loosen the upper jam nut securing the joystick to its base. Remove the joystick.

Joystick handle (boot removed)

Mounting nut (jam nut)

1/4-20 x 1"

capscrew Joystick assembly

Front dash

(ref.)

1/4" lockwasher

Joystick

Rubber boot

1. Remove four #10-24 x 5/8" button-head screws (14) and #10-24 J-nuts (13) securing the steering column bottom (5) and top (15) covers onto the steering column.

2. Disconnect the transmission shift switch (9) and horn switch leads from the wiring harness.

Model 3606 • Origin 10/99

MS0920

Figure 4–13. Joystick mounting arrangement.

4-13

Section 4

Joystick Handle Installation

1. Apply Loctite

#272 (red) to the threaded stud on the joystick handle. Position the joystick mounting stud into the base mounting hole and turn the handle to thread it into the base. Align the joystick in the forward position.

2. Secure the joystick by tightening the mounting nut (jam nut) at the threaded end of the joystick onto the threaded shaft in the joystick assembly base.

3. Connect the joystick wire lead to the logic board plug and install the rubber boot over the joystick.

4. Check for proper operation of all joystick functions.

B. Joystick Assembly Replacement

Joystick Assembly Removal

1. Park the vehicle on a firm, level surface. Set the park brake, ground the carriage, place the transmission in NEUTRAL (N) and turn the ignition OFF.

2. Remove the boot from the joystick by pulling the boot off the base (Fig. 4–14).

IMPORTANT: Before proceeding, determine which type of joystick mounting fasteners are used. Reach into the logic panel opening and back toward the joystick. From inside the console, feel along the front lower edge of the joystick base to determine whether "long" internallythreaded hex nuts are installed, or if nutserts are used. If long hex nuts are used, go to step 5 and follow the steps for go to step 4 and follow the steps for

Vehicles

Early Production Vehicles

Current Production Vehicles

. If nutserts are used,

Current Production

Remove the three flange-head capscrews and lockw ashers securing the joystick assembly to its mounting hole in the side console (Fig. 4–16). Save the three flange-head capscrews and lockwashers for reuse later.

Joystick

GO TO STEP 11.

Flange-head Capscrew

Lockwasher

Joystick

Boot

Base

SS1190

Figure 4–14. Remove the boot from the joystick.

3. Remove the four button-head capscrews holding the logic panel to the side console (Fig. 4–15). Carefully pry the logic console upward. Label, then disconnect the wiring harness leads at the logic panel. Remove the logic panel from the vehicle.

Button-head Capscrew

Logic Panel

SS1210

Figure 4–15. Remove the four button-head capscrews.

Figure 4–16. For

the flange-head capscrews and lockwashers securing

the joystick assembly to the console.

Early Production Vehicles

Current Production Vehicles,

remove

Pry the entire switch bezel out and away from the side console (Fig. 4–17). Label, then disconnect the wiring harness leads at the switches. Remove the switch bezel from the vehicle.

Switch Bezel

Side Console

Figure 4–17. For

remove the switch bezel from the vehicle.

Early Production Vehicles,

SS1200

SS1220

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Model 3606 • Origin 10/99

SkyTrak 3606 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

Section Cont ents