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 techni- individual doing the work, for the safety of the operator,
cian with complete information on the maintenance and and for the safe, reliable operation of the vehicle. All
repair of the Sky Trak International SKY TRAK Model references to the right side, left side, front, and rear are
3606 rough-terrain material handler. given from the perspective of the operator's position,
Particular effort has been made to produce a manual to facing forward (see figure below).
serve as a reference handbook for the experienced The Section Contents allows the user to quickly locate
service technician, but also provide essential step-by- any desired section. Each section begins with its own
step procedures for the professional development of table of contents, and, where applicable, an informative
the less experienced person. Remember that even the introduction and exploded-view illustration appears, to
best manual in the world is no substitute for an appro- show the location of major section components.
priate education, skill development that comes through Provision for supplementary information is made by
experience alone, safety, wise and judicious discern- Trak International in the form of Service Bulletins,
ment, and, ultimately, proper performance of service Service Campaigns, Service Training Schools, the
procedures. OmniQuip web site, other literature, and through
There are many variations in service environments and updates to the manual itself. Comments and sugges-
skill levels of repair technicians, as well as procedures, tions for improvement are welcomed and encouraged.
techniques, tools, and service parts. A service manual All information, illustrations and specifications con-
cannot possibly anticipate all such variations and tained in this manual are based on the latest product
provide advice or cautions for each one. Accordingly, information available at the time of publication
any departure from the instructions in this manual must approval. Trak reserves the right to make changes and
take into consideration both personal safety as well as improvements to its products, and to discontinue the
vehicle integrity. manufacture of any product, at its discretion at any time
This service manual provides general directions for without public notice or obligation. When additional
accomplishing service and repair procedures with information is desired to satisfy a situation not covered
tested, effective techniques. Following the procedures sufficiently, consult the nearest Sky Trak International
in this manual will help assure safety and equipment distributor, or the Sky Trak International Service
reliability. Appropriate service methods and proper Department at 1-414-268-8959.
repair procedures are essential for the safety of the

FRONT

TOP

LEFT RIGHT

FRONT REAR

BOTTOM

MS2240
REAR
All references to direction are as viewed from the operator’s position, facing forward.

© 1999 Sky Trak International

Model 3606 • Origin 10/99 i

 Section Contents

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

ii 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 SPECIFICATIONSAND 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

iv 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 WITHOUT CLOSED CAB

Sky Trak International (hereafter, Sky Trak) products
meet all applicable industry safety standards. Sky Trak
actively promotes safe practices in the use and mainte-
nance of its products through training programs, instruc-
tional manuals, and the pro-active efforts of all
employees involved in engineering, design, manufacture, Seat Base (ref.)
marketing and service.
Many factors contribute to unsafe conditions: carelessness,
fatigue, overload, inattentiveness, unfamiliarity, even Owners/Operators
drugs and alcohol, among others. Although equipment Manual Holder
damage can usually be repaired in a brief period of time, MS2630
death and irreparable injury are permanent. For optimal FRONT
safety, encourage everyone to think, and to act, safely. Figure 1–1. The Owners/Operators Manual holder is
located beneath the seat (without closed cab option).
Read, understand and follow the information in this man-
ual, and obey all locally-approved safety practices, proce-
WITH CLOSED CAB
dures, rules, codes, regulations and laws. Prior to
performing any maintenance on the vehicle, consider all FRONT
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 Seat Base
involved. (ref.)
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. Owners/Operators MS2620

Manual Holder
1.2 OWNERS/OPERATORS MANUAL Figure 1–2. The Owners/Operators Manual holder is
The vehicle must be driven and operated as a consequence located at the left side of the seat base (closed cab option).
of, or when performing, service, maintenance and test pro-
cedures. The service technician must, therefore, thor- 1.3 SAFETY INFORMATION
oughly read, understand, and follow the Sky Trak 3606 The following information provides general safety instruc-
Owners/Operators Manual. tions, including signal words, hazard statement definitions,
An owners/operators manual is supplied with each vehicle notification of hazards, methods to help avoid hazards,
and must be kept in the holder or storage compartment and the consequences of failing to follow the safety
located to the left and below the operators seat (for vehi- information. For safe maintenance of the vehicle, read,
cles without the closed cab option, see Fig. 1–1; for vehi- understand and follow all DANGER, WARNING, and
cles with the closed cab option, see Fig. 1–2). CAUTION information.
In the event that the owners/operators manual is missing, The information in this manual does not replace any
consult the local Sky Trak distributor or the Sky Trak Ser- other safety rules or proper judgment. Governmental
vice Department before proceeding. 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 require-
ments in effect before operating, maintaining, servicing
or testing the vehicle. Safety depends on following safety
requirements.

1-2 Model 3606 • Origin 10/99

 Safety

1.3.1 Safety Alert Symbol 1.4 ACCIDENT PREVENTION TAGS

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 causes of death or injury. OS2180

Also, know where to obtain medical assistance, how to Figure 1–3. Accident Prevention Tag.
use a first-aid kit and fire extinguisher/fire suppression
system. Keep emergency telephone numbers (fire and Before beginning any maintenance or service, place an
police departments, ambulance, rescue squad or para- Accident Prevention Tag on both the ignition switch and
medics, etc.) nearby. If working alone, routinely check the steering wheel (Fig. 1–4), stating that the vehicle
with another person to help assure personal safety. should not be operated. Copies of Accident Prevention
Tags are provided on pages 1-9 and 1-10.
1.3.2 Signal Words
Three types of hazard statements are used in this man-
ual. Each signal word indicates the existence and degree
of relative risk of the hazard described within the state-
ment that follows the signal word. The three types of haz-
ard statements use the following signal words:
DANGER
DANGER: DANGER

DANG
ER

The signal word DANGER denotes an extremely hazard-

ous 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.
OS1520
WARNING
WARNING: Figure 1–4. Place Accident Prevention Tags on both
the ignition switch and the steering wheel.

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 CAUTION denotes a reminder of safety

practices or directs attention to unsafe practices on or
near the vehicle which could result in personal injury if
the proper precautions are not taken.

Model 3606 • Origin 10/99 1-3

 Section 1

1.5 SAFETY INSTRUCTIONS DO NOT use a hoist, jack, or jack stands only to support
equipment. Always support equipment with proper-
Following are general safety statements to consider capacity blocks or approved stands. Hoist or jack failure
before performing maintenance procedures on the can allow the equipment to tip or to fall.
vehicle. Additional statements related to specific tasks
and procedures are located throughout this manual and COMPRESSED AIR: Before and during the use of com-
are listed prior to any work instructions to provide safety pressed air, wear eye protection and advise other per-
information before the hazard occurs. sonnel in the work area that compressed air is about to
For all safety messages, carefully read, understand and be used.
follow the instructions before proceeding. HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
1.5.1 Personal Hazards special service tools only as recommended.
HAIR and CLOTHING: DO NOT wear loose clothing or
jewelry. Tie up or restrain hair. Wear the correct safety 1.5.3 General Hazards
equipment for the job (including but not limited to: hard SOLVENTS: Only use approved solvents, and solvents
hat; safety shoes; safety glasses, goggles, or face shield; that are known to be safe for use.
heavy gloves; hearing protection; reflective clothing; wet-
weather gear; respirator or filter mask). HOUSEKEEPING: Keep the work area and operator’s
cab clean and remove all hazards (debris, oil, tools, etc.).
EYE PROTECTION: Always wear appropriate eye pro-
tection when chiseling, grinding, sanding, welding, paint- FIRST AID: Immediately clean, dress, and report all inju-
ing, repairing hydraulic systems, or checking, testing or ries resulting in bleeding or opened skin (cuts, abrasions,
charging the battery. burns, etc.), no matter how minor. Know where the First
Aid Kit is, and how to use it.
BREATHING PROTECTION: Wear respiratory protection
when grinding or painting. CLEANLINESS: Wear eye protection, and clean all com-
ponents with a high-pressure or steam cleaner before
HEARING PROTECTION: Always wear hearing protection attempting service.
in a high-noise area.
When removing hydraulic components, plug hose ends
FOOT PROTECTION: Wear protective footwear with and connections to prevent excess leakage and contami-
reinforced toe caps and slip-resistant soles. nation. Place a suitable catch basin beneath the vehicle
LIFTING: NEVER lift a heavy object without the help of at to capture fluid run-off.
least one assistant or a suitable sling and hoist.
1.5.4 Operational Hazards
1.5.2 Equipment Hazards OPERATIONAL CONSIDERATIONS: Before operating
the vehicle, carefully read, understand and follow the
OWNERS/OPERATORS MANUAL: Before operating the
owners/operators manual.
vehicle, carefully read, understand and follow the Owners/
Operators manual. ENGINE: Stop the engine before performing any service.
OPERATIONAL PROTECTION: Before operating the DANGEROUS START: Place a warning sign on vehicles
vehicle or returning it for operational use, check that the that are dangerous to start. Disconnect battery leads if
cab and all roll-over protection systems and falling-object leaving the vehicle unattended. Place Accident Prevention
protection systems (ROPS/FOPS) are intact, undamaged Tags on the steering wheel and ignition key switch before
and secure. Replace any component as required. attempting to perform any service or maintenance.
LIFTING OF EQUIPMENT: Before using any lifting VENTILATION: Avoid prolonged engine operation in
equipment (chains, slings, brackets, hooks, etc.), verify enclosed areas with inadequate ventilation.
that it is of the proper capacity, in good working condition,
and properly attached. RADIATOR CAP: Always wear steam-resistant, heat-
protective gloves when opening the radiator cap. Cover
NEVER stand or otherwise become positioned under a cap with a clean, thick cloth and turn slowly to the first
suspended load or under raised equipment. The load or stop to relieve pressure.
equipment could fall or tip.

1-4 Model 3606 • Origin 10/99

 Safety

SOFT SURFACES AND SLOPES: NEVER work on a 1.6 SAFETY DECALS

vehicle parked on soft surfaces or slopes (inclined ground
or hills). Vehicle must be on hard, level surface with Locations of vehicle safety and other decals are shown
wheels blocked when necessary before performing any on the following pages. As part of routine maintenance,
service. Obtain assistance, block all wheels, and add check that ALL safety and informational decals on the
supports if necessary before beginning any work. vehicle are present and readable. Keep the safety decals
clean. If a replacement decal is needed, refer to the
SUPPORTS AND STRAPS: Install safe, stable supports, owners/operators manual and parts catalog for the latest
slings or straps beneath or around a component or struc- parts numbers and ordering information. Or, contact
tural member before beginning any work. OmniQuip Parts Worldwide directly at:
FLUID PRESSURE: Before loosening any hydraulic or
diesel component, hoses or tubes, turn engine OFF. Wear
1-888-872-5123
heavy, protective gloves and eye protection. NEVER
check for leaks using any part of your body; use a piece
of cardboard or wood instead. If injured, 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, gan-
grene, and other serious personal injury. Relieve all pres-
sure before disconnecting any component, part, line or
hose. Slowly loosen parts and allow release of residual
pressure before removing any part or component. Before
starting engine or applying pressure, use components,
parts, hoses and pipes that are in good condition, con-
nected and tightened to the proper torque. Capture fluid
in an appropriate container and dispose of in accordance
with prevailing environmental regulations.

PRESSURE TESTING: When conducting any test, only

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

LEAVING VEHICLE: Lower the attachment to the ground

before leaving the vehicle.

TIRE PRESSURE: Always keep tires inflated to the

proper pressure to help prevent dangerous travel and
load-handling situations. DO NOT over-inflate tires.

Model 3606 • Origin 10/99 1-5

 Section 1

Safety Decal List – Earlier Models

1. No Riders WARNING 7. Safety Instructions
2. Vehicle Rollaway WARNING 8. Moving Parts WARNING
3. Electrocution DANGER 9. Explosive Gases WARNING
4. Load Chart Booklet 10. Carrying Personnel WARNING
5. Tipover DANGER – Operating 11. Boom Extend Stripes
6. Tipover DANGER – Tire Pressure 12. Boom Angle Indicator

DANGER DANGER
LOW TIRE
CONTACTING
ELECTRIC
POWER LINES
NEVER operate
vehicle within
10 feet (3m) of
3 6 PRESSURE
can result
MAINTAIN
proper tire
in tipover. pressure at
can result in electric power all times.
electrocution. lines.

9
2 5

11 12

SAFETY INSTRUCTIONS
1. Read operator’s manual
3. Allow no riders.
10
1 before operating.
7
4. Use an approved work
2. Fasten seat belt. platform to lift or lower
personnel.

OS1511
OS1256

Note: Many of these hazard related decals are available free of charge by calling
OmniQuip Parts Worldwide at 1-888-872-5123.

1-6 Model 3606 • Origin 10/99

 Safety

Safety Decal List – Later Models

1. No Riders WARNING 7. Safety Instructions
2. Vehicle Rollaway WARNING 8. Moving Parts WARNING
3. Electrocution DANGER 9. Explosive Gases WARNING
4. Load Chart Booklet 10. Carrying Personnel WARNING
5. Tipover DANGER – Operating 11. Boom Extend Stripes
6. Tipover DANGER – Tire Pressure 12. Boom Angle Indicator

DANGER DANGER
NEVER operate VEHICLE DO NOT DO NOT raise
CONTACTING
ELECTRIC
POWER LINES
vehicle within
10 feet (3m) of
TIPOVER
can result
travel
with the
boom while
on a slope
5
can result in electric power in death or boom unless load
electrocution. lines.
serious injury. raised. is level.

9
DANGER SAFETY INSTRUCTIONS
1. Read operator’s manual
3. Allow no riders.
6 before operating.
7
MAINTAIN
proper tire 4. Use an approved work
LOW TIRE PRESSURE pressure at 2. Fasten seat belt. platform to lift or lower
can result in tipover. all times. personnel.

WARNING 4
VEHICLE ALWAYS
ROLLAWAY engage
can cause parking
death or brake
serious before
injury. dismounting.

WARNING 11 12

1 10
Allow no riders.
OS1241

OS1255

Note: Many of these hazard related decals are available free of charge by calling
OmniQuip Parts Worldwide at 1-888-872-5123.

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

OS2180

1-10 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 2.3.2 Straight Thread O-ring Fitting

WARRANTY INFORMATION (non-adjustable)
The replacement of any part with any other than a Sky When the vehicle leaves the factory, it is equipped only
Trak authorized replacement part can adversely affect with straight thread O-ring fittings. Customer-added
the safety, performance, or durability of the vehicle, and accessories may differ; therefore, consult the manufac-
may void the warranty. Sky Trak International assumes turer's product literature for information.
no liability whatsoever for unauthorized replacement 1. Verify that both threads and sealing surfaces are free
parts. of burrs, nicks, scratches, and any foreign material.
A warranty registration form must be filled out by the Sky 2. Lubricate the new O-ring with a light coating of
Trak distributor, signed by the purchaser, and returned to hydraulic oil.
Sky Trak when the vehicle is sold and/or put into use. 3. Tighten fitting to the proper torque according to the
Registration activates the warranty period and helps to following chart:
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the distributor SAE Torque
has returned the business reply card of the warranty reg- Size lb/ft Nm
istration form to Sky Trak.
4 22-26 30-35
6 46-54 62-73
2.2 SERIAL NUMBER LOCATIONS
8 95-105 129-142
When ordering replacement parts or making service
10 125-135 170-183
inquiries about the vehicle, various serial numbers are
required to help assure the provision of 12 165-175 224-237
correct parts and information. Before ordering parts or 16 245-255 332-346
initiating service inquiries, make note of the pertinent 20 270-290 366-393
serial numbers.
24 365-385 495-522
2.3 TORQUE VALUES
2.3.3 Straight Thread O-ring Fitting
(adjustable)
2.3.1 Fastener Rating
When the vehicle leaves the factory, it is equipped only
All fasteners (nuts, bolts, washers, etc.) are equal to SAE
with straight thread O-ring fittings. Customer-added
Grade 5 (PC8.8) and are plated, unless otherwise specified.
accessories may differ; therefore, consult the manufac-
Unless otherwise specified, the following values apply for turer's product literature for information.
Grade 5 (PC8.8) nuts and bolts:
1. Verify that both mating parts are free of burrs, nicks,
Size Torque Size Torque scratches, and any foreign material.
Inch lb/ft Nm mm Nm lb/ft 2. Lubricate the new O-ring with a light coat of hydraulic
1/4 9 12 6.0 10 7 oil.
5/16 18 24 8.0 25 18 3. Back off the locknut as far as possible.
3/8 31 42 10.0 50 37 4. Screw the fitting into the port by hand until the
7/16 50 68 -- -- -- backup washer contacts the face of the port and is
pushed all the way towards the locknut.
1/2 75 102 12.0 80 59
5. To position the fitting, unscrew by the required
9/16 110 150 14.0 130 95
amount, but not more than one full turn.
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

Model 3606 • Origin 10/99 2-3

 Section 2

6. Hold the fitting in the desired position and tighten to Acres 0.4 Hectares (ha)
the proper torque according to the following chart:
MASS (weight)
Adjustable Straight-thread O-ring Fitting Torque Chart
Ounces (oz) 28 Grams (g)
SAE Torque Pounds (lb) 0.4536 Kilograms (kg)
Size lb/ft Nm Short tons (2000 lb) 0.9 Metric ton (t)
4 14.5-17.5 20-24
VOLUME
6 37-43 50-58
Teaspoons (tsp) 5 Milliliters (ml)
8 75-85 102-115
Tablespoons (Tbsp) 15 Milliliters (ml)
10 115-125 156-170
Cubic inches (in3) 16 Milliliters (ml)
12 155-165 210-224
Fluid ounces (fl oz) 30 Milliliters (ml)
16 225-235 305-319
Cups (c) 0.24 Liters (l)
20 260-280 353-380
Pints (pt) 0.47 Liters (l)
24 340-360 461-488
Quarts (qt) 0.95 Liters (l)
2.3.4 Metric Conversion Factors Gallons (gal) 3.8 Liters (l)
3
Cubic feet (ft ) 0.03 Cubic meters (m3)
A. Approximate American to Metric Conversions Cubic yards (yd3) 0.76 Cubic meters (m3)
When this is known Multiply by - - -To Find AIR PRESSURE

TORQUE (moment of force) Pounds per square 6.895 Kilopascals (kPa)

inch (psi)
Pound/feet (lb/ft) 1.356 Newton meters (Nm)
HYDRAULIC PRESSURE
Pound/inches (lb/in) 0.113 Newton meters (Nm)
Pounds per square 0.069 Bars
POWER
inch (psi)
Horsepower (hp) 745.7 Watts
TEMPERATURE (exact)
SPEED (velocity) To determine degrees Celsius (°C), subtract 32, then
Miles per hour 1.609 Kilometers per hour multiply by 0.56; (°F - 32) x 0.56 = °C.
(mph) (km/hr; kph)
FUEL CONSUMPTION B. Approximate Metric to American Conversions
Miles per gallon, 0.425 Kilometers per liter (km/l) When this is known Multiply by - - -To Find
US (mpg)
TORQUE (moment of force)
[Miles per gallon values are commonly converted to
liters/100 kilometers; mpg (Imperial x l/100 km = 282; Newton meters (Nm) 0,738 Pounds/feet (lb/ft)
US mpg x l/100 m = 235)] Newton meters (Nm) 8,85 Pounds/inches (lb/in)
LENGTH (distance) POWER
Inches (in) 25.4 Millimeters (mm) Watts 0,0013 Horsepower (hp)
Inches (in) 2.5 Centimeters (cm) SPEED (velocity)
Feet (ft) 30.5 Centimeters (cm) Kilometers per hour 0,621 Miles per hour (mph)
Feet (ft) 0.305 Meters (m) (km/hr; kph)
Yards (yd) 0.9 Meters (m) FUEL CONSUMPTION
Miles (mi) 1.6 Kilometers (km) Kilometers per liter 2,352 Miles per gallon, US (mpg)
AREA (km/l)
Square inches (in2) 6.5 Square centimeters (cm2) [Miles per gallon values are commonly converted to liters/
100 kilometers; mpg (Imperial x l/100 km = 282;
Square feet (ft2) 0.09 Square meters (m2)
US mpg z l/100 km = 235)]
Square yards (yd2) 0.8 Square meters (m2)
Square miles (mi2) 2.6 Square kilometers (km2)

2-4 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

LENGTH (distance)
Millimeters (mm) 0,0394 Inches (in)
Centimeters (cm) 0,394 Inches (in)
Meters (m) 3,281 Feet (ft)
Meters (m) 1,1 Yards (yd)
Kilometers (km) 0,621 Miles (mi)
AREA
Square centimeters 0,4 Square inches (in2)
(cm2)
Square meters (m2) 1,1 Square yards (yd2)
Square kilometers 0,6 Square miles (mi2)
(km2)
Hectares (10000 m2) 2,5 Acres
MASS (weight)
Grams (g) 0,035 Ounces (oz)
Kilograms (kg) 2,2 Pounds (lb)
Metric ton (1000 kg) 1,1 Short tons
(t)
VOLUME
Milliliters (ml) 0,03 Fluid ounces (fl oz)
Milliliters (ml) 0,06 Cubic inches (in3)
Liters (l) 2,1 Pints (pt)
Liters (l) 1,06 Quarts (qt)
Liters (l) 0,26 Gallons (gal)
3
Cubic meters (m ) 35 Cubic feet (ft3)
Cubic meters (m3) 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 determine degrees Fahrenheit (°F), multiply degrees
Celsius (°C) by 1.8, then add 32; (°C x 1.8) + 32 = °F.

Model 3606 • Origin 10/99 2-5

 Section 2

2.4 SPECIFICATIONS V

2.4.1 Vehicle Dimensions (Fig. 2-1)

M
With Standard 12-ply 13.00-24 Tires I

Ref. Description
A. Length W

(without attachment) 221.0" (5613 mm)

B. Width 98.0" (2489 mm)
C. Height (boom lowered) 91.75" (2330 mm)
D. Wheelbase 122.0" (3099 mm)
E. Tread 84.0" (2134 mm) P

F. Ground Clearance 17.0" (432 mm) J

N
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) 0.0

J. Maximum lift height, Q C

boom retracted 18' 6" (5638,8 mm) T
R S
0.0 F
K. Maximum below grade depth,
boom extended 2' 5" (736,6 mm) K O U D

L. Maximum reach, L A
from front of front tires 24' 8" (7518,4 mm)
M. Maximum reach at maximum lift angle, B E
boom extended 67.2" (1707 mm) G

N. Maximum reach at maximum lift angle, MS2110

boom retracted -26.2" (-665,48 mm) Figure 2–1. Vehicle dimensions with standard tires.
O. Maximum reach at minimum lift angle,
boom extended 24' 2" (7366 mm) 2.4.2 Performance Specifications
P. Maximum boom lift angle 68° Performance criteria is based on full throttle engine
speed unless otherwise specified or not applicable:
Q. Minimum boom lift angle -3.8°
R. Angle of approach N/A A. Travel Speed (standard tires, no load)
S. Angle of departure 33° 4-SPEED 3-SPEED
First gear 4.3 mph 4.2 mph
Fork tilt angle: (6,9 km/hr) (6,8 km/hr)

T. At minimum boom angle up 8.1° Second gear 9.1 mph 9.2 mph
(14,6 km/hr) (14,8 km/hr)
U. At minimum boom angle down -108.3°
Third gear 15.3 mph 17.7 mph
V. At maximum boom angle up 80.8° (24,6 km/hr) (28,5 km/hr)
W. At maximum boom angle down -21.8° Fourth gear 20.8 mph N/A
(33,5 km/hr)

Frame tilt angle (not shown): B. Braking Distance (standard tires, no load)
Right 10.0° 4-SPEED 3-SPEED
Left 10.0° From road speed
to stop 29.0 ft (8,8 m) 21.4 ft (6,5 m)

2-6 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

C. Cylinder Times (with no load, at full throttle) F. Fuel Consumption

Function Approximate Times, in seconds Average, depending on load/duty:
Boom extend 12.00 2 gal/hr (1,67 Imp gal/hr, or 7,57 l/hr)

Boom retract 7.00 G. Steering Wheel

Boom lift retracted 12.75
Maximum number of turns, lock to lock
Boom lower retracted 10.75 3.80 turns
Fork tilt up 4.20 Minimum number of turns, lock to lock
Fork tilt down 3.75 3.20 turns
Frame tilt left to right
H. Breakout Force
with boom down 8.50
Frame tilt left to right with boom above 40° and emergency Utility bucket (calculated at -24° lip angle, max moment)
brake engaged 24.0 to 30.0 15,100 lb (6.855,4 kg).

Frame tilt right to left 2.4.3 Weights

with boom down 13.50
Frame tilt right to left with boom above 40° and emergency A. Basic Vehicle
brake engaged 24.0 to 30.0 Curb Weight 20,195 lbs (9.160 kg)

D. Draw Bar Pull Operating Load 6,600 lbs (3.000 kg)

Per SAE drawbar test, 200 ft (61 m) track
B. Working Weight
4-SPEED 3-SPEED Machine working weight is figured with 48" carriage, two
Peak drawbar 48" pallet forks, 25%-full fuel tank, and standard bias ply
in 1st gear tires (no hydrofill):
at converter stall Front Axle Rear Axle TOTAL
(no load) 15,000 lb 13,250 lb Open Cab 8,390 lb 12,540 lb 20,930 lb
(6.810,0 kg), slip (6.015,5 kg), no slip (3,8 kg) (5,6 kg) (950 kg)
Peak drawbar Closed Cab N/A N/A N/A
in 1st gear
at converter stall C. Attachments
(rated load) 16,750 lb 13,250 lb
(7.604,5 kg), no slip (6.015,5 kg), no slip Std 48" carriage with shaft ....................... 456 lb (205 kg)
Std 60" carriage with shaft .................... 526 lb (236,7 kg)
E. Engine Performance
Std 72" carriage with shaft .................... 677 lb (304,6 kg)
Low idle setting for all engines = 1050 +/- 50 RPM 48" side tilt carriage
with shaft and cylinder.............................. 640 lb (288 kg)
Displace- Horse- Peak
Engine Model
ment
High Idle
power Torque 60" side tilt carriage
with shaft and cylinder.............................. 700 lb (315 kg)
Perkins 1004.4T 243 CID 2600 +/- 108 HP @ 277 lb/ft
Turbo 100 2400 rpm @ 1600 72" side tilt carriage
rpm with shaft & cylinder .............................. 770 lb (346,5 kg)
Perkins 1004.42 258 CID 2600 +/- 86 HP 221 lb/ft 52" swing carriage
Natural/ 100 @ 2400 @ 1600
EPA rpm rpm with shaft & cylinders ............................ 950 lb (427,5 kg)
Cummins 4BT3.9 239 CID 2700 +/- 110 HP @ 293 lb/ft 72" swing carriage
Turbo 100 2500 rpm @ 1500 with shaft and cylinder...................... 1,135 lb (510,75 kg)
rpm
Bucket, 1.125 yd3 (0,855 m3) ................... 760 lb (342 kg)
Note: Engine manufacturer’s maximum “high idle” setting Broom, 8 foot (2,44 m) .......................... 1,100 lb (495 kg)
is lockwired and sealed. DO NOT disturb this setting. Pallet forks, 2.25 x 4 x 48 (5,7 x 10 x 122 cm),
quantity: 2 ............................................. 312 lb (140,4 kg)

Model 3606 • Origin 10/99 2-7

 Section 2

Block forks, 2 x 2 x 48 (5 x 5 x 122 cm) C. Tamper Proofing

quantity: 6................................................. 480 lb (216 kg)
A tamper-proof means is in place on the following adjust-
Lumber forks, 1.75 x 7 x 60 (4 x 17,8 152,4 cm) able components prior to machine shipment. This can
quantity: 2.............................................. 466 lb (209,7 kg) either be tamper-proof paint, or a steel tamper-proof cap.
Auger drive unit ..................................... 285 lb (128,2 kg) DO NOT attempt to defeat, by-pass or alter any tamper-
proof device.
Auger mounting frame................................ 180 lb (81 kg)
• Hoist cylinder counterbalance valves (1)
Auger (various sizes available)............................... Varies
• Main valve port relief valves (5)
Auger extension (various sizes available) .............. Varies
• Extend cylinder counterbalance valves (2)
2.4.4 Miscellaneous Specifications • Steering relief valve (1)
• Fork cylinder counterbalance valves (2)
A. Wheels and Tires
• Pilot relief valve (1)
Wheel lug nut torque ............................370 lb/ft (500 Nm)
• Main system relief valve (1)
Air Pressure • Park brake relief (1)
13.00-24, 12-ply (minimum) tires ........... 65 psi (448 kPa)
D. Fork Ratings
Tire Footprint Area All approved forks for this vehicle are marked with a
maximum load capacity rating. This rating is stamped on
(area is established under max tip load)
the left edge of the fork, just below the fork pivot shaft
13.00-24, 12-ply tires @ 65 psi (448 kPa), (Fig. 2–2). The rating is listed in U.S. pounds and based
Vehicle with no load: ............................ 140 in2 (910 cm2) upon a 24" (610 mm) load center.
13.00-24, 12-ply tires @ 65 psi (448 kPa), This rating specifies the maximum load capacity that the
Vehicle with rated load: ................... 165 in2 (1072,5 cm2) individual fork can safely carry at a maximum load center
of 24" (610 mm).
Maximum Ground Pressure Since forks are always used in multiples, the total rating
of any combination of forks is the sum of their rated
Vehicle with no load,
capacity.
13.00-24 12-ply tires @ 65 psi (448 kPa):
............................................................ 75 psi (516,6 kPa) Other than block forks, use all forks in matched pairs.
Use block forks in matched sets.
Vehicle with 6,600 lb (2.994 kg) load,
13.00-24 12-ply tires @ 65 psi (448 kPa):
............................................................ 85 psi (585,4 kPa)
Stamped
Note: Maximum ground pressure at tip = (machine Fork Rating
weight + load) / (foot print area x 2)
in. )
24 mm
1 0
B. Valve Relief Settings Load (6
4000 x 24

Center
Main system relief .............3,500 +/- 100 psi (241,5 Bars)
Port relief boom hoist ........3,700 +/- 100 psi (255,3 Bars)
4000 x 24

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/relieving valve,
stabilizer cylinder........................100 +/- 25 psi (6,9 Bars) OS0390

Power steering relief..........2,500 +/- 100 psi (172,5 Bars) Figure 2–2. The stamped fork rating specifies the
Park brake relief ......................... 550 +/- 50 psi (38 Bars) maximum load capacity that the individual fork can
safely carry at a maximum load center of 24" (610 mm).

2-8 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

2.5 FLUIDS, LUBRICANTS AND 2.5.2 Wheel Ends

CAPACITIES
A. Wheel-end Lubricants
2.5.1 Axles (Differential Housings) and In general, use gear oil with an API classification of GL-5
Transfer Case that meets the requirements of U.S. ordinance specifica-
tion MIL-L-2105 and MIL-L-2105D, respectively. The oil
A. Axle and Transfer Case Lubricants should be a 90W, a multi-grade 80W-90, or 80W-140 with
In general, use gear oil that meets the requirements of EP properties (80W-90 EP). Products known to meet
U.S. ordinance specification MIL-L-2105C with an API these requirements include:
classification of GL-5. The oil should be a multi-grade • BP TRANS GEAR 80W90
80W90 with EP properties. • CHEVRON ULTRA GEAR LUBE 80W90
Products known to meet these requirements include: • CITGO PREMIUM GEAR LUBE 80W90
• AMOCO GEAR LUBE 80W90 • MOBIL MOBILUBE HD 80W90
• ARCO HD 90W GEAR LUBE DO NOT add additional friction modifier to factory-filled
• BP TRANS GEAR 80W90 wheel ends. All wheel ends are factory-filled by the man-
• CATERPILLAR 80W90 EP GL-5 ufacturer with oil. If a wheel end is drained for service, it
should be refilled with the gear oils listed above.
• CHEVRON ULTRA GEAR LUBE 80W90
Note: DO NOT use synthetic oil without the express writ-
• CITGO PREMIUM GEAR LUBE 80W90
ten consent of the manufacturer.
• CONOCO UGL 80W90
• EXXON GEAR OIL GX80W90 B. Wheel-end Capacity
• FRANKLIN GEAREX AGMA 5 EP GEAR OIL Wheel end capacity.............. 1.4 qt (44.8 oz, or 1,324 ml)
• KENDALL NS-MP 80W90
2.5.3 Lubrication Points (grease fittings)
• MOBIL MOBILUBE HD 80W90
• MP GEAR LUBE GL-5 80W90 Lubricants
• PENNZOIL 409L 80W90 When lubricating any component via the grease fittings,
• QUAKER STATE HIGH PERFORMANCE 80W90 use multi-purpose lithium-based grease with EP additives
that meets NLGI Grade-2 specifications. Products known
• QUAKER STATE SYNTHETIC 80W90
to meet these requirements include:
• SHELL SPIRAX HD 80W90
• AMOCO AMOLITH EP2
• STUART M2C-105A 80W90
• ARCO LITHOLINE EP2
• SUNOCO DURO GEAR GL-5, SYNTHETIC
• BENZ MOLY-SERVICE EP2
• SUNOCO MULTI-PURPOSE GL-5
• CHEVRON DUROLITH EP2
• TEXACO DIFFERENTIAL GEAR LUBE 80W90
• CITGO H EP2
• TEXACO MULTIGEAR EP 80W90
• GULF GULFCROWN EP2
• UNICAL 76 MP GEAR LUBE-LS
• MOBILE MOBILUX EP2
• VALVOLINE
• SHELL ALVANIA EP2
HIGH PERFORMANCE GEAR LUBE 80W90
• SUN PRESTIGE 742EP
Note: Use of a premium grade 80W140 gear oil is rec-
ommended for operation where the ambient (outside air) • TEXACO MULTIFAX EP2
temperature is consistently above 80°F (27°C). Note: Refer to section 2.12.2 Maintenance Schedule
and Checklist for lubrication intervals and grease fitting
B. Axle and Transfer Case Capacities locations.
Axles (differential housings) ............................ 18 qt (17 l)
Transfer case ................................................. 1.5 qt (1,4 l)

Model 3606 • Origin 10/99 2-9

 Section 2

2.5.4 Hydraulic System 2.5.5 Engine

A. Hydraulic Fluids A. Engine Fluids and Lubricants

The hydraulic system is factory filled with ISO Grade 46 1. Engine oil:
anti-wear hydraulic oil. When filling the hydraulic system, Diesel Engine Oil, SAE 10W-30, or 15W40
use an anti-wear hydraulic oil meeting ISO Grade 46 with
-40°F (-40°C) pour point/ASTM viscosity SUS 215 at In general, use a premium-quality 10W-30 diesel engine
100°F (38°C), or a 10W motor oil that meets the require- (motor) oil. Additives are not necessary. For most climates,
ments of U.S. ordinance specification MIL-L-2104C. use 15W40 motor oil that meets API, CD or CE (severe
Products known to meet these requirements include: duty diesel engine) specifications. In cold climates where
ambient (outside air) temperatures are consistently below
• AMOCO RYKON 46 32°F (0°C), 10W30 motor oil can be used; however, con-
• ARCO DURO AW S-215 tinuous use of low viscosity oil may cause premature
• BENZ PETRAULIC 46-7C engine wear.

• CASTROL AGRICASTROL HDD 2. Cooling system (engine coolant):

• CASTROL/DEUSOL CRD In general, use a 50/50-mix of premium-quality ethylene

glycol (commonly referred to as “anti-freeze/anti-boilover”)
• CHEVRON AW HYDRAULIC OIL 46 and water. Additives are not necessary.
• CITGO PACEMAKER XD-46 3. Fuel:
• ESSO ESSOLUBE D-3HP In general, use No. 2 diesel fuel. From November 15 to
• ESSO ESSOLUBE XD-3 March 15 when operating in cooler climates where ambi-
• GULF HARMONY 46 AW ent (outside air) temperatures are consistently at or
below 32°F (0°C), use a 50/50 mix of #1 and #2 diesel
• ISO-46 HYDRAULIC OIL fuels. Use good quality diesel fuel and change the fuel
• MOBIL DTE-25 filter regularly. Additives are not necessary.
• SAE 10W MOTOR OIL
B. Engine Capacities
• SHELL RIMULA CT
1. Engine oil capacity:
• SHELL RIMULA TX
TOTAL CAPACITY FILTER
• SHELL RIMULA X
WITH FILTER CHANGE CAPACITY
• SHELL TULLUS 46
Cummins Turbo ......... 11.6 qt (11,0 l)............ 1.3 qt (1,2 l)
• SUN SUNVIS 821 WR
Perkins Turbo ............ 9.0 qt (8,5 l)............... 1.5 qt (1,5 l)
• TEXACO RANDO HD 46
Perkins Natural.......... 9.0 qt (8,5 l)............... 1.5 qt (1,5 l)
Note: For -30°F to +70°F (-34°C to 21°C), 5W20 motor 2. Cooling system capacity (w/o heater):
oil with -50°F (-45°C) pour point can be substituted. How-
ever, above 70°F (21°C), hydraulic system oil must be Cummins Turbo ......... 5.0 gal (18,9 l)
changed to ISO-46 hydraulic oil or SAE 10W motor oil. Perkins Turbo ............ 5.0 gal (18,9 l)
Perkins Natural.......... 5.0 gal (18,9 l)
B. Hydraulic System Capacity
Coolant system overflow bottle capacity:
System capacity ................................... 59.5 gal (225,2 l)
CAPACITY CAPACITY
Reservoir capacity ................................ 32.2 gal (121,9 l) 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 RECOMMENDED LUBRICANTS FOR CLARK-HURTH

T12000 POWER SHIFTED TRANSMISSION
A. Transmission Fluid
150
Vehicle transmissions are factory filled with 10W motor 140
60
oil. Any suitable 10W motor oil, which meets the require- 130
120 50
ments of U.S. ordinance specification MIL-L-2104C, can Temperature Range "3"
110
be used. Products known to meet these requirements 100 40 If using Dexron*,
include: 90
30
Use ONLY Dexron*
80 or Dexron II D*
• ARCO TRACTOR FLUID or equivalent 70
20
60 See NOTE Below
• CASTROL AGRICASTROL HDD 3
50 10
• CASTROL/DEUSOL CRD 40
• ESSO ESSOLUBE D-3HP 30 0
• ESSO ESSOLUBE XD-3 20
-10
10
• SAE 10W MOTOR OIL 0 -20
• SHELL RIMULA CT -10
• SHELL RIMULA TX -20 -30
-30
• SHELL RIMULA X -40 -40
-50
In general, use any approved 10W or 5W20 motor oil -50
-60
(depending on ambient temperatures; see information
Farenheit Celsius
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 Chart 2-1. Transmission fluid temperature range.
(38°C).
PREFERRED OIL VISCOSITY: Select the highest vis-
For -30°F to +120°F (-34°C to 49°C), Dexron* II transmis- cosity compatible with prevailing ambient temperatures
sion fluid with a -50°F pour point may be substituted. and the oil application information listed under Section
5W20 motor oil may be substituted for use with tempera- 2.5.6 A. Transmission Fluid.
ture conditions of -30°F to 70°F (-34°C to 21°C) only.
The Clark Hurth T12000 modulated shift transmission
Products known to meet these requirements include: used in this vehicle should use ONLY C-3 or Tempera-
• AMOCO RYKON 46 ture Range 3 transmission fluids, Dexron* or Dexron II
• ARCO DURO AW S-215 D*.
• BENZ PETRAULIC 46-7C Note: Dexron II D* is not compatible with graphitic clutch
• CHEVRON AW HYDRAULIC OIL 46 plate friction material UNLESS IT MEETS THE
• CITGO PACEMAKER XD-46 or equivalent APPROVED C-3 SPECIFICATIONS.
• GULF HARMONY 46
• ISO-46 HYDRAULIC OIL *Dexron and Dexron II D are registered trademarks of General
• MOBIL DTE-25 Motors Corporation.
• SHELL TULLUS 46
• SUN SUNVIS 821 WR
• TEXACO RANDO HD 46 B. Transmission Capacity
If anti-wear hydraulic oil as specified above is not available, Capacity w/ filter change ................. 3.4 gal (12,9 l)
a suitable tractor fluid may be substituted which meets Filter .................................................... 1.5 qt (1,4 l)
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

Model 3606 • Origin 10/99 2-11

 Section 2

2.5.7 Drive Shaft Splines B. Anti-corrosion Need Areas

IMPORTANT: DO NOT disassemble any of the drive Coat all unplated pins and all bores for cylinder pins, attach-
shafts (see Section 6 Transfer Case of this manual for ment pivot pins, chain sheave pins, the quick-attach lock
information covering drive shafts and U-joints). To help pin, and all quick-attach lock pin bores. On the boom,
ensure optimum performance, the drive shaft assemblies coat the fork shaft and unpainted boom slide pathways.
are specially balanced as a unit at the factory. When ser-
vicing any flange yoke, slip yoke or drive shaft tube, order 2.5.9 Electrical
a complete assembly. Refer to the parts manual for
ordering information. A. Basic Ratings
Respective of the above statement, should it become Battery Type ................ 12Vdc, Negative (-) ground/earth,
necessary to coat the transmission input drive shaft Maintenance Free
splines, use molybdenum disulfide grease. Molybdenum
Battery Rating ..........................1,000 cold cranking amps
disulfide grease specifically formulated for this purpose is
@ 0°F (-18°C)
marketed by several manufacturers under various
names, including: Number of Batteries ............................................. One (1)
Aldrich Chemical Co., Inc. Alternator Rating .................................................65 amps
Product name: Aldrich MOLYBDENUM (IV) SULFIDE,
Catalog Number 23,484-2 B. Fuse Ratings, amps
Package Size: 5 g (0.175 oz) • Main (S/N 8249 and Before) ..................................... 40
100 g (3.5 oz)
500 g (17.5 oz) (S/N 8250 and After) ........................................ 30
Contact: • Cold Start (Optional) ................................................. 15
Aldrich Chemical Co., Inc. • Logic Panel .............................................................. 7.5
P.O. Box 335
Milwaukee, Wisconsin 53201 USA • Display Panel ........................................................... 7.5
Telephone: (414) 273-3850 • Fuel Shutoff ............................................................. 7.5
DOW CORNING INC. • Neutral Sense .......................................................... 7.5
Product name: MOLYKOTE® 77 Paste • Neutral Relay/Starter ............................................... 7.5
Contact:
Dow Corning Corporate Center • Hourmeter ................................................................ 7.5
P.O. Box 994 • Horn ......................................................................... 7.5
Midland, MI 48686-0994 • Stabil-TRAK ............................................................. 7.5
Telephone: (517) 496-4400
• Stabilizer Lock Relay ................................................ 7.5
2.5.8 General Anti-corrosion • Steering Solenoids ................................................... 7.5
• Park Brake Sense Relay .......................................... 7.5
A. Anti-corrosion Compound
• Transmission Solenoids ........................................... 7.5
For general anti-corrosion protection, use a wax film rust
• Transmission Relay (without Closed Cab Option)..... 7.5
inhibitor that provides a protective film two ten-thousandths
of an inch (0.0002", or 0,00005 mm) thick. One such rust • Transmission Relay (with Closed Cab Option)........... 15
inhibitor that is specifically formulated for this purpose is • Switch Lamps (Optional) .......................................... 7.5
LPS 3. It is marketed by:
• Closed Cab Option - Front Wiper Motor .................. 7.5
LPS Laboratories, Inc.
• Closed Cab Option - Skylight Wiper Motor .............. 7.5
4647 Hugh Howell Rd.
Tucker GA 30085-5052 • Closed Cab Option - Rear Wiper Motor ................... 7.5
Phone: 1-800-241-8334 • Closed Cab Option - Blower Motor ........................... 25
Fax: (770) 493-9206
• Closed Cab Option - Power WIndow Motor .............. 30
Note: Anti-corrosion protection is especially important in • Closed Cab Option - Power Accessories Relay ........ 40
frame and stabilizer cylinder pin support bores for protec-
tion from fretting corrosion wear. • 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 C. White Paint

Unless otherwise specified, paint components as indi- Durable, premium white paint is available in both a con-
cated in the following sections. venient 16-ounce (480 ml) spray can for touch-ups, and
in a production-sized one gallon (3,8 l) container for
A. Orange Paint extensive repainting. Consult the current Sky Trak Model
3606 PARTS MANUAL for the applicable part number
Durable, premium Sky Trak orange paint is available in
and ordering information.
both a convenient 16-ounce (480 ml) spray can for touch-
ups, and in a production-sized one gallon (3,8 l) container • Boom Extend Cylinder
for extensive repainting. Consult the current Sky Trak • Extend Cylinder Mount Bracket (some models)
Model 3606 PARTS MANUAL for the applicable part
number and ordering information. Use orange paint on all D. Gray Paint
vehicle components except as specified in paragraphs
2.5.10 A, B, C and D. The following parts must be painted dark gray (Ref.: Sky
Trak Color Chip 8528102):
B. Black Paint • Wheels
Durable, premium black paint is available in both a conve- • Engine mount/Hyd. tank
nient 16-ounce (480 ml) spray can for touch-ups, and in a • Counterweight
production-sized one gallon (3,8 l) container for extensive
• Cab Mount
repainting. Consult the current Sky Trak Model 3606
PARTS MANUAL for the applicable part number and Durable, premium gray paint is available in both a conve-
ordering information. nient 16-ounce (480 ml) spray can for touch-ups, and in a
production-sized one gallon (3,8 l) container for extensive
• Boom Angle Indicator Pointer
repainting. Consult the current Sky Trak Model 3606
• Wheels (some models) PARTS MANUAL for the applicable part number and
• Brake Pedal ordering information.
• Radiator • Wheels (some models)
• Seat Adapter Plate • Fuel Tank Cradle
• Radiator Shroud • Hydraulic Fluid Reservoir
• Transmission Oil Cooler • Battery Cover Panel
• Axles
• Drive Shafts 2.5.11 Thread Locking Compound
• Drop Box For general thread-locking purposes, Loctite® products,
• Forks manufactured by Loctite Corporation, are recommended.
• Mirrors and Mirror Brackets Contact:
• Air Cleaner Loctite Corporation
• Steering Column 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 2. Hoses must remain in good condition. Obvious signs

of external hose wear or hydraulic fluid leaking or
Dirt and abrasive dust reduce the efficient working life of weeping indicates the need to replace the hose
parts and systems, and lead to the costly replacement of assembly. If in doubt, replace the hose.
components. To help increase the service life of parts,
clean the exterior of all parts before beginning any repairs. 3. Replace if any of the following conditions exist:

Use cleaning fluids and solvents suitable for cleaning • Ballooning (replace hose immediately!)
parts that do not create safety hazards. Certain types of • Kinking, crushing, stretching or deforming
cleaning fluids can cause skin irritation and damage to • Concealed corrosion of wire reinforcement
components (such as rubber, electrical parts, etc.).
• Chafed outer cover
Servicing the hydraulic system in particular requires
cleanliness. 2.8.2 Hose and Tube Installation
Follow these precautions before attempting to service
1. When installing a new hose, loosely connect each
any hydraulic component:
end and verify that the hose takes up the designed
1. Flush hose and tube assemblies with a solvent position before tightening the connection completely.
compatible with hose materials. Blow excess solvent Tighten clamps sufficiently to hold the hose without
away with shop air. crushing it, and to prevent movement and chafing.
2. Cap hydraulic fittings, hoses and tube assemblies, 2. If a hose is replaced on a moving part, move the part
and protect threads until time of installation. Clean up through its entire range of motion to verify that the
any hydraulic fluid spillage immediately. hose will not incur damage. Adjust as necessary.
3. Flush hydraulic reservoir, fuel tank, and gear housing 3. When installing any hose, verify that it does not
with a suitable solvent to remove paint, metal chips, become kinked or twisted.
etc.
4. NEVER allow freely-moving or unsupported hoses to
4. Protect hydraulic system components from airborne contact each other or a related work surface. Such
contaminants. Plug all cylinder, valve, reservoir, tank contact causes chafing and reduces hose life.
and pump openings until time of installation.
5. Use clean, filtered oil when filling the system. Maintain 2.9 BEARINGS
the hydraulic system at a minimum cleanliness level
of ISO code 18/15-particle ration count. 2.9.1 Bearing Removal
1. NEVER remove bearings unless absolutely
2.7 REPLACEMENT necessary! Always use the recommended puller to
ALWAYS use the correct tool when removing or replac- reduce the risk of bearing or related component
ing any part or performing any service. damage.
Replace O-rings, seals, and gaskets whenever they are 2. When bearings or bushings are removed, verify that
disturbed. NEVER mix new and old seals or O-rings, the bearing or bushing is free from discoloration,
regardless of apparent visual condition. Always lubricate nicks, scuffing, and signs of overheating. If in doubt,
new seals and O-rings with hydraulic oil before installation. replace the bearing or bushing.

2.8 HOSES AND TUBES 2.9.2 Bearing Cleaning

Wear safety glasses. Clean bearings acceptable for ser-
2.8.1 Hose and Tube Inspection vice in a suitable solvent. NEVER spin-dry a bearing with
1. Damaged, dented, crushed, or leaking hose and tube compressed air; this can cause metal-to-metal contact
fittings restrict oil flow and the operation of the and bearing damage. Compressed air can also cause a
system being served. Fittings showing signs of bearing to come apart. After cleaning a bearing, immerse
movement from their original position have failed and it in clean lubricating oil until needed.
must be replaced. ALWAYS replace the entire hose
or tube assembly if the fittings are damaged.

2-14 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

2.9.3 Bearing Installation 4. Purge the hydraulic system of air by operating all
vehicle functions through their entire range of motion
1. Always install bearings carefully to help avoid
several times.
damaging their delicate surfaces.
5. Check for proper operation of all components.
2. Install bearings using one of the following methods:
6. Retract all cylinders fully. Turn the engine OFF and
• PRESS FIT for installation on rotating parts such
check the hydraulic reservoir level. Recheck the level
as shafts and gears;
when the hydraulic oil is cold.
• PUSH FIT into static locations such as reduction
7. Replace the hydraulic filter if required.
gear housings.
3. Always install the bearing into the rotating part first 2.11.2 After Electrical/Electronic Component
whenever possible. Service
4. Use a press or the proper installation tools when 1. Check the torque of all fasteners securing replaced
installing a bearing or bushing. electrical/electronic components.
5. In the absence of a press or proper installation tools, 2. Check wiring connections to components.
carefully heat the casing and/or bearing in hot oil to
assist in the installation. 3. Verify that wiring components are dry and free of
moisture.
2.10 PRESSURE TESTING AND 4. Check connectors for broken, frayed, or loose wires.
ADJUSTMENT 5. Check for brittle or frayed wire shielding.
Prior to pressure testing or adjustment, verify that all 6. Connect the negative (-) battery cable terminal to the
hoses and tubes are in good condition and that all fittings battery; if it is disconnected.
are tight. 7. Start the engine and bleed the hydraulic system of air.
Use pressure gauges with the proper ranges and ratings 8. Recalibrate sensors as required.
to measure the specified pressures.
9. Check the operation of the replaced component(s).
Use correct test procedures to help prevent personal
injury, damage to the system or test equipment. 2.11.3 After Hydraulic Component Service
Verify that the hydraulic oil is at proper operating temper- 1. Check torque of fasteners on replaced components.
ature, 80°-120°F (27°-49°C), before adjusting the pressure
reducing valve, or relief valves. If necessary, operate the 2. Check that hoses and tubes are properly attached,
vehicle to raise the oil temperature. In the absence of a positioned, and tightly connected.
temperature gauge, the oil temperature can be checked 3. If a hydraulic component failed and contaminated the
by placing a hand against the side or the bottom of the system, flush the system, clean the hydraulic oil
reservoir; if the tank is too hot to keep the hand in contact reservoir (tank), and replace the hydraulic oil filter.
with it, the oil temperature should be within the proper 4. After normal hydraulic component maintenance,
range. check the hydraulic fluid level and add fluid as
required.
2.11 AFTER SERVICE STARTUP AND
5. Start engine and bleed hydraulic system of air.
CHECKS Operate all boom functions through their full range of
motion several times. Cycle the hoist and extend
2.11.1 After Service Startup cylinders to bleed air from the system. Visually check
Note: Refer to the owners/operators manual for engine for leaks.
cold-start procedures. 6. Recalibrate sensors as required.
1. Check fluid levels. 7. Check operation of all systems in the hydraulic circuit
2. Connect the negative (-) battery cable to the battery if by operating the controls through all functions several
it is disconnected. times.

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.

Model 3606 • Origin 10/99 2-15

 Section 2

2.11.4 After Brake System Service 12. Run engine for two minutes at idle to help prime the
torque converter and transmission lines.
1. Check the oil level in the axle and replenish with SAE
80W90 or SAE 80W140 oil as required. 13. Recheck the level of fluid in the transmission with the
engine running at idle.
2. Bleed the brakes.
14. Add ISO 46 10W motor oil as necessary to bring the
3. Check brake pressure.
fluid level up until it begins to run freely from the
4. Check brake operation. UPPER oil level check plug hole. Install the oil level
plug. Recheck the oil level when it reaches operating
2.11.5 After Fuel System Service temperature (180-200°F, or 83-94°C).
1. Drain and flush fuel tank; if it was contaminated. 15. Recheck all drain plugs, lines, connections, etc., for
2. Bleed fuel system. leaks and tighten where necessary.

3. Fill fuel tank with fresh, clean fuel, as required. 2.11.7 After Tire and Wheel Service
2.11.6 After Transmission Service or 1. Check air pressure.
Replacement 2. Check wheel nut torque. Tighten to 370 lb/ft (500 Nm).
1. Check transmission oil level and add 10W motor oil
as required. In general, use an anti-wear hydraulic oil 2.11.8 After Engine Service
meeting ISO Grade 46 with -40°F (-40°C) pour point/ Consult the qualified service agent (manufacturer’s rep-
ASTM viscosity SUS 215 at 100°F (38°C) or other resentative and/or service manual) for proper procedures
lubricant that meets these specifications (refer to before engine startup.
Section 2.5.6 Transmission for information on
transmission lubricants). 2.11.9 After Boom Service
2. Replace transmission filter. 1. Check wear pads.
3. Check torque on drive shaft yoke retaining bolts. 2. Check chain tension adjustment.
Tighten these M12 bolts to 156 lb/ft (212 Nm).
3. Apply grease at all lubrication points (grease fittings).
4. Refer to the Clark-Hurth 12000 transmission
maintenance manual for servicing the transmission 4. Check for proper operation by operating all boom
after overhaul or repair. functions through their full range of motion several
times.
5. Wear suitable eye protection. When an overhauled or
repaired transmission is installed, thoroughly clean 2.11.10 After Axle Service
the oil cooler lines to and from the transmission.
1. Check fluid levels.
6. Drain and flush the entire system.
2. Check torque on drive shaft flange yoke retaining
7. Disconnect and clean all transmission lines. When
bolts. Tighten these M12 bolts to 156 lb/ft (212 Nm).
possible, remove transmissions lines from the vehicle
for cleaning. 3. Check wheel nut torque. Tighten to 370 lb/ft (500 Nm).
8. Thoroughly clean transmission filter screens and 4. Check toe-in if required.
cases, and replace transmission filter elements. 5. Apply grease at all lubrication points (grease fittings).
9. “Back flush” the transmission oil cooler with oil and 6. Refer to the axle manufacturer’s maintenance
compressed air until all foreign material is removed. manual for further information.
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.

2-16 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

2.12 MAINTENANCE INSTRUCTIONS 2.12.1 Maintenance Schedule and Checklist

Maintenance Introduction A. 10 Hour Intervals
WARNING: DO NOT perform service or main-
tenance on the vehicle with the engine running.
Contact with moving parts can cause serious 10 H20

injury or death.
Drain Check Check Check
Fuel/Water Engine Engine Hydraulic
This section contains a routine equipment checklist and a Separator Coolant Oil Oil
maintenance schedule and checklist with references to Level Level Level
pertinent procedures and instructions. To help prevent
problems before they occur, follow the maintenance
schedule.
Note: Lubrication and Maintenance Chart decals are Check
Check Check
located inside the engine compartment cover (Fig. 2–3). Transmission Tire Boom Wear
These decals contain a general maintenance schedule Oil Pressure Pads
Level
that should be followed to maintain the vehicle in good
MS0530
operating condition. The same schedule information is
presented in this manual, except that it contains a more Figure 2–4. Ten-hour interval maintenance schedule
detailed account of how to perform these specific mainte- and checklist.
nance operations.
At ten hour intervals, perform the following:
• Drain the fuel/water separator (see 2.12.7).
Lubrication chart • 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).
Maintenance chart
• 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).

B. At First 50 Hours of Use

50
Change Engine Change Change Change
Oil and Filter Transmission Hydraulic Transfer
Filter Filter Case Oil
OS1170

Figure 2–3. Lubrication and maintenance charts are

located inside the engine cover.
Change Change
Axle Oil Wheel End Oil
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

(2)

250
PLACES
A
C F
Change Engine Check Check
Oil and Filter Transfer Case Axle
(Cummins) Oil Level Oil Level A
(2)
PLACES 2
D
E A
E
3 A 4
Check Apply Multi-Purpose
1 A
E
Wheel End Grease (MPG) At
E
Oil Level All Lubrication Points H
MS1350

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

schedule and checklist. B B B B B B

At 250 hour intervals, perform the following: H

• On a unit equipped with a Cummins engine, change

the engine oil and filter (see 2.12.6).
B B B VIEW IN DIRECTION
• Check the transfer case oil level (see 2.12.13). 1 2
VIEW IN DIRECTION OF ARROW OF ARROW
• Check the axle oil level (see 2.12.11).
• Check the wheel end oil level (see 2.12.12). G G

• Apply multi-purpose grease at all lubrication points

(Fig. 2–7). Lubricate the following components via
the grease fittings with a multi-purpose, lithium-
based grease every 250 hours (remove all excess
grease): G G
A. Hydraulic cylinder pins ..................................7 points
VIEW IN DIRECTION OF ARROWS 3 4
OS0561
B. Drive shaft slip joints and universal joints......9 points
Figure 2–7. Sky Trak Model 3606
C. Boom pivot pin ..............................................2 points
lubrication points.
D. Carriage Quick Attach pivot pin.....................2 points
E. Axle trunnion pivot pins .................................4 points D. 500 Hour Intervals
F. Boom attachments .......................................All points
G. Axle steering knuckles ..................................8 points 500
H. Tilt cylinder pivot pins....................................2 points Change Change Change Engine
Air Fuel Oil and Filter
Note: Shorten the lubrication interval on all lubrication Filter Filter (Perkins)
points when operating under severe conditions. MS1360

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).

2-18 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

E. 1,000 Hour Intervals Angled-cut Metal Wear

Wear Pad Insert Pad
1000 Indicator

Check Check Change Change

Boom Chain Fan Transmission Hydraulic
Tension Belt Oil and Filter Oil and Filter

0.25"
0.625" (6,4 mm)
Change Change Change
Transfer Axle Oil Wheel End Oil (15,9 mm)
Case Oil
MS1370
Wear Pad Boom
OS1230
Figure 2–9. One-thousand-hour interval maintenance Spacer Plate
schedule and checklist. Figure 2–11. Inspect boom wear pads for excessive wear.
At 1,000 hour intervals, perform the following: The boom wear pads that are under the most stress from
• Check boom chain tension (see 2.12.17). weight of the load will also wear faster than other pads.
For example, the lower pads at the front of the boom are
• Check the fan belt (see 2.12.8). under much more stress than the pads attached at the
• Change the transmission oil and filter (see 2.12.10). top front or sides of the boom. Consequently, the lower
• Change the hydraulic oil and filter (see 2.12.9). pads will require service more often.

• Change the transfer case oil (see 2.12.13). B. Boom Wear Pad Replacement
• Change the axle oil (see 2.12.11).
Each boom wear pad is manufactured with a convenient
• Change the wheel end oil (see 2.12.12). wear pad indicator. This is the angled cut at each end of
all boom wear pads (Fig. 2–11). The total thickness of a
F. 2,000 Hour Intervals new boom wear pad is 0.625 inch (15,9 mm). The angled
cut will provide a total wear thickness of 0.25 inch (6,4 mm).
This will leave approximately 0.375 inch (9,5 mm) of total
2000 unused base material.
Change The pads must NEVER be worn past the angled cut indi-
Engine
Coolant cator, or the metal pad insert that holds the pads in place
will begin to wear into the boom pad sliding surfaces.
MS1380
Pads worn past this point will gouge the boom surfaces,
Figure 2–10. Two-thousand hour interval maintenance resulting in premature wear of any new boom wear pads
schedule and checklist. installed, and requiring eventual, expensive replacement
of the boom. Replacement of boom wear pads must be
At 2,000 hour intervals, perform the following:
performed when the boom wear pads indicate.
• Change the engine coolant (see 2.12.5).
C. Boom Wear Pad Lubrication
2.12.2 Boom Wear Pad Maintenance
IMPORTANT: The boom has been factory lubricated for
A. Boom Wear Pad Check proper wear pad break-in and will normally not require
further lubrication. However, after replacing any wear
Daily, and every 10 hours of engine operation, visually pad(s), or after prolonged periods of inoperation, light
inspect the boom wear pads between the boom sections lubrication of the boom wear surfaces with a rust inhibitor/
at the rear and front of the boom for excessive wear lubricant such as LPS 3 or equivalent is recommended to
(Fig. 2–11). keep the boom wear surfaces lubricated properly. Light
The average expected service life of boom wear pads lubrication of the boom wear surfaces is also recommended
varies depending on the particular location of each wear in salt air climates, and when the vehicle is stored, to help
pad within the boom, vehicle use, operating conditions, prevent rusting. LPS 3 is marketed by:
and the load weight. LPS Laboratories, Inc.
If load weights are at or near maximum capacity, or if the 4647 Hugh Howell Rd.
vehicle is operating in very dirty or dusty conditions, the Tucker GA 30085-5052
boom wear pads will wear at a much faster rate. Phone: 1-800-241-8334
Fax: (770) 493-9206

Model 3606 • Origin 10/99 2-19

 Section 2

2.12.3 Air Cleaner B. Air Cleaner Element: Change or Clean

A. Engine Air Filter Restriction Warning Indicator

500
1 2 3 4 MS2180 OS0790

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

D N
R As indicated by the air cleaner restriction indicator, and/or
every 500 hours, change or clean the air cleaner element.
Engine Air Filter Restriction
Early Production
Warning Indicator Outer Primary Element
All air cleaner manufacturers agree that attempting to
clean or wash an element increases the chance for ele-
ment 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,
Current Production Engine Air Filter Restriction the dirt-holding capacity is reduced and the risk of dirt
Warning Indicator OS0222 reaching the clean side of the filter is increased. Filters
should NEVER be washed more than six times or
Figure 2–12. Engine air filter restriction warning indicator.
retained for more than one year's service, whichever
The operator’s display panel includes an indicator light comes first.
(Fig. 2–13) that illuminates to alert the operator when If an element is washed, use a non-sudsing detergent
restricted air flow to the engine is sensed. This indicates that dissolves combustion residues without damaging the
that the air filter needs servicing. NEVER operate the filter media. One such detergent that is specifically
vehicle without the air cleaner assembly and both filters formulated for this purpose is FM 1400. This cleaner
in place. contains biodegradable synthetic detergents and is
environmentally safe. FM 1400 is marketed by:
Air Cleaner Cover Air Cleaner Filter Service Corp.
2105 W. Apache
Farmington, New Mexico 87401
Telephone: (505) 326-1127
Retaining
Clips Inner Safety Element
An inner safety element (Fig. 2–15) should NEVER be
Vactuator
Valve 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.

OS0440

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

2-20 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

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

Air Cleaner Primary Safety Air Cleaner stream of water [less than 40 psi (2,8 kPa), without
Cover Element Element Element 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 C. Air Intake System-Inspection

Valve (ref.) 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
OS0450 prevent air intake system leakage.
Figure 2–15. Engine air cleaner components.
2.12.4 Optional Closed Cab Air Filters
To change elements:
The optional closed cab has two air filters, the recircula-
1. Unlatch the three retaining clips (Fig. 2–13) and
tion air filter (Fig. 2–16) and the fresh air intake filter (Fig.
remove the air cleaner cover (Fig. 2–15).
2–17). Both of these filters require periodic inspection
2. Remove the wing nut and the primary element. and maintenance.
Inspect the element for damage. DO NOT clean or
reuse a damaged element. Recirculation Air Filter
3. Thoroughly clean the interior of the air filter canister Periodically remove and inspect the recirculation air filter
and vactuator valve. (Fig. 2–16) located directly below the seat. Gently hand
4. If replacing the safety element, carefully slide it out. wash with water, a mild detergent may also be used if the
Always discard this element and replace it with a new filter is saturated with dirt.
element.
Recirculation
5. Slide the new primary element over the safety Air Filter
element, making sure the sealing edge is flush with
the base of the air cleaner. Install and tighten the
wing nut securely.
6. Position the canister cover in place and secure it by
latching the three retaining clips. Vent Cover
Sky Trak recommends changing filters. If a replacement
filter is not available, carefully follow these procedures to
clean a primary element: Truss-head Bolt
OS1810
1. Remove loose particles from the filter with compressed
air [maximum 30 psi (2,1 kPa)] or water hose Figure 2–16. Periodically remove and inspect
[maximum 40 psi (2,8 kPa) without nozzle]. Rotate the recirculation air filter.
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.

Model 3606 • Origin 10/99 2-21

 Section 2

Fresh Air Intake Filter

Periodically remove the cab rear panel and inspect the Radiator Cap
fresh air intake filter (Fig. 2–17). The filter must be
cleaned sometimes as often as twice a day, depending Radiator
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
Coolant
pressurizing the cab. The filter should be replaced when Overflow
required. Bottle
Note: Correctly position the filter so the air flow is
directed into the cab.

Filter Latch

Radiator Drain Plug

Filter
Latch OS0481

Figure 2–19. Check the coolant level in the overflow bottle.

B. Drain and Flush the Radiator

Note Direction
of Air Flow 2000
OS1790

REAR OF CAB with REAR PANEL REMOVED MS3000 OS0810

Figure 2–17. Periodically remove and inspect Figure 2–20. Drain and flush the radiator
the recirculation air filter. every 2,000 hours of engine operation.
1. Level the vehicle, ground the attachment, place the
2.12.5 Engine Cooling System travel select lever in NEUTRAL (N), engage the
parking brake switch and shut off the engine.
A. Engine Coolant Level Check (10 Hour Intervals)
WARNING: DO NOT attempt this procedure
when the engine is hot. Wait for the engine,
10 muffler, and tailpipes to cool down before pro-
ceeding. Failure to do so could result in severe
MS2140 OS0800 burns.
Figure 2–18. Check the engine coolant level every 2. Unlatch, unlock and open the engine cover. Allow the
10 hours of engine operation.
engine to cool before proceeding. Draining and
1. Level the vehicle, ground the attachment, place the flushing the cooling system while the engine is hot
travel select lever in NEUTRAL (N), engage the can cause cracks in the engine block.
parking brake switch and shut off the engine.
WARNING: NEVER remove the radiator cap
2. Unlatch, unlock and open the engine cover. while the engine is hot. The cooling system is
3. Check the coolant level in the overflow bottle (Fig. 2–19). under pressure. Hot coolant can cause severe
When the coolant is hot, the bottle should be half to burns or eye injury. Wear protective clothing
three-quarters full. When the coolant is cool, the and safety glasses.
bottle should be one-quarter to half full. Add coolant
(use a 50/50 mixture of ethylene glycol and water) as 3. Slowly turn the radiator cap to the first stop and allow
required through the overflow bottle. 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 Dispose of properly.
9. Reconnect the hose to the fitting on the neck of the
Fitting on Neck of
radiator fill tube. Close the radiator drain plug or
Radiator Fill Tube
petcock.
Coolant
Overflow 10. Fill the radiator completely with a 50/50 mixture of
Bottle ethylene glycol and water. Replace the radiator cap.
Add coolant to the overflow bottle until the bottle is
Hose from half to three-quarters full. This “overfilling” will
Bottom of compensate for any air in the cooling system.
Overflow
11. Clean dirt and debris from the radiator core.
Bottle
Radiator
12. Start and run the engine until normal engine
Drain operating temperature is reached, then turn the
engine OFF. Check for leaks while the engine is
Funnel 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
OS0472 radiator cap.
Figure 2–21. Drain coolant from the overflow bottle.
14. The overflow bottle should be one-quarter to half full.
4. Place a funnel at the base of the radiator (Fig. 2–22) If not, fill as necessary with a 50/50 mixture of
to channel the drained coolant into a container. ethylene glycol and water.
Unscrew the radiator drain plug and allow the coolant
to drain into the funnel. 2.12.6 Engine Oil and Filter
5. Detach the hose from the fitting on the neck of the
radiator fill tube and drain any coolant from the A. Engine Oil Recommendations
overflow bottle into the funnel. The use of quality engine oil combined with the appropri-
6. Flush the radiator with clean water, and drain again. ate oil and filter change intervals are critical factors in
maintaining engine performance and durability. Refer to
7. Remove the engine block drain plug (Fig. 2–23) and
the engine manufacturer’s manual for recommended oil
drain any coolant from the engine block. Replace the
types for various operating conditions).
engine block plug.
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 Coolant Drain OS0580

Cummins Engine Perkins Engines

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

Model 3606 • Origin 10/99 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. Oil Filter Oil Fill Cap
Oil Drain
B. Oil Level Check Oil Fill Plug Oil Fill
Cap Dipstick Cap
(PERKINS ENGINE)

10 Oil Filter
MS2140 OS0820 Dipstick (Opposite
Side of
Figure 2–23. Check the oil level Engine)
every 10 hours of engine operation. Oil
Filter Dipstick
1. Level the vehicle, ground the attachment, place the
Oil Oil
travel select lever in NEUTRAL (N), engage the
Drain Plug Drain Plug
parking brake switch and shut off the engine.
(CUMMINS ENGINE) (CUMMINS ENGINE)
2. Unlock and open the engine cover. S/N 9179 and Before S/N 9180 and After
3. Remove the engine dipstick (Fig. 2–24). Check the oil OS0462
mark on the dipstick. The oil should be between the Figure 2–26. Location of items relevant to checking the
full and add marks. On Cummins engines, the oil engine oil level and changing the oil and filter.
mark should be within the crosshatched area of the
Change the oil and filter after the first 50 hours of vehicle
dipstick.
operation, at 250-hour intervals for Cummins engines,
and 500-hour intervals for Perkins engines. To change
FULL the oil and filter:
1. Operate the engine until it reaches operating
temperature (approximately five minutes).
ADD 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.
Perkins Engines Cummins Engine 6. Allow the oil to drain completely into the receptacle.
OS0521
Transfer the oil to a container with a cover and label
Figure 2–24. Check the oil level mark on the dipstick. the container as used motor oil. Dispose of properly.
4. Add oil as required. Replace the dipstick. 7. Remove the oil filter and clean the filter sealing
surface.
C. Oil and Filter Change 8. Apply a thin coat of clean engine oil to the new filter
mating surface.
250
Cummins 9. Install the new oil filter and hand tighten. Use an oil
filter wrench or strap to tighten the filter down an
50 500 additional one-quarter to half turn. DO NOT
MS2150 MS2170 Perkins MS2180 OS0830
overtighten.
10. Clean and reinstall the oil drain plug into the engine
Figure 2–25. Change the engine oil and engine oil filter.
oil pan.

2-24 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

11. Remove the engine oil fill cap and add oil (refer to the 4. Loosen the fuel filter drain cock. Allow the water to
engine manufacturer's manual for recommended oil drain into the glass container until clear fuel is visible.
types for various operating conditions). Engine oil After draining is complete, tighten the drain cock.
capacity with filter change is: Dispose of drainage properly.
Perkins Engine . . . . . . . . 9.0 quarts (8,5 liters) 5. Close and lock the engine compartment cover.
Cummins Engine . . . . 11.6 quarts (11,0 liters)
12. Reinstall the oil fill cap. Start the engine and allow it B. Change Fuel Filter
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. 500
DO NOT overfill.
14. Look for oil leaks at the filter and drain plug. Tighten
OS0870
as required. MS2180

Figure 2–29. Change the fuel filter every

2.12.7 Engine Fuel System 500 hours of engine operation.

A. Drain Water from Fuel Water Separator/Filter Change the fuel filter every 500 hours of engine operation,
or at shorter intervals with water evidence of contami-
nated fuel.

10 PERKINS ENGINE
H20
1. Level the vehicle, ground the attachment, place the
MS2140 OS0851
travel select lever in NEUTRAL (N), engage the
Figure 2–27. Drain water from the fuel-water parking brake switch and shut off the engine. Allow
separator/filter every 10 hours of engine operation. engine to cool.
1. Level the vehicle, ground the attachment, place the 2. Unlock and open the engine cover. Clean the outside
travel select lever in NEUTRAL (N), engage the surfaces of the filter assembly.
parking brake switch and shut off the engine. Allow 3. Loosen the drain cock at the bottom of the canister
the engine to cool. (Fig. 2–30) to remove it and allow the fuel-water to
2. Unlock and open the engine compartment cover. drain into a suitable container. Dispose of properly.
Canister
3. Position a suitable glass container beneath the fuel
filter drain cock (Fig. 2–28), located on the underside
of the fuel filter.

Fuel Water Fuel

Separator Filter

Drain Cock

OS0731

Figure 2–30. Perkins drain cock location.

OS1730 OS1740
Drain Cock Drain Cock 4. Unscrew the canister to remove it from the base.
Clean the base. Properly dispose of the canister.
(PERKINS ENGINE SHOWN) (CUMMINS ENGINE SHOWN)
5. Lightly lubricate the new fuel filter gasket with clean
Figure 2–28. Position a suitable glass container No. 2 diesel fuel. If the engine has been completely
beneath the fuel filter drain cock. run out of fuel, prefill the canister with clean fuel.

Model 3606 • Origin 10/99 2-25

 Section 2

6. Screw the new canister onto the base. Hand tighten C. In-line Fuel Strainer
only.
(Every 500 hours of engine operation)
7. Remove air from the fuel system. See Venting Air
1. Level the vehicle, ground the attachment, place the
from the Fuel System. (see 2.12.7 D)
travel select lever in NEUTRAL (N), engage the
8. Close, latch and lock the engine cover. parking brake switch and shut off the engine. Allow
engine to cool.
CUMMINS ENGINE 2. Unlock and open the engine cover.
1. Level the vehicle, ground the attachment, place the 3. On both Perkins and Cummins engines, the in-line
travel select lever in NEUTRAL (N), engage the fuel strainer is located down line from the engine lift
parking brake switch and shut off the engine. Allow pump (Fig. 2–32). Loosen the two hose clamps
engine to cool. securing the strainer in place.
In-line In-line
2. Unlock and open the engine cover. Clean around the Fuel Strainer
Fuel Strainer
fuel-filter head (Fig. 2–31).

Filter
Head

Gasket

Fuel Filter OS0590

Lift Pump Lift Pump

Perkins Engines Cummins Engine

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

OS1450 4. Remove and properly dispose of the old strainer.
Figure 2–31. Cummins fuel filter location. 5. Install the new strainer with the arrow pointing toward
the lift pump.
3. Clean the filter head gasket surface and replace the
O-ring. 6. Assemble the hoses to the strainer and tighten the
hose clamps.
4. Fill the new fuel filter with clean No. 2 diesel fuel.
7. Remove air from the fuel system. See Venting Air
5. Lubricate the O-ring seal with clean lubricating oil.
from the Fuel System. (see 2.12.7 D)
6. Install the fuel-filled filter and tighten by hand. DO
8. Close and lock the engine cover.
NOT over tighten.
Note: DO NOT overtighten. DO NOT tighten with D. Venting Air from the Fuel System
mechanical means (tools, etc.). Mechanical over-tightening
may distort the threads or damage the O-ring seal. WARNING: DO NOT vent air from the fuel sys-
tem of a hot engine. Allow the engine to cool
Controlled venting is provided at the injection pump before attempting to purge air from the fuel sys-
through the fuel drain manifold. Small amounts of air tem. Failure to do so could create a fire hazard.
introduced by changing the fuel filter element will be
vented automatically as long as the element was filled Air must be vented from the fuel system whenever any
with fuel prior to installation. 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

IMPORTANT: DO NOT attempt to start the engine until

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

PERKINS ENGINE

Vent Filter Head

Plug

Hand
Plunger

Lift
Pump OS1450

Figure 2–35. Cummins vent screw, hand plunger

and lift pump locations.
OS0731
1. To vent the low pressure lines and fuel filter, open the
Figure 2–33. Perkins vent plug and filter head locations.
vent screw located on the filter head. Operate the
1. To vent air from the low pressure fuel lines, loosen hand plunger on the lift pump until fuel flowing from
the vent plug until fuel, free of air, comes out of the the fitting is free of air. Tighten the vent screw and
vent plug. Tighten the vent plug. torque to 7 lb/ft (9 Nm).
Note: If the lift pump drive cam is at the point of maxi- IMPORTANT: When cranking the engine with the starter
mum lift, it will not be possible to operate the priming motor to vent air from the fuel system, DO NOT energize
lever. In this situation, the crankshaft must be turned one the starter solenoid or crank the engine for more than
revolution. 15 seconds at a time. Wait two minutes between each
15-second cranking interval.
2. Loosen the high pressure connections at the
injectors. Verify that the manual stop control is in the 2. Operate the starter motor for no more than 15 seconds.
RUN position. Operate the starter motor until fuel, The process of venting the high pressure fuel lines
free of air, comes out of the pipe connections. involves energizing the starter motor, which rotates
Tighten the connections to 16 lb/ft (22 Nm). the crankshaft, which, in turn, operates the fuel pump
to purge air from the high pressure fuel lines.
High Pressure Line Injector
WARNING: KEEP CLEAR of spraying fuel.
Diesel fuel will spray when venting high pres-
sure lines. The fuel pressure is sufficient to
penetrate the skin and cause serious bodily
injury. Wear protective clothing and safety
glasses.

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.

Model 3606 • Origin 10/99 2-27

 Section 2

Alternator
Fan
Pulley
Pulley
High-pressure
Fuel Lines

Injector Crankshaft
1/4" to 3/8"
Pulley
(6,4 to 9,4mm)
Deflection

0A0362

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

OS0990

Figure 2–36. Cummins injector and high-pressure 5. If the fan belt needs adjustment, loosen both
fuel line locations. alternator mounting bolts and use a fan-belt tensioner
to carefully pry the alternator to tighten the belt. DO
4. Tighten the fitting to 22 lb/ft (30 Nm). Repeat this NOT overtighten. Retighten the alternator mounting
procedure for each fitting until the engine runs bolts.
smoothly. With the engine running, visually check for 6. Recheck fan belt deflection. Adjust as necessary.
leaks. Turn the ignition switch OFF. 7. Close and lock the engine compartment cover.

2.12.8 Engine Fan Belt

CUMMINS ENGINE
1. Ground the attachment, place the travel select lever
in NEUTRAL (N), engage the parking brake switch
1000 and shut off the engine. Allow engine to cool.
2. Unlock and open the engine cover.
MS2190 OS0880
3. The Cummins engine is equipped with an automatic
Figure 2–37. Inspect the engine fan belt belt tensioner (Fig. 2–39). Rotate the tensioner up
every 1,000 hours of engine operation. 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
PERKINS ENGINE resistance or rough spots in bearing travel.
1. Ground the attachment, place the travel select lever 4. Spin the fan and check for wobble or excessive play.
in NEUTRAL (N), engage the parking brake switch Maximum play should be 0.006 inch (0,15 mm).
and shut off the engine. Allow engine to cool.
5. To install the fan belt, position the belt over the
2. Unlock and open the engine cover. grooved pulleys. While holding the tensioner up, slide
3. Inspect the fan belt. Replace if cracked or frayed. the belt over the water pump pulley.
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).

2-28 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

Automatic
Belt Tensioner
Pulley

Alternator
Pulley

Water Pump Hydraulic Oil

Pulley Crankshaft Sight Glass
Pulley OS1590

Figure 2–41. Check the hydraulic oil level

OS0770
via the sight glass.

Figure 2–39. Cummins engine fan belt adjustment points. 5. Reinstall the hydraulic oil fill cap. Close and lock the
engine cover.
6. Close and lock the engine compartment cover.

2.12.9 Hydraulic System Oil And Filter

B. Hydraulic Oil and Hydraulic Oil Filter Change
A. Hydraulic Oil Level Check

10 1000
MS2140 OS0660

MS2190 OS0840
Figure 2–40. Check the hydraulic oil level
every 10 hours of engine operation. Figure 2–42. Change the hydraulic oil filter after the first 50
hours of engine, and every 1,000 hours thereafter.
1. Level the vehicle, ground the attachment, place the
travel select lever in NEUTRAL (N), and engage the Change the hydraulic oil filter after the first 50 hours of
parking brake switch. engine operation, and every 1,000 hours of operation
2. Fully retract all hydraulic cylinders and shut off the thereafter.
engine. Also, the hydraulic oil filter must be changed anytime the
3. Allow the hydraulic oil to cool. hydraulic oil filter restriction warning indicator light on the
operator's instrument panel begins to flicker ON and OFF
4. Unlock and open the engine cover. Locate the hydraulic at high idle (Fig. 2–43).
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.

Model 3606 • Origin 10/99 2-29

 Section 2

1 2 3 4

F P
D N
R

Hydraulic Oil Filter Restriction Early Production Hydraulic Oil

Warning Indicator 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.
Hydraulic Oil Filter Restriction Current Production
Warning Indicator OS0222
8. Clean the filter head sealing surface.

Figure 2–43. Hydraulic oil filter restriction warning

Filter Sight
indicator for early production (top)
Head Glass
and current production (bottom) vehicles.
1. Level the vehicle, ground the attachment, place the Element
travel select lever in NEUTRAL (N), and engage the
parking brake switch.
WARNING: DO NOT change the hydraulic oil Seal
or the hydraulic oil filter with the engine running.
Contact with moving parts can cause serious
injury or death.

2. Fully retract all hydraulic cylinders and shut off the

engine.
3. Unlock and open the engine cover. Allow the hydraulic
oil to cool. Hydraulic
Reservoir
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. Drain Plug OS1600

5. Place a suitable container under the hydraulic reservoir Figure 2–45. Replace the hydraulic filter element and add
drain plug. The container must be large enough to hydraulic oil as required.
hold 32 gallons (121,9 liters) of hydraulic oil.
9. Remove the magnetic drain plug and allow the
6. To facilitate removal of the hydraulic oil filter head and
hydraulic oil to drain into the container. Clean loose
filter, the hydraulic oil return line may need to be
particles from the magnetic drain plug. Transfer the
swiveled out of the way, and the indicator wiring
used hydraulic oil to a container with a cover and
unplugged. DO NOT crimp the hydraulic oil return
label the container as used hydraulic oil. Dispose of
line or indicator wiring. Rotate and remove the
properly.
hydraulic oil filter head; be prepared for a large
amount of oil to be displaced. 10. Reinstall the magnetic drain plug into the hydraulic oil
reservoir.

2-30 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

11. Fully install a new hydraulic oil filter element onto the 3. Remove the transmission dipstick (Fig. 2–46). Check
hydraulic oil filter head until the filter seats. Slide the the transmission oil level.
filter assembly into the reservoir. Secure the filter
Hose, Hydraulic
head by tightening the nuts loosened earlier.
Reservoir to
12. If the hydraulic oil return line was swiveled out of the Main Pump
way, reposition the line. If the indicator wiring was
unplugged, reconnect it. Transmission
Oil Filter
13. Remove the fill cap and fill with ISO Grade 46
hydraulic oil until the oil level is visible within the Breather
lower end of the sight glass. Reservoir capacity is (ref.)
32 gallons (121,9 liters). Reinstall the fill cap.
Thoroughly clean or wipe up any spilled hydraulic oil. Transmission
Dipstick
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.
OS0680
WARNING: DO NOT use your hand or any
part of your body to check for hydraulic leaks. Figure 2–47. Transmission oil level dipstick location.
Hydraulic oil leaking under pressure can pene- 4. As required, add a premium grade of transmission
trate the skin and cause severe personal injury. fluid (see Section 2.5.6 A. Transmission for a list of
When checking for hydraulic leaks, wear safety approved fluids) to the transmission to bring the level
glasses and gloves to help provide protection up to the full mark.
from spraying hydraulic oil. Use a piece of card-
board or paper to search for leaks. B. Transmission Oil and Filter Change
16. Check for leaks.

2.12.10 Transmission Oil And Filter

1000
A. Transmission Oil Level Check MS2190 OS0950

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

10 change the transmission oil and transmission oil filter.
1. Level the vehicle, ground the attachment, place the
MS2140 OS0890 travel select lever in NEUTRAL (N), and engage the
parking brake switch.
Figure 2–46. Every 10 hours of engine operation,
check the transmission oil level. 2. Unlock and open the engine compartment cover.
Allow the engine and transmission to cool.
1. Level the vehicle, ground the attachment, place the
travel select lever in NEUTRAL (N), and engage the 3. Place a suitable receptacle under the transmission
parking brake switch. drain plug (Fig. 2–49). Remove the drain plug and
allow the transmission oil to drain into the receptacle.
2. Check the transmission oil level with the engine at
Transfer the used transmission oil into a suitable
idle and the oil at normal operating temperature.
covered container and label the container as used oil.
Dispose of properly.

Model 3606 • Origin 10/99 2-31

 Section 2

2.12.11 Axle Oil

Transmission
Filter A. Axle Oil Level Check
Transmission
Dipstick 250
MS2170 OS0920

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.
Transmission
Drain Plug
OS1010

Figure 2–49. Location of transmission maintenance items.

Axle Fill/
4. Clean and reinstall the transmission drain plug into Level Plug
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 Drain Plug OS1581
temperature conditions of -30°F to 70°F (-34°C to 21°C)
Figure 2–52. Axle fill/level plug
only. Refer to Section 2.5.6. A. Transmission Fluid. (front axle shown; rear axle similar).
6. Apply a thin film of clean 10W motor oil (that meets 2. Clean the area around the axle fill/level plug (Fig. 2–52),
ISO 46 standards) to the new filter gasket. Install the then remove the plug from the axle housing.
new filter and torque 20-25 lb/ft (27-34 Nm).
3. Add a premium grade of SAE 80W90 or SAE 80W140
7. Transmission oil may be added through either the fill axle oil to bring the oil level up, even with the bottom
plug (Fig. 2–50) or dipstick. Remove the fill plug or of the plug hole.
dipstick and fill with approximately 3.4 gallons (12,9
liters) of 10W motor oil. Check the level by taking 4. Reinstall the axle fill/level plug.
intermittent dipstick readings as outlined in
Transmission Oil Level Check. DO NOT overfill. B. Axle Oil Change
Reinstall the fill plug or dipstick when finished.
Transmission
1000
Filter
MS2190 OS0970

Fill Plug
Figure 2–53. Every 1,000 hours of engine operation,
Breather change the axle oil.
(ref.)
1. Level the vehicle, ground the attachment, place the
Transmission travel select lever in NEUTRAL (N), engage the
Dipstick 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.
OS0690 Remove the plug from the axle housing and allow the
axle oil to drain completely.
Figure 2–50. Fill the transmission through the fill plug or
dipstick opening. 4. Transfer the oil to a container with a cover and label
the container as used axle oil. Dispose of properly.
8. Close and lock the engine compartment cover.

2-32 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

5. Clean and reinstall the drain plug. Remove the axle B. Wheel End Oil Change
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 1000
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).
MS2190 OS0980
7. Reinstall the axle fill/level plug into the axle housing.
Figure 2–56. Every 1,000 hours of engine operation,
2.12.12 Wheel End Oil change the wheel-end oil level at all four wheel-ends.
1. Position the vehicle on level ground and move the
WARNING: DO NOT perform service or main-
vehicle forward or backward to place the wheel end
tenance on this vehicle with the engine running.
fill/drain plug in the six o'clock position (Fig. 2–57).
Contact with moving parts can cause serious
injury or death. Wheel End

A. Wheel End Oil Level Check

250
MS2170 OS0930

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

the wheel-end oil level for all four wheel-ends.
Wheel End
1. With the vehicle on level ground, move forward or Fill/Drain Plug
backward enough to align the oil level line (Fig. 2–55)
horizontally. OS1020

2. Ground the carriage, place the travel select lever in

Figure 2–57. Drain each wheel-end every 1,000 hours of
NEUTRAL (N), engage the parking brake switch and engine operation.
shut the engine off.
2. Ground the carriage, place the travel select lever in
3. Clean the area around the wheel end fill/drain plug.
the NEUTRAL (N) position, engage the parking brake
Slowly remove the plug; pressure may be present.
switch and shut the engine off.
Check the oil level. It should be even with the bottom
edge of the hole. 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.
Wheel End Wheel End
4. Allow the axle oil to drain completely into the
Fill/Drain
Plug 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
Oil Level horizontally.
Line 6. Fill the wheel end with a premium grade of SAE 80W90
or SAE 80W140 axle oil. The wheel end is full when
OS0710
the oil is level with the bottom of the plug hole. Wheel
Figure 2–55. Wheel-end oil should be even with the bottom end oil capacity is approximately 1.4 quarts (1,3 liters).
edge of the fill/drain plug hole. 7. Clean and reinstall the wheel end fill/drain plug.
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.

Model 3606 • Origin 10/99 2-33

 Section 2

2.12.13 Transfer Case Oil 2. Clean the area around the transfer case oil level plug,
oil drain plugs and the oil fill/vent cap (Fig. 2–61).
A. Transfer Case Oil Level Check
Vent Cap Oil Fill Plug
250
MS2170 OS0910

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). Oil Drain Plug Oil Level Plug
OS0722

Vent Cap Oil Fill Plug Figure 2–61. Remove the oil drain plug from the transfer
case to drain the oil.
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.

Oil Level Plug

7. Remove the oil fill/vent cap and oil level plug.
Oil Drain Plug
OS0722 8. Fill the transfer case with SAE 80W90 or SAE 80W140
gear oil. The transfer case is full when oil is level with
Figure 2–59. Clean the area around the
transfer case oil level plug. the bottom of the oil level plug hole. Total transfer
case gear oil capacity is 1.5 qt (1,4 l).
3. Remove the oil level plug from the transfer case and
9. Replace the oil fill/vent cap and oil level plug. Wipe
check the oil level.
up any spilled gear oil.
4. Add a premium grade of SAE 80W90 or SAE 80W140
gear oil as required through the oil level hole or oil fill/ 2.12.14 Wheels and Tires
vent cap. Bring the oil level up and even with the oil
level plug hole. A. Tire Pressure Check
5. Clean and reinstall the oil level plug and oil fill/vent
plug. 10
MS2140 OS0900
B. Transfer Case Oil Change
Figure 2–62. Every ten hours of engine operation, check
the air pressure in all four tires.
1000 DANGER: LOW TIRE PRESSURE can result
in vehicle tipover.
MS2190 OS0960
MAINTAIN proper tire pressure at all times.

Figure 2–60. Every 1,000 hours of engine operation, Check all four tires:
change the transfer case oil. 1. Remove the valve stem cap.
1. Level the vehicle, ground the carriage, place the 2. Check tire pressure using a premium-quality gauge.
travel select lever in NEUTRAL (N), engage the Proper inflation pressure cannot be determined
parking brake switch and shut the engine OFF. visually. Pressure should be 65 psi (448 kPa)

2-34 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

minimum for 13.00 - 24, 12-ply tires. Maximum panel (Fig. 2–64) illuminates when the alternator is no
ground pressure with a full load is 93 psi (641 kPa). longer able to charge the battery.
3. Add air as required. DO NOT overinflate.
4. Replace the valve stem cap.
1 2 3 4
B. Wheel Lug Nut Check F P
D N
Every ten hours of engine operation, check the torque on
R
all lug nuts. Tighten as required.
1. Wire brush the area around the lugs if necessary. Alternator Charging
Early Production
Foreign material such as dirt, concrete, mud, etc. can Warning Indicator
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).
1
10

7 5
Alternator Charging
Current Production
Warning Indicator OS0222

Figure 2–64. Typical alternator charging warning indicator.

3 4 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
located directly underneath the radiator assembly
6 8
(Fig. 2–65).

9 2 OS0740

Figure 2–63. Lug nut torque sequence. Radiator

2.12.15 BATTERY
Battery
A. Battery Inspection, Testing and Service

WARNING: A lead-acid battery produces flam-

mable and potentially explosive gases. To help
avoid personal injury when checking, testing or
charging the battery:
• DO NOT use smoking materials near a battery.
• Keep arcs, sparks and open flames away OS1040
from the battery.
Figure 2–65. The battery is located beneath the radiator.
WARNING: • Provide adequate ventilation and
wear safety glasses

The battery is of maintenance-free design. The battery is

filled with electrolyte and charged when shipped with the
vehicle. A warning indicator light on the operator's display

Model 3606 • Origin 10/99 2-35

 Section 2

3. Wear safety glasses and visually inspect the battery. C. Jump Starting
Check terminals for corrosion. Replace the battery if
it has a cracked, melted or damaged case. WARNING: NEVER jump start the vehicle
directly at the starter motor or starter solenoid.
WARNING: Fluid (electrolyte) in electric stor- Serious personal injury or death could result
age batteries contains sulfuric acid, a POISON from the vehicle lurching forward or backward
that can cause SEVERE CHEMICAL BURNS. and running over personnel attempting to jump
Avoid all contact of fluid with eyes, skin or cloth- start the vehicle.
ing. Use proper protective gear when handling
batteries. DO NOT tip a battery beyond a 45°
angle in any direction. If contact with battery WARNING: To help avoid personal injury when
fluid does occur, follow the First Aid sugges- jump starting with another vehicle, DO NOT
tions in the “Battery Fluid (electrolyte) First Aid” allow the vehicles to contact each other.
box below. NEVER jump start a frozen battery. A frozen
battery could explode and cause serious per-
sonal injury. Keep arcs, sparks, lighted smoking
Battery Fluid (electrolyte) First Aid materials and open flames away from the bat-
• External Contact: Flush with water. tery. A lead-acid battery produces flammable
and potentially explosive gases. Wear safety
• Eyes: Flush with water for at least 15 minutes and get
glasses when working near a battery.
medical attention immediately.
• Internal Contact: Drink large quantities of water. Follow The jumper or booster battery must be a 12-volt type. A
with Milk of Magnesia, a beaten egg or vegetable oil vehicle used for jump starting must also have a negative
and get medical attention immediately. DO NOT take ground electrical system. When handling and connecting
fluids that induce vomiting. jumper cables, DO NOT allow premature or unintended
contact with any part of the vehicle.
IMPORTANT: In case of internal contact DO NOT take
fluids that induce vomiting! To jump start the vehicle:
1. Connect the positive (+) jumper cable to the positive
(+) post of the discharged battery.
B. Battery Charging 2. Connect the other end of the positive (+) jumper
cable to the positive (+) post of the booster battery.
WARNING: DO NOT charge a frozen battery. 3. Connect one end of the negative (-) jumper cable to
A frozen battery could explode and cause seri- the negative (-) post of the booster battery.
ous personal injury. Allow the battery to thaw
before “jump starting” the vehicle or connecting 4. Make the final cable connection to the engine block
a battery charger. ground or to the ground point furthest away from the
battery.
Under normal operating conditions, the alternator will 5. From the operator’s seat with the seat belt fastened,
keep the battery charged. The alternator may not be able check that the parking brake switch is engaged.
to charge a battery that has been completely discharged Place the travel select lever in NEUTRAL (N). Turn
for an extended period of time. Under this condition, a the ignition switch to the START position (fully
battery charger or a “jump start” is required to recharge clockwise) to crank the engine. Release the key
the battery. when the engine starts. DO NOT energize the starter
An attempt to “jump start” the vehicle and let the engine solenoid or crank the engine for more than 15
run so the alternator charges the battery can be made seconds at a time. Wait two minutes between each
before using a battery charger. 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.
Electrical
9. Remove the positive (+) jumper cable connected to Fuse and
the positive (+) post of the discharged, but now Relay Panel
charging, battery.
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. Lower
Dash
Panel OS1093
2.12.16 Fuse and Relay Replacement
Figure 2–66. Remove the lower dash panel
Note: There are three (3) types of fuse and relay panels to gain access to the fuses and relays.
currently in use on the Sky Trak Model 3606. Vehicles
with serial number 8249 and before use the fuse and
relay panel shown in Fig. 2–68. Mid-production vehicles
with serial number 8250 through 9398 use the fuse and
relay panel shown in Fig. 2–69. Current production vehi-
cles with serial numbers 9399 and after use the fuse and
relay panel shown in Fig. 2–70. Fuse and
Relay Panel
IMPORTANT: Shut off the engine and disconnect the
negative battery cable before checking the electrical sys-
tem. 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 OS1092
relay. The main causes of blown fuses include a shorted
Figure 2–67. Location of fuses and relays.
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 Before checking a malfunctioning electrical circuit, exam-
circuit before replacing a fuse. Check the circuit for ine the applicable wiring diagram (see Section 10: Elec-
shorts, grounding or defective electrical components. trical System) to help identify the components involved.
To gain access to the fuses and relays, remove the three Problems can often be identified by noting whether other
screws securing the lower dash panel to the cab (Fig. 2– components related to the circuit are functioning properly.
66). The fuses and relays are conveniently mounted When several components or circuits fail at one time, the
under the lower left side of the operator’s console (Fig. 2– problem is probably related to a poor ground connection,
66). Remove the four screws securing the panel to gain because several circuits share that same connection.
access to the fuses. See Section 10 Electrical System for further information.

Model 3606 • Origin 10/99 2-37

 Section 2

Vehicles Stamped with S/N 8249 and Before Vehicles Stamped with S/N 8250 through 9398

Perkins Cold
Hourmeter Neutral Display Logic
Start (optional)
Relay/Starter Panel Panel Neutral
Neutral Relay/Starter
*Cold Start Sense
Fuel Shut-off Main 15 7.5

30
Display Panel Hourmeter
Neutral 7.5

7.5 7.5 7.5 7.5

Sense Fuel Shut-Off *Switch Lamps
Main Fuse
Logic
Switch Lamps
Panel
Stabil-TRAK Solenoid Trans. Relay 7.5 7.5 Horn
Trans- 7.5 7.5 7.5 7.5

Stabilizer Lock Relay mission Park Brake 7.5 7.5 7.5 *Aux.
Relay Sense Relay Detent
Mode
Transmission
Solenoids Steer
Solenoids
Horn
Stabil-TRAK
Steer Solenoid
Trans- Solenoids Stabilizer Lock Relay
mission
Park Brake Reverse Relay
Solenoids Neutral Relay
Sense
Forward Relay
Trans. Relay #3
Stabilizer Lock
Trans. Relay #2 Relay
Boom Switch
Trans. Relay #1
Neutral Relay Relay
Forward Relay
*Optional OS1770
Reverse Relay
Trans. Relay 1 Figure 2–69. Vehicles stamped with serial number 8250
Trans. Relay 2 through 9398 use the fuse and relay panel shown here.
Trans. Relay 3
Boom Switch Relay
Stabilizer Lock Relay OS1113

Figure 2–68. Vehicles with serial number 8249 and before

use the fuse and relay panel shown here.

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 and After the intermediate boom (Fig. 2–72). The inner boom
should extend 2.25 inches (57 mm) to 2.75 inches
Neutral *Light Pkg (B)
*Window Logic (70 mm) beyond the end of the intermediate boom. If
Relay/Starter Motor Panel *Light (A)
Pkg
Neutral the measurement is less than 2.25 inches (57 mm),
*Cold Start Sense the chains require adjustment.
Hourmeter
Main 15 7.5 20

Display 30 30 20 *Front
Panel Wiper 2.25"-2.75"
7.5 7.5 7.5 7.5 7.5
Fuel *Skylight (57-70 mm)
Shut-Off Wiper/Washer
*Blower Motor *Rear Wiper
25 7.5 7.5 7.5
Stabil-TRAK
Solenoid Horn

B
7.5 7.5 7.5 7.5 7.5

Park Brake 7.5 7.5 7.5 15

*Switch
Sense Relay Lamps
Trans.
Trans. Relay
Solenoids *Aux.
Detent
Mode
Inner Boom Intermediate Boom OS1060
Steer
Solenoids
*Power Accessory Stabilizer *Power Window Figure 2–72. Measure the distance between the inner
Relay (40 Amp) Lock Relay Motor Relay (40 Amp) boom and the intermediate boom.
Reverse Relay
Neutral Relay
B. Boom Chain Adjustment
Forward Relay
Trans. Relay #3 1. Park the vehicle on level ground. Place the travel
Stabilizer Lock
Trans. Relay #2 Relay select lever in NEUTRAL (N), engage the parking
Boom Switch brake switch and raise the boom to a horizontal
Trans. Relay #1 boom. Retract the boom completely and shut the
Relay
engine off.
*Optional OS2190 2. Loosen the retract chain locknut (Fig. 2–73) located
Figure 2–70. Vehicles stamped with serial number 9399 on the bottom at the front of the outer boom.
and after use the fuse and relay panel shown here.

2.12.17 Boom Chains

A. Boom Chain Tension Check

Retract

1000 Chain
Locknut
Outer Boom OS1070
MS2190 OS0940
Figure 2–73. Turn the retract chain locknut at the front of
Figure 2–71. Every 1,000 hours of engine operation, check the outer boom.
both boom chains for proper tension.
3. Unlock and open the rear cover.

1. Park the vehicle on level ground. Place the travel 4. While preventing the clevis end from turning, tighten
select lever in NEUTRAL (N), engage the parking the extend chain locknut (Fig. 2–74) located at the
brake switch and raise the boom to a horizontal rear of the outer boom.
boom. Retract the boom completely and shut the
engine off.

Model 3606 • Origin 10/99 2-39

 Section 2

1. Install a properly charged battery. Secure the hold-

Retract
down strip and attach the cables.
Chain
Locknut Clevis 2. Change the engine oil and filter to remove
End condensation or other residuals.
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
OS1440
When transporting the vehicle, make use of all four
Figure 2–74. Prevent the clevis end from turning,
tiedowns (Fig. 2–75).
and tighten the extend chain locknut
at the rear of the outer boom.

5. Periodically measure the distance between the inner Vehicle Frame

boom and the intermediate boom. Repeat Step 4 (S/N 8084 and After)
until a distance of 2.5 inches (63,5 mm) is obtained
between the inner boom and the intermediate boom
(Fig. 2–72).
VIEW IN DIRECTION OF ARROW A
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.
A B
2.12.18 Storage

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
VIEW IN DIRECTION OF ARROW B
manual).
OS2150
4. Apply LPS 3 (or equivalent) to all exposed hydraulic
cylinder rods. Figure 2–75. When transporting the vehicle,
make use of all four tiedowns.
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 oper-
ating it, perform the following steps:

2-40 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

2.13 EMERGENCY OPERATIONS 4. An 8 mm Allen®-head socket and torque wrench are

needed to properly disable the parking brakes. Scribe
2.13.1 Towing a Disabled Vehicle a line on the socket to aid in accurately counting the
number of turns each bolt makes during the
IMPORTANT: After the vehicle has been towed to a procedure.
secure location, reactivate the parking brake. Carefully
follow these procedures from start to finish. Consult your 5. At the base of the front axle, locate the six parking
local Sky Trak Distributor or the Sky Trak Service Depart- brake release bolts (three bolts per side; for early
ment if you are unsure about any part of this procedure, production vehicles, see Fig. 2–77; for current
or for specific instructions for your particular situation. production vehicles, see Fig. 2–78). Thoroughly
clean all dirt and debris from the six bolt recesses.
Towing a disabled vehicle should only be attempted as a
last resort, after exhausting all other options. Make every EARLY PRODUCTION
effort to repair the vehicle, and move it under its own
power, before using the following emergency towing pro-
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 Parking Brakes

WARNING: BLOCK ALL FOUR WHEELS.
Failure to do so could result in death or serious
injury from vehicle roll away.

1. Place an Accident Prevention Tag on both the ignition One of Six Parking
key and the steering wheel (Fig. 2–76) stating that Brake Release Bolts
the vehicle should not be operated. If a tag is not
available, tape over the ignition switch. OS1581

Figure 2–77. Clean all dirt and debris from the six parking
brake release bolt recesses (early production vehicles).

CURRENT PRODUCTION

DANGER

DANG
ER

OS1520

OS1520

Figure 2–76. Place an Accident Prevention Tag on both the

ignition switch and the steering wheel.
2. Block all four wheels to help prevent the vehicle One of Six Parking
from moving after the parking brake is disabled. Brake Release Bolts
3. Position the towing vehicle in place. Attach any
MS2590
chains needed to secure the disabled vehicle.
Figure 2–78. Clean all dirt and debris from the six parking
brake release bolt recesses (current production vehicles).

Model 3606 • Origin 10/99 2-41

 Section 2

6. For early production vehicles, see Fig. 2–79; for 7. Use a torque wrench to alternately turn parking brake
current production vehicles, see Fig. 2–80. release bolts A, B and C (Fig. 2–79 or Fig. 2–80)
Alternately turn the parking brake release bolts A, B inward (clockwise) until a torque of 22 lb/ft (30 Nm) is
and C inward (clockwise) two to three complete turns reached. This will take approximately a half-turn. DO
until resistance is felt. NOT exceed 50 lb/ft (68 Nm).
EARLY PRODUCTION 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)
Turn Clockwise to is reached. This will take approximately a half-turn.
Release Brake DO NOT exceed 50 lb/ft (68 Nm).

Steering
9. Clear the area of any unnecessary personnel.
Cylinder (ref.) 10. Carefully remove the wheel blocks from each of the
four tires. Tow the vehicle to a secure location.
A
2.13.3 Reactivating the Parking Brakes
WARNING: BLOCK ALL FOUR WHEELS.
Failure to do so could result in death or serious
Brake injury from vehicle roll away.
FRONT
Release
Bolt B Upon arriving at a secure location with the towed vehicle,
block all four wheels and continue following these proce-
C dures.
Left Side, Cross-section 1. Block all four wheels to help prevent the vehicle from
of Front Axle OS0500 moving. Clear the area of any unnecessary
Figure 2–79. Alternately turn parking brake release personnel.
bolts A, B and C inward until resistance is felt 2. For early production vehicles, see Fig. 2–81; for
(early production vehicles). current production vehicles, see Fig. 2–82. Use a
torque wrench to alternately turn parking brake
CURRENT PRODUCTION release bolts A, B and C outward (counter-clockwise)
a half-turn until the torque drops to 22 lb/ft (30 Nm).
EARLY PRODUCTION
Turn Clockwise to
Release Brake Turn Steering
Counter-clockwise Cylinder (ref.)
Steering to Activate Brake
Cylinder (ref.)
A
A

B
Brake FRONT
FRONT
Release
Bolt B C
Brake Snap
Release Ring Left Side, Cross-section
C Bolt of Front Axle
OS0510
Left Side, Cross-section
of Front Axle MS2600 Figure 2–81. Alternately turn parking brake release
Figure 2–80. Alternately turn parking brake release bolts A, B and C outward until torque decreases
bolts A, B and C inward until resistance is felt (early production vehicles).
(current production vehicles).

2-42 Model 3606 • Origin 10/99

 General Information, Specifications, and Maintenance

CURRENT PRODUCTION
3. Use a torque wrench to alternately turn parking brake
release bolts A, B and C outward (counter-clockwise)
Turn Steering until the torque decreases sharply.
Counter-clockwise Cylinder (ref.)
to Activate Brake 4. For early production vehicles, see Fig. 2–81; for
current production vehicles, see Fig. 2–82.
A 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.
B 5. The parking brakes should now be re-activated and
FRONT
the front wheels locked. Carefully remove the
C blocking from the four tires.
Brake Snap 6. Verify that the parking brake works.
Release Ring Left Side, Cross-section 7. Remove the Accident Prevention Tags from the
Bolt of Front Axle ignition switch and steering wheel.
MS2610

Figure 2–82. Alternately turn parking brake release

bolts A, B and C outward until torque decreases
(current production vehicles).

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 DO NOT weld, grind, drill, repair or modify the cab in
modular design, allowing for a relatively quick, simple any way. Any modification or damage to cab structural
exchange of the entire cab and/or component parts. The components requires cab replacement. The lives of the
cab is bolted to the cab mount, which in turn is bolted operator and others are potentially at stake.
to the frame. To help ensure optimum safety, protection and perfor-
The operator’s cab is a protective structure. The cab mance, replace the cab if it is damaged. Refer to the
itself contains roll-over protective and falling object pro- SKY TRAK Model 3606 Parts Manual for ordering infor-
mation.
tective structures (ROPS/FOPS) for the operator.
The cab contains the seat, operating controls, numer-
ous panels, steering and brake components, and more.
WARNING: The protection offered by this Covers and mirrors on the vehicle exist for safety, pro-
ROPS/FOPS will be impaired if subjected to tection and appearance. They are relatively simple to
any modification or structural damage at which remove and replace.
time replacement is necessary. ROPS/FOPS
must be properly installed using fasteners of
correct size and grade, torqued to their speci-
fied value.

Legend
1. Operator’s Protective Structure 12. Hex-lock elastic nut, 3/4-10 23. Lock washer, 3/4"
ROPS/FOPS 13. Button-head capscrew, 1/4-20 x 3/4 24. Cab panel, front
2. Headliner 14. Owners/Operators Manual holder 25. Window spacer
3. Cab rear panel 15. Flat washer, 1/4" 26. Window edge seal bulb
4. Button-head capscrew, 5/16-18 x 1 16. Hex-lock elastic nut, 1/4-20 27. *Right side window
5. Flat plastic washer, 5/16" 17. Floor mat 28. Window clip, w/offset
6. Retaining nut, 5/16-18 18. Self-drilling screw, #12-14 x 1 29. Screw
7. Hex-head capscrew, 5/16-18 x 1 19. Cab panel, front LH 30. Window clip
8. Lock washer, 5/16" 20. Cab isolator 31. Spray adhesive, 10 ounce spray can
9. Rebound washer 21. Rebound washer (for item 17)
10. Cab panel, rear LH 22. Hex-head capscrew, 3/4-10 x 3-3/4", 32. *Steel mesh window (option),
11. Flat washer, 5/16" Grade 8 glued in

4-2 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

General Overview

2
3 4
5
1

30

29
29
28 6
27 78
9 5 4
26 7
8
25 9 6

13
12
10
78
11
6

14
15
24 16 6
17

5 18
4 6
19

5
4
Frame (ref.)

32
20 MS1530

Cab mount (ref.)

31
21
20
22 Torque to 280 lb/ft (380 Nm)

21
23 PF0780

22 Torque to 280 lb/ft (380 Nm)

PS0330

Model 3606 • Origin 10/99 4-3

 Section 4

4.1 SERIAL NUMBER DECAL 4.2.1 Cab Removal

The cab serial number decal (Fig. 4–1) is located along WARNING: Wear protective footwear with
the top right side of the cab, near the mirror. Information reinforced toe caps and slip-resistant soles.
specified on the serial number plate includes the cab Failure to comply can result in foot injury from
model number, the cab serial number and other data. falling objects or other bodily injury from slip-
Write this information down in a convenient location to ping or falling.
use in cab correspondence.
Serial WARNING: NEVER lift a heavy object without
Number Decal the help of at least one assistant or a suitable
sling and hoist. Failure to comply can result in
serious personal injury.
Mirror
IMPORTANT: Remove and label cab panels and other
components as needed before removing the cab from the
vehicle. Label, disconnect and cap hydraulic hoses.
Transfer cab parts to the replacement cab after the
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,
MS0840 place the travel select lever in NEUTRAL (N), engage
the parking brake switch and shut the engine OFF.
Figure 4–1. Location of the cab serial number decal.
Open the engine hood. Allow the engine and
hydraulic fluid to cool.
4.2 CAB REPLACEMENT
2. Disconnect the battery negative (-) ground cable at
WARNING: Risk of death or severe personal the battery negative (-) terminal (Fig. 4–2).
injury. NEVER modify, weld or drill the cab.

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. Battery negative
(-) terminal
IMPORTANT: To help ensure safety and optimum per-
formance, replace the cab if it is damaged. Refer to the
SKY TRAK Model 3606 Parts Manual for ordering infor-
mation. OS1040

Before performing any inspection, maintenance or ser- Figure 4–2. Disconnect the battery negative (-) cable.
vice operation, thoroughly clean the vehicle. DO NOT
3. Remove the joystick assembly (see 4.2.6 Joystick
spray water or cleaning solution in, on, near or around
Replacement). Label, disconnect and cap the six
the operator’s dash panels and electrical components.
hydraulic hoses mounted at the base of the joystick
Inspect the cab, its welds and mounts. If modification, assembly.
damage, a cracked weld and/or fatigued metal is discov-
4. Remove the logic board panel, mounted in the front
ered, replace the cab. Contact Sky Trak or the local Sky
dash, just forward of the joystick mounting location
Trak distributor with any questions about the suitability or
(see. Fig. 4–3). Disconnect the wiring connector.
condition of a cab.
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

20
16 19
Cab (ref.)
21 13
22

Logic board 10
panel (ref.) 9 11
8
17 6 13
2 1617 18
1316 7 6
5
23 17
1 15 16 2
24 2
2
13
16 2
2 13
17 14

2 12
13
16 3
15 17 14
16 15
17
4 MS0850

Figure 4–3. Operator’s cab inner console and dash panel components.
1. Front dash 9. Well nut, #10-32 17. Hex-head capscrew,
2. Retaining nut, 5/16-18 10. Button-head capscrew, 5/16-18 x 1-1/4"
3. Lower dash cover #10-32 x 3/4" 18. Armrest
4. Self-drilling screw, #12-14 x 1" 11. Load chart holder 19. Rear tool bin
5. Slotted hex-head capscrew, 12. Console support 20. Hex-head capscrew, 5/16-18 x 2"
#10-24 x 1" 13. Rebound washer 21. Retaining ring
6. Spacer 14. Hex-lock elastic nut, 5/16-18 22. Flat washer, 1/2"
7. Fender washer 15. Flat washer, 5/16" 23. Conduit, 1/4" x 5" long
8. Hex-lock elastic nut, #10-24 16. Lock washer, 5/16" 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 LH Rear cab panel (ref.)
any spilled hydraulic fluid. Fuel filler
Fuel breather hose
WARNING: Explosion and fire hazard. Cap or
Clamp
safely cover the fuel tank and beaded hose tee
Beaded hose tee
openings.
Upper clamp
7. Remove the cab rear panel (item 3 in the General Vehicle Fuel hose
Overview illustration on page three). From behind the frame
(ref.) Lower clamp
cab, loosen the lower clamp (Fig. 4–3) securing the
fuel hose to the fuel tank. Remove the lower end of Fuel tank
the fuel hose from the fuel tank. Cap or safely cover
the fuel tank opening.
8. Loosen the clamp securing the fuel breather hose
Cab mount
(Fig. 4–3) to the top of the beaded hose tee. Remove MS0860

the lower end of the fuel breather hose from the hose Figure 4–3. Loosen the clamps and remove the fuel tank
tee. Cap or safely cover the hose tee opening. hoses from their fittings. Cap or safely cover the openings.

Model 3606 • Origin 10/99 4-5

 Section 4

9. Remove the front cab-to-cab-mount attaching 12. Route the wiring harness out of the cab. Cut and
hardware (refer to items in the General Overview dispose of plastic wire ties as needed. Secure the
illustration on page three). Front hardware includes wiring harness against the frame, safely away from
3/4-10 hex-lock elastic nuts (12), 3/4-10 x 3-1/2" the cab.
Grade 8 hex-head capscrews (22), 3/4" lock washers 13. Remove the mirrors and all other cab components,
(23) and rebound washers (21). Rear hardware as needed, if not previously removed.
includes 3/4-10 hex-lock elastic nuts (12), 3/4-10 x
3-1/2" Grade 8 hex-head capscrews (22), and 14. Use a hoist or overhead crane and sling attached to
rebound washers (21). the cab. Carefully begin to lift the cab. Stop and
check that all wiring, fuel tank components, hydraulic
Note: ALWAYS replace elastic-lined nuts with new hoses and fasteners are disconnected or removed. If
elastic-lined nuts to help ensure proper fastening. the throttle cable is still attached to the cab,
10. Remove two 3/4-10 hex-lock elastic nuts (item 12 in reposition or remove the throttle cable as necessary.
the General Overview illustration on page three), two 15. When all wiring, hydraulic hoses and fasteners are
3/4-10 x 3-3/4" Grade 8 hex-head capscrews (22) disconnected or removed, carefully and slowly lift the
and two rebound washers (21). Tap the capscrews cab and remove it from the cab mount. Readjust the
out of the cab isolators (20) from above, as required. position of the sling as needed to help balance the
11. Disconnect the throttle cable at the engine bracket cab during removal.
(Fig. 4–4). Route the cable out of the engine 16. When the cab is completely clear of the vehicle,
compartment, then close the engine hood. Allow the carefully lower it to the ground. Block up or support
cable to hang beneath the cab mount for now. the cab so that it does not move or fall. Assure that
Slotted no personnel enter the cab while it is dismounted
pan-head from the vehicle.
screw 17. Inspect the condition of the fuel tank, fuel hoses,
Throttle cable
Cable fittings, clamps, hydraulic hoses, cab isolators, etc.
clamp Replace parts as indicated by their condition.
#10 lock washer 18. Inspect and replace other vehicle parts that are
#10-24 exposed with the cab removed. Repair or replace as
hex nut Rod end required.

Bracket Throttle
lever
extension
1/4-28 NF
hex-lock
elastic nut
Cummins Engine

Slotted
pan-head
screw
Bracket

Cable
clamp
Rod end
#10 lock washer
Washer
#10-24
1/4-28 NF
hex nut Throttle
hex-lock
lever
extension elastic nut

Perkins Engine MS0870

Figure 4–4. Throttle cable to engine bracket mounting.

4-6 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

4
2
3
5

S/N 8249 - 9398*

S/N 9399 and After*

15 7.5 15 7.5 20
30 30 30 20

36 7.5

35 7.5 7.5 7.5 7.5

7.5 7.5 7.5 7.5 7.5

25 7.5 7.5 7.5

7.5 7.5

7.5 7.5 7.5 7.5

1 7.5 7.5 7.5

7.5

7.5
7.5

7.5
7.5 7.5

7.5
7.5

15

*See Section 2
for fuse and relay
11
panel information.
7
8 10
34
9

37
33 32 11
13
8
23 20 22
12
29 14
31 28
30 21 9
11

25 16
24 17
26 15 38
25 23 18
25 19
27
Before S/N 8249*
MS0880
1. Cab harness 14. Park brake switch 27. Hex-lock elastic nut, #10-24
2. Back-up alarm 15. Round-head wood screw, #6 x 1/2" 28. Flat washer, 1/4"
3. Hex-lock elastic nut, 1/4-20 16. Hourmeter 29. Lock washer, 1/4"
4. Flat washer, 1/4" 17. Machine bushing washer, 0.63" ID 30. Hex nut, 1/4-20
5. Boom sensor 18. Ignition switch (includes item 19) 31. Plastic tie
6. Service brake switch 19. Ignition key (set of two) 32. Hex jam nut, M6-1 CI4
7. Side console (logic board) panel 20. Fuse, 7.5 amp 33. Lock washer, M6
8. Button-head capscrew, #10-32 x 3/4" 21. Fuse, 40 amp 34. Signal horn
9. Well nut, #10-32 22. Fuse, 15 amp (Perkins cold start only) 35. Tube clip
10. Steer select switch 23. Sealed relay, 12V, 40A 36. Hex lock nut, 1/2-13
11. Switch bezel 24. Slotted pan-head screw, #10-24 x 3/4" 37. Attachment tilt mode switch
12. Auxiliary detent switch (optional) 25. Narrow flat washer, #10 38. Attachment tilt direction harness
13. Front console dash 26. Slotted pan-head screw, #10-24 x 5/8"
Figure 4–6. Label and disconnect wiring harnesses and wire leads at their connectors.

Model 3606 • Origin 10/99 4-7

 Section 4

4.2.2 Cab Installation 3/4-10 x 3-3/4" Grade 8 hex-head capscrews (22)

that secure the cab (1) to the cab mount (ref.). Tap
WARNING: Explosion and fire hazard. Cap or the capscrews into the cab isolators (20) from below,
safely cover the fuel tank and beaded hose tee as required, but DO NOT distort or damage the cab
openings. isolators.
Note: ALWAYS replace elastic-lined nuts with new
WARNING: Wear protective footwear with elastic-lined nuts to help ensure proper fastening.
reinforced toe caps and slip-resistant soles. 9. At the front of the cab (1), install but DO NOT tighten
Failure to comply can result in foot injury from the two 3/4-10 hex-lock elastic nuts, two 3/4" lock
falling objects or other bodily injury from slip- washers (23), two rebound washers (21) and two 3/4-
ping or falling. 10 x 3-1/2" Grade 8 hex-head capscrews (22). Tap
the capscrews into the cab isolators (20) from below,
WARNING: NEVER lift a heavy object without as required, but DO NOT distort or damage the cab
the help of at least one assistant or a suitable isolators.
sling and hoist. Failure to comply can result in
serious personal injury. Note: ALWAYS replace elastic-lined nuts with new
elastic-lined nuts to help ensure proper fastening.
IMPORTANT: Transfer and install cab panels and other
10. From behind the cab, position the lower clamp (Fig.
components as needed after the cab is securely
4–3) on the fuel hose. Remove any cap or safety
mounted on the vehicle.
cover from the fuel tank opening. If needed, secure
1. Cap or safely cover any fuel-tank or fuel-fitting the fuel filler to the cab and the top end of the fuel
openings. Inspect vehicle parts that are exposed with hose to the fuel filler.
the cab removed. Repair or replace as required.
11. Slip the lower end of the fuel hose onto the fuel hose
2. Block all four wheels to help prevent the vehicle neck on the fuel tank and tighten the lower clamp.
from moving. Assure that there is sufficient overhead
12. Position a clamp on the fuel breather hose (Fig. 4–3).
and side clearance for cab installation.
Remove any cap or safety cover from the beaded
3. Disconnect the cable at the battery negative (-) hose tee. If needed, secure the top end of the fuel
terminal (Fig. 4–2) as required. breather hose to the fuel filler with another clamp.
4. Install cab isolators (item 20 in the General Overview 13. Secure the bottom end of the fuel breather hose to
illustration on page three) into the mounting holes on the beaded hose tee.
the cab mount.
14. From beneath the cab, route and connect the cab
5. Use a hoist or overhead crane and sling attached to wiring harness (Fig. 4–6). Install plastic conduit as
the cab (1). Carefully begin to lower the cab onto the required to protect the wiring as it passes through
cab mount. Stop and check that wiring, fuel tank metal openings. Secure wiring with plastic wire ties
components, hydraulic hoses, etc., will not be as needed.
pinched or damaged as the cab is lowered.
15. Route the joystick, power steering and service brake
6. Route the throttle cable (Fig. 4–4) from beneath the hydraulic hoses from the frame into the cab. Using
cab to the engine compartment by simply positioning the hose labels made and attached earlier, connect
the cable under the frame, then up between the the hoses at the joystick, power steering valve and
transmission and engine. Bring the cable across the brake control valve. Wipe up any spilled hydraulic
side of engine to the throttle cable bracket. DO NOT fluid.
attach the cable to the throttle lever extension on the
16. Check that the cab is not distorting, pinching,
engine at this time.
crushing or damaging the throttle cable, wiring or
7. Carefully and slowly lower the cab (item 1 in the hydraulic hoses. Make adjustments as necessary.
General Overview illustration) onto the cab mount.
17. Tighten the cab-to-cab-mount hardware (refer to the
Align the cab with the cab isolators (20) as the cab is
General Overview illustration). Torque the 3/4-10
lowered. Readjust the position of the sling as needed
hex-lock elastic nuts (12) and 3/4-10 x 3-1/2" Grade 8
to help balance the cab during installation.
hex-head capscrews (22) to 280 lb/ft (380 Nm).
8. Install the cab-to-cab-mount attaching hardware
18. After the cab is securely mounted to the vehicle,
(items 12, 21, 22 and 23). At the rear of the cab,
install all parts in the cab as required.
install but DO NOT tighten the two 3/4-10 hex-lock
elastic nuts (12), two rebound washers (21) and two 19. Connect the throttle cable at the engine (Fig. 4–4)
and, if necessary, to the throttle pedal.

4-8 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

20. Connect the battery negative (-) ground cable An optional three-inch wide seat belt is available for
(Fig. 4–2). those locations that require a three-inch seat belt.
21. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any A. Seat Replacement
faulty conditions. The seat can be removed from the cab by removing the
fasteners, including two tether cables, which secure the
WARNING: DO NOT use your hand or any
seat to the cab. The seat belt is also easily removed by
part of your body to check for hydraulic leaks.
removing the nuts, spacers, washers and capscrews
Hydraulic oil leaking under pressure can pene-
securing it to the seat frame. The seat tethers are
trate the skin and cause severe personal injury.
secured to the seat with the seat belt capscrews.
When checking for hydraulic leaks, wear safety
glasses and gloves to help provide protection The seat and seat slides may be removed from the sus-
from spraying hydraulic oil. Use a piece of card- pension unit and mounting plate by removing four lock
board or paper to search for leaks. nuts and flat washers that attach the seat slides to the
suspension unit.
22. Start the engine and check the operation of all
controls. Check for hydraulic fluid leaks. Check the Standard Seat Removal
hydraulic fluid level in the tank and add fluid as
required. Working from the outside rear of the cab, remove the rear
cab panel (item 3 in the General Overview illustration) to
4.2.3 Operator’s Seat and Seat Belt gain access to the seat tether mounting hardware. The
rear cab panel is secured to the cab with 5/16-18 button-
Three types of operator’s seats are used. These include head capscrews (4), 5/16" flat plastic washers (5) and
the standard operator’s seat (Fig. 4–7), and two optional 5/16-18 retaining nuts (6).
seats that include a headrest and are covered in either
deluxe vinyl or deluxe cloth material and include head- Note: Early production operator’s cabs included a
rests. The seat belt is attached to the seat assembly. threaded hole for tether mounting. In Fig. 4–9, items 13
through 16 are not used on early production cabs.
Standard Optional 1. Remove the 3/8-16 hex-lock elastic nuts
seat seats (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
MS0890
close proximity of the seat to the cab wall. Move the
seat all the way forward, and tip the seat back all the
Figure 4–7. Seat styles include standard and optional. way forward to gain access as needed to the tether
The seat assembly consists of upper (backrest) and mounting hardware from inside the cab. If necessary,
lower (bottom) cushions mounted on an adjustable sus- remove the seat base mounting hardware before
pension unit (Fig. 4–8). Three seat adjustments can be removing the right-side tether.
made: fore and aft position, suspension stiffness and Note: Early production operator’s cabs included a
backrest angle. Seat adjustment information is contained threaded hole for tether mounting. In Fig. 4–9, items 13
in the owners/operators manual. through 16 are not used on early production cabs.
Backrest angle 3. Remove four 5/16-18 hex-lock elastic nuts
adjustment lever
(12, Fig. 4–9) and four 5/16 flat narrow washers
Suspension
adjustment securing the seat (1) to the seat support (9).
knob Note: ALWAYS replace elastic-lined nuts with new
elastic-lined nuts to help ensure proper fastening.
Fore & aft Seat 4. Carefully remove the seat (Fig. 4–9) from the cab.
adjustment belt Remove the seat belt assembly and tethers (or
handle transfer these parts to the replacement seat) with the
OS0200
seat out of the cab.
Figure 4–8. Seat positions and stiffness can be adjusted.

Model 3606 • Origin 10/99 4-9

 Section 4

Standard Optional
seat seats 1
1
7
5 2
3 6 7 2
3
4
8 4
2
5 5

3 2
8 5 3 4
6
7
4 6
8
9
14
9 13
12
10 11
11 11
12

16
15
9
14
10
13

11
12

MS0900

Figure 4–9. Standard (left) and optional (right) seats.

Standard Operator’s Seat Parts Legend Optional Operator’s Seat Parts Legend
1. Seat 1. Deluxe seat (covered with CLOTH or VINYL),
2. Tether with suspension
3. Spacer 2. Tether
4. Retractable seat belt assembly (includes items 5 through 8) 3. Spacer
5. Washer 4. Retractable seat belt assembly (includes items 5 through 8)
6. Hex-head capscrew 5. Hex nut
7. Hex-head capscrew 6. Hex-head capscrew
8. Hex nut 7. Flat washer
9. Seat support 8. Hex-head capscrew, 5/16-18 x 1", Grade 5
10. Hex-head capscrew, 5/16-18 x 1", Grade 5 9. Narrow flat washer, 5/16"
11. Narrow flat washer, 5/16" 10. Hex-lock elastic nut, 5/16-18
12. Hex-lock elastic nut, 5/16-18 11. Hex jam nut, 3/8-16
13. Hex jam nut, 3/8-16 12. Flat washer, 3/8"
14. Flat washer, 3/8" 13. Rebound washer
15. Rebound washer 14. Hex-lock elastic nut, 3/8-16
16. Hex-lock elastic nut, 3/8-16

4-10 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

Standard Seat Installation 5. Attach the rear cab panel (refer to the General
Overview illustration) to the cab with 5/16-18 button-
1. Install the seat belt assembly (4, Fig. 4–9) and
head capscrews, 5/16 plastic washers and 5/16-18
tethers (2) on the seat with the seat out of the cab.
retaining nuts.
2. Within the cab, access to the right-side tether
(Fig. 4–10) is restricted due to the closeness of the Optional Seat Removal
seat to the cab wall. Move the seat all the way
forward, and tip the seat back all the way forward to 1. Working from the outside rear of the cab, remove the
gain access as needed to the tether mounting rear cab panel (refer to the General Overview
hardware from inside the cab. If necessary, install the illustration on page three) to gain access to the seat
right-side tether before securing the seat base tether mounting hardware. The rear cab panel is
mounting hardware. secured to the cab with 5/16-18 button-head
capscrews, 5/16 plastic washers and
Note: Early production cabs included a threaded hole for 5/16-18 retaining nuts.
tether mounting. In Fig. 4–9, items 13 through 16 are not
used on early production cabs. 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.
Cab
2. Remove the 3/8-16 hex-lock elastic nuts (optional
seat item 14, Fig. 4–9) and rebound washers (13)
Hex-lock
securing the tethers (2) to the rear of the cab.
elastic nut Note: ALWAYS replace elastic-lined nuts with new
elastic-lined nuts to help ensure proper fastening.
Rebound
washer 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
Tether
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
Right-side hardware before removing the right-side tether.
seat belt 4. Remove four 5/16-18 hex-lock elastic nuts (10,
hardware Fig. 4–9), eight 5/16 flat narrow washers (9), and four
MS0910
5/16-18 x 1" Grade 5 hex-head capscrews (8)
securing the seat (1) to the cab seat platform.
Figure 4–10. Typical late-model seatbelt tether attachment.
Note: ALWAYS replace elastic-lined nuts with new
3. Position the seat on the seat support (9, Fig. 4–9). elastic-lined nuts to help ensure proper fastening.
Align the seat bracket mounting holes with the holes
5. Remove the seat from the cab. Remove the seat belt
in the seat support. Secure the seat to the seat
assembly and tethers (or transfer these parts to the
support with four 5/16-18 hex-lock elastic nuts (12)
replacement seat) with the seat out of the cab.
and four 5/16 flat narrow washers securing the seat
(1) to the seat support (9). Torque to 18 lb/ft (24 Nm).
Optional Seat Installation
Note: ALWAYS replace elastic-lined nuts with new
1. Install the seat belt assembly (4, Fig. 4–9) and
elastic-lined nuts to help ensure proper fastening.
tethers (2) on the replacement seat with the seat out
4. Working at the outside rear of the cab with the rear of the cab.
cab panel removed (refer to the General Overview 2. Access to the right-side tether (Fig. 4–10) is
illustration on page three), secure the tethers (2, Fig. restricted due to the closeness of the seat to the cab
4–9) to the cab with 3/8-16 hex-lock elastic nuts (16) wall. Move the seat assembly all the way forward,
and rebound washers (15). and tip the seat backrest all the way forward to gain
Note: Early production cabs included a threaded hole for access as needed to the tether mounting hardware
tether mounting. In Fig. 4–9, items 13 through 16 are not from inside the cab. If necessary, install the right-side
used on early production cabs. tether before securing the seat base mounting
hardware.
Note: ALWAYS replace elastic-lined nuts with new
elastic-lined nuts to help ensure proper fastening.
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 1
used on early production cabs.
2
3. Position the seat on the seat base. Align the seat
bracket mounting holes with the holes in the cab seat
14 3
platform. Secure the seat to the seat base with four
5/16-18 hex-lock elastic nuts (10, Fig. 4–9), eight 15
5/16 flat narrow washers (9), and four 5/16-18 x 1"
Grade 5 hex-head capscrews (8) securing the seat 13
(1) to the seat support. Torque to 18 lb/ft (24 Nm). Horn
14 12 4 switch
Note: ALWAYS replace elastic-lined nuts with new 11 lead
elastic-lined nuts to help ensure proper fastening.
9 10
4. Working from the outside rear of the cab with the rear
cab panel removed (refer to the General Overview 6 5
illustration on page three), secure the tethers (2, Fig.
8 7
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.
Power
5. Attach the rear cab panel (refer to the General steering
Overview illustration on page 4-3) to the cab with valve
5/16-18 button-head capscrews, 5/16 plastic washers
and 5/16-18 retaining nuts. Service brake
pedal
4.2.4 Controls
Operator’s cab controls (Fig. 4–11) include the steering PS0540

wheel, horn button, ignition switch, transmission shifter, Figure 4–12. Steering column, steering wheel and shifter.
service brake pedal, throttle pedal and joystick.
Steering Column Parts Legend
Steering
wheel 1. Horn button cover
Horn
Transmission 2. Thin nut, M18-1,5
button
shifter Joystick 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
Ignition 8. Hex nut, #10-32
switch 9. Transmission shift control switch
10. Transmission shifter spacer
11. Lock washer, 3/8"
Service brake
pedal Throttle 12. Hex socket-head screw, 3/8-16 x 1"
pedal OS0091 13. J-nut, #10-24
14. Button-head screw, #10-24 x 5/8"
Figure 4–11. Operator’s cab controls.
15. Steering column top cover

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).

4-12 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

Steering Wheel Removal 3. Remove the four 3/8-16 x 1" hex socket-head screws
(12) and 3/8 lock washers (11) securing the steering
1. Carefully pry the horn cover button out of its recess in
column (6) to the steering valve.
the steering wheel. Disconnect the horn wire lead.
4. Remove the steering column from the cab.
2. Remove the thin M18-1,5 nut securing the steering
wheel to the splined steering column shaft.
Steering Column Installation
3. Use a steering wheel puller to remove the steering
wheel from the splined shaft. 1. Position the steering column (item 6, Fig. 4–12)
within the cab and engage the splined lower end of
Steering Wheel Installation the steering shaft with the power steering valve.
Press the steering column shaft down into the power
1. Install the steering wheel (Fig. 4–12) onto the splined steering valve. Fully engage the splines.
steering column shaft.
2. Align the four steering column mounting holes with
2. Secure the steering wheel with a thin M18-1,5 nut. the dash panel and power steering valve mounting
Torque the nut to 50 lb/ft (68 Nm). holes. Secure the steering column with four 3/8-16 x
3. Connect the horn wire lead, then press the horn 1" hex socket-head screws (12) and 3/8 lock washers
cover button into its recess in the steering wheel. (11). Torque to 31 lb/ft (42 Nm).
3. Connect the transmission shift switch (9) and horn
Transmission Shift Control Switch Removal switch leads to the wiring harness.
1. Remove four #10-24 x 5/8" button head screws (item 4. Install the steering column bottom (5) and top (15)
14, Fig. 4–11) and four #10-24 J-nuts (13) securing covers onto the steering column. Secure with four
the steering column bottom (5) and top (15) covers #10-24 x 5/8" button-head screws (14) and #10-24
onto the steering column (6). J-nuts (13).
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 4.2.6 Joystick Replacement
#10 lock washers (7) securing the transmission shift
control switch (9) to the steering column (6). A. Joystick Handle Replacement

3. Disconnect the electrical connector and remove the Joystick Handle Removal
transmission shift control switch (9).
1. Remove the rubber boot (Fig. 4–13) from the joystick.
Transmission Shift Control Switch Installation Slide the boot up and over the joystick to reveal
wiring, a threaded shaft and mounting nut (jam nut).
1. Position the transmission shift control switch (item 9,
Fig. 4–12) onto the steering column (6). 2. Disconnect the wiring and loosen the upper jam nut
securing the joystick to its base. Remove the joystick.
2. Plug the electrical connector in to its harness lead.
3. Attach the transmission shift control switch with two Joystick handle
#10-32 x 1-1/2" hex socket-head screws (4), #10-32 (boot removed)
hex nuts (8) and #10 lock washers (7). Tighten the Mounting nut
screws and nuts securely but DO NOT overtighten. (jam nut)
Overtightening will cause the shift control switch to 1/4-20 x 1"
break. capscrew
4. Install the steering column bottom (5) and top (15) Joystick
assembly 1/4"
covers onto the steering column. Secure with four lockwasher
#10-24 x 5/8" button-head screws (14) and #10-24 Joystick
J-nuts (13). DO NOT overtighten.
Front dash
Rubber boot
Steering Column Removal (ref.)

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 MS0920
column.
Figure 4–13. Joystick mounting arrangement.
2. Disconnect the transmission shift switch (9) and horn
switch leads from the wiring harness.

Model 3606 • Origin 10/99 4-13

 Section 4

Joystick Handle Installation IMPORTANT: Before proceeding, determine which type

of joystick mounting fasteners are used. Reach into the
1. Apply Loctite® #272 (red) to the threaded stud on the
logic panel opening and back toward the joystick. From
joystick handle. Position the joystick mounting stud
inside the console, feel along the front lower edge of the
into the base mounting hole and turn the handle to
joystick base to determine whether "long" internally-
thread it into the base. Align the joystick in the
threaded hex nuts are installed, or if nutserts are used.
forward position.
If long hex nuts are used, go to step 5 and follow the
2. Secure the joystick by tightening the mounting nut steps for Early Production Vehicles. If nutserts are used,
(jam nut) at the threaded end of the joystick onto the go to step 4 and follow the steps for Current Production
threaded shaft in the joystick assembly base. Vehicles.
3. Connect the joystick wire lead to the logic board plug 4. Current Production Vehicles
and install the rubber boot over the joystick. Remove the three flange-head capscrews and
4. Check for proper operation of all joystick functions. lockwashers securing the joystick assembly to its
mounting hole in the side console (Fig. 4–16). Save
B. Joystick Assembly Replacement the three flange-head capscrews and lockwashers for
reuse later. GO TO STEP 11.
Joystick Assembly Removal
1. Park the vehicle on a firm, level surface. Set the park Joystick
Flange-head
brake, ground the carriage, place the transmission in Capscrew
NEUTRAL (N) and turn the ignition OFF.
2. Remove the boot from the joystick by pulling the boot Lockwasher
off the base (Fig. 4–14).

Joystick

Boot
SS1200

Figure 4–16. For Current Production Vehicles, remove

the flange-head capscrews and lockwashers securing
the joystick assembly to the console.
Base

5. Early Production Vehicles

SS1190
Pry the entire switch bezel out and away from the
Figure 4–14. Remove the boot from the joystick. side console (Fig. 4–17). Label, then disconnect the
3. Remove the four button-head capscrews holding the wiring harness leads at the switches. Remove the
logic panel to the side console (Fig. 4–15). Carefully switch bezel from the vehicle.
pry the logic console upward. Label, then disconnect
the wiring harness leads at the logic panel. Remove
the logic panel from the vehicle. Switch
Bezel
Button-head
Capscrew

Side
Console
SS1220

Logic Panel Figure 4–17. For Early Production Vehicles,

SS1210
remove the switch bezel from the vehicle.

Figure 4–15. Remove the four button-head capscrews.

4-14 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

6. From the outside rear of the cab (Fig. 4–18), remove

the four button-head capscrews and plastic washers
securing the outer rear panel to the cab. Remove the
outer rear panel.
Button-head
Capscrew
Cab Plastic Washer

Outer Rear Capscrews,

Panel Lockwashers
and Flat Washers
SS1230

Figure 4–18. Remove the button-head capscrews and

plastic washers securing the outer rear panel to the cab.
SS1240

7. From the outside rear of the cab, remove the three Figure 4–20. Remove the fasteners
hex-head capscrews, lockwashers and flat washers from inside the glove box.
securing the rear tool bin to the cab (Fig. 4–19). Save
the fasteners for reinstallation later.
9. Use a one-inch (25mm) wooden block (Fig. 4–21) or
Cab other suitable device to raise and hold the front dash,
Rear Tool allowing access to the nuts on the underside of the
Bin joystick. Remove the three long nuts, lockwashers
and flat washers from the underside of the joystick.
Remove the three flange-head capscrews. Save the
fasteners for reinstallation later.

Joystick Flange-head
Capscrew

Flat Washer
Lockwasher Flat Washer
Front Dash
Capscrew
Lockwasher
SS1250
Wooden Block
Figure 4–19. Remove the three hex-head capscrews,
"Long" Nut
lockwashers and flat washers SS1260
securing the rear tool bin to the cab.
Figure 4–21. Raise the dash with a wooden block and
remove the fasteners securing the joystick.
8. Inside the cab, raise the glove box armrest. Inside the
glove box (Fig. 4–20), remove the three capscrews,
10. Reach through the logic panel opening and position
lockwashers and flat washers securing the rear tool
the joystick wires as shown in Fig. 4–22 on the next
bin to the right side of the cab, to the right side cab
page. Raise the joystick enough to expose and allow
wall, and to the front dash. Slide the seat completely
access to the hydraulic hose fittings connected to the
forward and remove the rear tool bin. Save the
joystick control valve on the underside of the joystick.
fasteners for reinstallation later.
Note: As required, remove tie wraps securing the joy-
stick hydraulic hoses together beneath the vehicle frame.
Removing the tie wraps will allow the hoses to be pulled
further out of the joystick opening in the console.

Model 3606 • Origin 10/99 4-15

 Section 4

Logic Panel Joystick Ports As Viewed

Opening From Bottom Side

Joystick Wires SS1270

Small O-Ring Long Fitting
Figure 4–22. Reach through the logic panel opening and
position the joystick wires as shown.
Large O-Ring
Fitting
11. Use labels, tape or some type of permanent paint or SS1290
marker to mark the six hoses on the underside of the Figure 4–24. Joystick valve port fittings and O-rings.
joystick valve as shown in Fig. 4–23.
Joystick Joystick Assembly Installation
1. As required, carefully remove the rubber boot from
the joystick by pulling the boot off the joystick base
(Fig. 4–14) and lifting it over the joystick handle. Save
the boot for installation later.
Note: If installing a new joystick assembly, label or per-
manently mark the hose ports on the underside as
shown in Fig. 4–24. Remove any port plugs before pro-
Ports As Viewed ceeding.
From Bottom Side
2. Place the joystick in a vise or other suitable device.
Install new small and large O-rings and the six
straight fittings into the joystick valve ports
(Fig. 4–24) if necessary. To help avoid leaky
connections, always use new O-rings when servicing
Front Of the vehicle.
Vehicle 3. Position the joystick assembly above its mounting
hole in the console. Remove the plug from the hose
labeled "P" and secure the hose to the "P" port of the
joystick valve.
SS1280 4. Remove the plug from the hose labeled "T" and
secure the hose to the "T" port of the joystick valve.
Figure 4–23. Label the joystick hoses and ports as shown.
Remove the plugs from the remaining hoses one at a
12. Remove and plug the hose ends to help prevent time and secure each hose as labeled to the proper
excess hydraulic fluid spillage and to prevent fitting on the joystick control valve. Tighten all fittings
contaminants from entering the hydraulic system. securely.
13. Remove the joystick assembly from the vehicle. 5. Position the lower joystick wires as indicated in Fig.
14. Place the joystick in a vise or other suitable device. 4–22. Reach in through the logic panel opening and
Remove the six straight fittings from the joystick valve guide the wires up through the logic panel opening
ports (Fig. 4–24). Remove and discard all of the while lowering the joystick assembly down into its
small and large O-rings from the joystick valve and mounting hole in the console.
fittings (to help avoid leaky connections, always use
new O-rings when servicing the vehicle).

4-16 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

6. Connect all wire leads to the proper connectors on 14. Early Production Vehicles
the logic panel. Set the logic panel in its mounting Use a one-inch (25mm) wooden block or other
hole, but DO NOT secure with fasteners at this time. suitable device to raise and hold the front dash (Fig.
7. Check all joystick functions for proper operation: 4–26), allowing access to the underside of the
joystick. Install three flange-head capscrews through
8. Start the engine and move the joystick handle the mounting holes in the base of the joystick
rearward, activating the boom hoist function. The assembly and through the corresponding joystick
boom should raise or lift. assembly mounting holes in the console.
9. Move the joystick handle forward, activating the
boom lower function. The boom should go down.
Flange-head
10. Move the joystick handle to the right, activating the Joystick Capscrew
boom extend function. The boom should extend.
11. Move the joystick handle to the left, activating the
boom retract function. The boom should retract.
Logic Panel
12. If any of the functions fail to work as described, a Opening
hydraulic hose is most likely connected to the wrong Flat Washer
joystick valve port. Relocate hoses as required to Front Dash
Lockwasher
attain proper joystick function. Wooden Block
13. Current Production Vehicles "Long" Nut
Align the joystick assembly mounting holes with the SS1260

console holes (Fig. 4–25). Secure the joystick Figure 4–26. Raise the dash with a wooden block and
assembly to the side console with three flange-head install the fasteners to secure the joystick.
capscrews and lockwashers. GO TO STEP 16.
15. Reach through the logic panel opening and, from the
Joystick Flange-head underside of the joystick, secure the flat washers,
Capscrew lockwashers and long nuts to the flange-head
capscrews. Tighten all fasteners securely.
Lockwasher

Button-head
Capscrew

SS1200

Figure 4–25. For Current Production Vehicles, remove Logic Panel

the flange-head capscrews and lockwashers securing SS1210
the joystick assembly to the console.
Figure 4–27. Secure the logic panel to the console
with four button-head capscrews.

16. Connect the wiring harness leads to the logic panel

terminal. Install the panel with the graphic symbols
oriented properly as viewed from the operator's
position. Secure the panel to the side console with
four button-head capscrews (Fig. 4–27).

Model 3606 • Origin 10/99 4-17

 Section 4

20. Raise the armrest. From inside the glove box, install
the three capscrews, lockwashers and flat washers
and secure the tool bin to the right side of the cab, to
Joystick
the right side cab wall, and to the front dash.
21. From the outside rear of the cab, secure the rear tool
Boot bin (Fig. 4–30) to the cab with three flat washers,
lockwashers and hex-head capscrews.

Cab
Rear Tool
Bin
Base

SS1190
Figure 4–28. Slide the boot onto the joystick.
17. Install the joystick boot (Fig. 4–28) by pulling the boot
over the joystick handle and down onto the base.
Properly seat the boot "lip" within the grooves in the
joystick base to help provide a water-tight seal.
Note: If any tie wraps were removed from the joystick Flat Washer Lockwasher
hydraulic hoses beneath the vehicle frame, bundle the
Capscrew
hoses and secure with new tie wraps as required to pre-
vent the hoses from contacting any sharp edges or mov- SS1250

ing parts. Figure 4–30. Install the three hex-head capscrews,

18. Current Production Vehicles lockwashers and flat washers
securing the rear tool bin to the cab.
Wipe up any spilled hydraulic oil. This completes the
installation process for Current Production Vehicles.
19. Early Production Vehicles 22. From the outside rear of the cab (Fig. 4–31), secure
Move the seat all the way forward. Place the rear tool the outer rear panel to the cab with four plastic
bin (Fig. 4–29) into position within the cab. Align the washers and button-head capscrews.
mounting holes at the front of the tool bin with the Button-head
corresponding holes in the front dash panel. Capscrew

Rear Tool Bin Cab

Plastic Washer

Outer Rear
Panel

SS1230

Figure 4–31. Install the plastic washers and button-head

Capscrews, capscrews securing the outer rear panel to the cab.
Lockwashers
and Flat Washers
23. Connect the wiring harness leads to the terminals of
the switches within the switch bezel (Fig. 4–32). Snap
the bezel into its console mounting hole.
SS1240

Figure 4–29. Install the fasteners

from inside the glove box.

4-18 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

Service Brake Pedal Installation

1. Position the service brake pedal (Fig. 4–33) in its
Switch mounting location within the cab.
Bezel 2. Insert two brake pedal pivots into their mounting
locations on the service brake pedal.
3. Insert a 1/2" flat washer onto a 1/2-13 x 2" hex-head
Side capscrew. Work the capscrew through one side of
Console the brake pedal-to-cab mounting support. Secure
SS1220 with a 1/2" flat washer and a new 1/2-13 hex-lock
Figure 4–32. For Early Production Vehicles, elastic nut. Torque to 75 lb/ft (102 Nm).
snap the switch bezel into position in the side console.
Note: ALWAYS replace elastic-lined nuts with new
24. Wipe up any spilled hydraulic oil. This completes the elastic-lined nuts to help ensure proper fastening.
installation process for Early Production Vehicles.
4. Check the operation of the brake switch; adjust by
4.2.7 Service Brake Pedal Replacement threading the switch in or out as required.
5. Install and secure the lower dash cover (item 3, Fig.
Service Brake Pedal Removal 4–3) with three #12-14 x 1" self-drilling screws.
1. Remove the three #12-14 x 1" self-drilling screws
(refer to item 4 in Fig. 4–3) securing the lower dash 4.2.8 Throttle Pedal Replacement
cover (3, Fig. 4–3) to the cab.
Throttle Pedal Removal
2. Remove the lower dash cover.
1. Remove the three 1/4-20 x 1-1/4" hex-head
3. Remove the two 1/2-13 x 2" hex-head capscrews capscrews (item B, Fig. 4–34), 1/4" lockwashers (C)
(Fig. 4–33) and 1/2-13 hex-lock elastic nuts securing and SAE flat 1/4" washers (D) securing the throttle
the service brake pedal to the cab. Capture the four pedal assembly (A) to the cab floor (ref.).
1/2" flat washers and both brake pedal pivots as the
capscrews are removed. 2. Remove the extension spring (F) as required from
the throttle pedal assembly.
Note: ALWAYS replace elastic-lined nuts with new
3. Remove the hex jam nut (E) and SAE flat 1/4" washer
elastic-lined nuts to help ensure proper fastening.
(D) securing the throttle cable (G) to the throttle pedal
4. Remove the service brake pedal from the cab. assembly (A).
4. Remove the throttle pedal assembly (A) from the cab.

A
1/2-13 x 2" Brake control valve B
capscrew D G
C

1/2" flat Brake pedal to E To engine

washer cab mounting support compartment
Cable (see Fig. 4–2)
F clamp
(ref.)

Service Cab floor

brake (ref.) MS0930
pedal
M10 lock washer Figure 4–34. Throttle pedal mounting arrangement.

M10-1,5 x 30 mm
Brake 1/2" flat
capscrew
pedal washer 1/2-13 hex-lock
pivot elastic nut
PS0530

Figure 4–33. Service brake pedal mounting arrangement.

Model 3606 • Origin 10/99 4-19

 Section 4

Throttle Pedal Installation 4.2.9 Mirror Replacement

1. Install the hex jam nut (item E, Fig. 4–34) and SAE WARNING: A mirror with cracked glass can
flat 1/4" washer (D) onto the end of the throttle cable cause cuts. Handle a cracked or broken mirror
(G). Secure the cable to the throttle pedal (A). with care to help avoid personal injury.
Note: If throttle cable (G) replacement is required (refer
to Fig. 4–2), the cab must be unbolted from its mount and
raised slightly to permit cable removal.
2. If needed, attach one end of the extension spring (F) 1
to the throttle pedal lever beneath the pedal. Attach 3
the other end of the spring to the cable clamp (ref.). 4
5
3. Align the throttle pedal assembly (A) with its mount
holes in the cab floor (ref.).
4. Install three 1/4-20 x 1-1/4" hex-head capscrews (B), 2
1/4" lock washers (C) and SAE flat 1/4" washers (D)
securing the throttle pedal assembly (A) to the cab
floor. Torque to 9 lb/ft (12 Nm).

Throttle Adjustment
1. From within the cab, lightly depress the throttle pedal
(Fig. 4–35) to full-throttle position. As needed, adjust
the limit-stop screw until it touches the pedal. Tighten
the locknut to 120 to 125 lb/in (13,6 to 14,1 Nm).
Throttle
Limit-stop pedal
screw

Locknut

Cab
10 11
floor 9
8 6
MA0191 4 7

Figure 4–35. Adjust the throttle limit-stop screw.

IMPORTANT: During the full throttle check:
• DO NOT operate any hydraulic function;
• DO NOT steer or apply any pressure to MS0940
the steering wheel;
1. Convex mirror head 7. Mirror arm assembly
• Keep the transmission in NEUTRAL (N).
2. Mirror arm assembly 8. Hex-head capscrew,
2. Check the engine rpm at full throttle. If the rpm is not M6-1 x 14 mm
3. Hex-head capscrew,
2600 to 2800 rpm, readjust the throttle limit-stop M6-1 x 20 mm 9. Slotted round-head screw,
screw at the throttle pedal within the cab. 4. Lock washer, M6 #10-24 x 5/8"
5. SAE flat light washer, 1/4" 10. Lock washer, #10
6. Rear view mirror 11. Rear view mirror
assembly
Figure 4–36. Mirror mounting arrangement.
The vehicle is equipped with three rear-view mirrors (Fig.
4–36). These include two cab-mounted mirrors (items 6
and 11), one on the left (6), another on the top right (11),
and an engine hood mounted mirror (1).

4-20 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

Keep the mirrors clean for optimal operator performance. 4.3 CAB COVERS AND GUARDS
Replace any mirror with cracked glass as vehicle use and
vibration will eventually, if not immediately, cause the 4.3.1 Cover and Guard Replacement
crack(s) to worsen or the mirror glass to fall out. The vehicle is equipped with various covers and guards
The mirror mounted on the left side of the cab (item 6, (Fig. 4–37). Removal and installation are easily accom-
Fig. 4–36) and the hood-mounted mirror head (1) are plished by observing the mounting configurations as
attached to mirror arm assemblies. These mirror heads shown in the illustration.
can be replaced independently of the arm and mounting
hardware. 4.3.2 Engine Hood
The mirror assembly (item 11, Fig. 4–36) and mirror
assembly arms (2 and 7) are secured to the vehicle with Engine Hood Removal
screws (3, 8 and 9) and washers (4, 5 and 10). Removal
WARNING: Risk of severe personal injury.
and installation are easily accomplished by observing the Contact with hot engine or other components
mounting configurations illustrated in Fig. 4–36. will cause burns. Allow engine and components
to cool completely before proceeding. Failure to
comply will result in personal injury.
4.2.10 Cab Panel Replacement
1. Park the vehicle on a firm, level surface. Allow
The cab is equipped with various panels, as shown in sufficient overhead clearance for engine hood
Fig. 4–37 and in the General Overview illustration on removal. Level the vehicle, ground the attachment,
page three. Removal and installation are easily accom- place the travel select lever in NEUTRAL (N), engage
plished by observing the mounting configurations as the parking brake switch and shut the engine OFF.
shown in the illustrations. Open the engine hood. Allow the engine and
hydraulic fluid to cool.
Note: If performing this procedure outside where blow-
ing wind is a factor, control hood movement at all times.
Wind can cause the hood to move unexpectedly.
2. Unlock and raise the hood (item 1, Fig. 4–37).
3. Support the hood in a suitable manner. Disconnect
the top spring clip (11) from the gas spring (15).
Reattach the spring clip to the gas spring and lower
the gas spring down out of the way. It is not
necessary to detach the lower spring clip or to
remove the gas spring.
4. Remove the cotter pins (18) and washers (4) from the
clevis pins (19). Remove the clevis pins.
5. With the help of at least one assistant, carefully lift
and remove the cover.
6. Store the cover securely to help prevent damage.

Model 3606 • Origin 10/99 4-21

 Section 4

Engine Hood Installation Note: If performing this procedure outside where blow-
ing wind is a factor, control hood movement at all times.
WARNING: Risk of severe personal injury. Wind can cause the hood to move unexpectedly.
Contact with hot engine or other components
will cause burns. Allow engine and components 2. With the help of at least one assistant, lift the hood
to cool completely before proceeding. Failure to into position, aligning the hinges (2 and 6) over their
comply will result in personal injury. mounts on the engine panel (20).
3. Insert the cotter pins (18) through the hinges and
1. Park the vehicle on a firm, level surface. Allow engine panel mount. Secure with washers (4) and
sufficient overhead clearance for engine hood clevis pins (19).
installation (item 1, Fig. 4–37). Level the vehicle,
ground the attachment, place the travel select lever in 4. Support the hood in a suitable manner. Attach the
NEUTRAL (N), engage the parking brake switch and gas spring (15). Secure the gas spring with spring
shut the engine OFF. Allow the engine and hydraulic clips (11) as required. Remove the support.
fluid to cool. 5. Close the cover slowly and carefully, checking for,
and rectifying, any obstruction or hinge binding.
6. Close and lock the cover. Pull up on the cover and
assure it is securely latched.

Hood and Covers Parts Legend

1. Engine hood 19. Clevis pin, 3/8" diameter 35. Adjustable trigger latch
2. Rear hood hinge 20. Engine panel 36. Heavy flat washer, 1/2"
3. Black moulding, 7" long 21. Hex-head capscrew, 37. Hex-lock elastic nut, 1/2-13
4. Flat narrow washer, 3/8" 3/8-16 x 1-1/2" 38. Hex-head capscrew,
5. 1/4-20 x 1" 22. Hex-head capscrew, 1/2-13 x 1-1/4"
5/16-18 x 1" 39. SAE flat light washer, 1/4"
6. Front hood hinge
23. Lock washer, 5/16" 40. Hex-lock elastic nut, 1/4-20
7. Latch retainer ring
24. Rear engine cover 41. Flat washer, 1/4"
8. Black moulding, 16" long
25. Retainer nut, 5/16-18 42. Hex-head capscrew,
9. Latch, w/key (includes item 10)
26. Hex-lock elastic nut, 3/8-16 1/4-20 x 2-1/4", Grade 5
10. Key
27. Front engine cover 43. Rubber hook
11. Clip spring
28. Hex-head capscrew, 44. Anchor bracket
12. Ball stud, 13 mm 5/16-18 x 1/2" 45. Hook bracket
13. Flat washer, 5/16" 29. Front cover bracket 46. Slotted pan-head screw,
14. Hex-lock elastic nut, 5/16-18 30. Rear cover bracket #10-24 x 1-1/4"
15. Gas spring 31. Rear door striker 47. Flat washer, #10
16. Cover support 32. Gas spring 48. Hex-lock elastic nut, #10-24
17. Hex-head capscrew, 33. Ball stud, 10 mm
5/16-18 x 1-1/4"
34. Rear cover
18. Cotter pin

4-22 Model 3606 • Origin 10/99

 Cab, Covers and Mirrors

1
10
9 2
7
14
12
40
3 11 13
39
6
15
48 7
5 4 13 14
47
12
11
3 16
46 19 17
3 18 37 34
45
36
8

20 38
14
13
10
32
21 13 35
33
33 14 13
22 14
23
13
31
22

25
26 24

4
13
14

25

Frame (ref.)

30

23 13 13
22
23
28
27 40
43 41 28 29

42
13
40 23
5 13 28
44 22 23
41
MS0950

Figure 4–37. Covers and guards.

Model 3606 • Origin 10/99 4-23

 Section 4

4-24 Model 3606 • Origin 10/99

 Section 5
Axles, Wheels and Tires

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Legend ................................................. 5-2
General Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.1.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.1.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 AXLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
NOTE: Detailed axle service instructions (covering the axle, differential, brakes and
wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting
information) are provided in the Carraro Model 26.25M Maintenance and Repair Man-
ual, part number CA355027 (front axle with park brake) and CA355028 (rear axle).
5.2.1 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2.2 Axle Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.3 WHEELS AND TIRES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.3.1 Removing Wheel and Tire Assembly from Vehicle . . . . . . . . . . 5-10
5.3.2 Wheel Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.3.3 Wheel Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . 5-11
5.3.4 Installing Wheel and Tire Assembly onto Vehicle . . . . . . . . . . . 5-11
5.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Model 3606 • Origin 10/99 5-1

 Section 5

Introduction
The front (park-brake equipped) and rear (no park located opposite each other. The position of the pinion,
brake) Carraro axles are designed for heavy-duty, off- supported by two bearings, is adjusted through the
road industrial use. Each axle consists of a beam-type addition or subtraction of adjusting shims.
axle case, housing the differential center section, The wheel hubs containing the epicyclic reduction
inboard wet-disc brakes, a pair of trumpet-like shaft gears are supported by two tapered roller bearings.
housings, and stub-axle/wheel-hub units at each end. The brakes are oil-bath (wet) disc type, operated by an
O-rings and oil seals retain fluid within the axle. The annular piston and equipped with an automatic wear
axles have a semi-floating mounting configuration. compensation device. The double-rod hydraulic steer-
Each axle center is secured to the vehicle frame with ing cylinder is mounted on the differential support.
semi-rotating front and rear supports, and at one side Directional steering input is transmitted to the axles by
with a cylinder, anchor and plate. The frame tilt means of articulated track rods that allow toe-in adjust-
cylinder is mounted on the right side of the front axle ments. Two specially designed support trunions (one
and the stabilizer cylinder is mounted on the left side of front, one rear) attach the axle center to the chassis
the rear axle. Steer cylinders and swivels are mounted and allow the axle to pivot freely, limited by the cylinder
inboard on each axle. Power to the axles is transmitted attached to one side.
from the engine flywheel, connected to the transmission
drive plate and torque converter, out through a NOTE: Detailed axle service instructions (covering
driveshaft connected to the transfer case. The transfer axle, brakes and wheel-end safety, repair, disassembly,
case distributes power through output drive shafts to reassembly, adjustment and troubleshooting informa-
the front and rear axle differentials, which work tion) are provided in the Carraro Model 26.25M Mainte-
through gearing to turn the wheel and tire assemblies nance and Repair Manual, part number CA355027
and to ultimately cause the vehicle to move. (front axle with park brake) and CA355028 (rear axle).
One wheel type with nominal dimensions of 9" x 24" is
The front differential is equipped with limited-slip, self- used on the vehicle. The wheel is a welded two-piece
locking gears, supported by two bearings. The design design with ten one-inch diameter holes equally spaced
of the differential permits adjustment to the bevel gear on a 13.188" diameter bolt circle. A 12-ply, or better,
set. Internal axle service and adjustment procedures directional-tread tire, 13.00 x 24 in size, can be used on
are not the scope of this publication and are thoroughly this vehicle. Tires are filled only with air when the vehi-
covered in the appropriate Carraro axle manual. The cle is shipped from the factory.
beveled ring gear is adjusted by means of ring nuts

Legend
1. Left Beam Trumpet 14. Bushing 27. Oil Plug, M30-2
2. O-ring 15. Thrust Washer 28. Breather, M10-1
3. Left Brake Flange 16. Right Brake Flange 29. Bolt, M12 X 110 Mm
4. O-ring 17. Right Beam Trumpet 30. Central Body
5. Bushing 18. Breather, M10-1 31. Front Support
6. Bushing 19. Bolt 32. Bolt
7. Rear Support 20. Belleville Washer 33. Washer
8. Bolt 21. Shim 34. Internal Snap Ring
9. Grease Nipple, M8-1 22. Bushing 35. Bolt, M16-1,5
10. Thrust Washer 23. Bushing 36. O-ring
11. Bushing 24. Oil Seal 37. Pin
12. Bushing 25. Spherical Bearing
13. O-ring 26. Belleville Washer

5-2 Model 3606 • Origin 10/99

 Axles, Wheels and Tires

General Overview

Front of vehicle

1 31 6
27

28
14
2 11
10
3
9
2 30 32

27 28
37
35 36
34 33 4 29
6

27
15 4
5 20
13 16
2 17 21
12
7 22
8
9 18

23
24

19
25
26

PS0200

Model 3606 • Origin 10/99 5-3

 Section 5

5.1 GENERAL INFORMATION 5.2 AXLE ASSEMBLIES

Note: Detailed axle service instructions (covering axle,
5.1.1 Axle Serial Number Plate brakes and wheel-end safety, repair, disassembly, reas-
The front axle serial number plate is located on a mount- sembly, adjustment and troubleshooting information) are
ing pad on the inboard portion of the right beam trumpet. provided in the Carraro Model 26.25M Maintenance and
The rear axle serial number plate is located on a mount- Repair Manual, part number CA355027 (front axle with
ing pad on the inboard portion of the left beam trumpet. park brake) and CA355028 (rear axle).
Information on the serial number plate is required in cor-
Several special axle service tools are required to properly
respondence regarding the axle.
service the axle assemblies. Contact the local Sky Trak
International parts distributor or Carraro USA for ordering
information.
Front of vehicle

WARNING: Risk of serious personal injury or

Serial number death if components are assembled improperly,
plate location if incompatible, worn or damaged components
are used, or if components are used in a non-
approved application. Obtain proper training,
MS2660 follow recommended procedures, and use
Figure 5–1. Axle serial number plate location
proper tools and safety equipment. Wear safety
(front axle shown). glasses at all times when working on the vehi-
cle and vehicle components.
Supply information from the axle serial number plate • DO NOT attempt carrier and differential
when communicating about an axle assembly or axle removal and installation, and differential and
components. pinion disassembly and assembly, without
thoroughly understanding instructions in the
5.1.2 Specifications appropriate Carraro publications.
Axle, wheel and tire specifications are listed in Section 2 • Before disassembling any parts inside the
General Information, Specifications and Maintenance carrier, remove the entire axle assembly from
Instructions. the vehicle and securely support it with the
pinion facing up in an appropriate stand or
5.1.3 Maintenance rack.
• When removing the axle assembly from the
Axle, wheel and tire maintenance instructions are vehicle, properly support the vehicle. An
detailed in Section 2 General Information, Specifications improperly supported vehicle can cause seri-
and Maintenance Instructions. ous injury or death.
• If servicing axle components with the axle
attached to the vehicle, securely support the
carrier, differential, pinion assemblies and
wheel ends.
• Dispose of waste material in accordance with
local regulations and procedures.

5-4 Model 3606 • Origin 10/99

 Axles, Wheels and Tires

PERIODIC OPERATION REQUIREMENT: Every two

CAUTION: The use of replacement parts pro-
weeks, drive the vehicle far enough to cause the drive-
vided by other than the original manufacturer is
train components to make several complete revolutions.
not recommended, as such use may cause unit
This will help assure that internal components receive
failure and affect vehicle safety. Supply infor-
lubrication to minimize deterioration caused by environ-
mation from the axle serial number plate when
mental factors such as high humidity.
communicating about an axle assembly or axle
components.
• Risk of personal injury. Exercise extreme SUBMERSION: If the vehicle has been exposed to water
care when using snap rings or spring-loaded deep enough to cover the hubs, disassemble the wheel
retention devices. ends and inspect for water damage and contamination. If
• It is impossible to know, evaluate and advise the carrier housing was submerged in water, especially if
regarding all conceivable ways in which ser- the water level was above the vent tube (breather), drain
vice may be performed, or of the possible the axle and inspect internal parts for water damage and
hazardous consequences of each method. contamination. Before assembling and refilling the unit
Accordingly, whenever a service procedure with the specified lubricant(s), clean, examine and
or tool is used which is not recommended, replace damaged parts as necessary.
assure that both personal safety and
vehicle safety are maintained by the Note: Whenever bearings are removed, regardless of
selected method. hours and condition, replace them with new bearings.
Use a suitable puller for bearing removal. Clean, inspect
and lubricate all bearings just prior to reassembly. If
IMPORTANT: When replacing a fastener, replace it with replacement of a damaged bearing cup or cone is neces-
one of equal or higher grade and quality. Torque fasten- sary, replace the cup and cone as a set.
ers to the specified value for the application.
• Some service operations require the use of tools spe-
5.2.1 Axle Replacement
cifically designed for the purpose. Use the special tools
A. Removal
when and as recommended.
• DO NOT pound, beat or hammer on end yokes and WARNING: Risk of death or severe personal
flanges to remove or to install them. Damage to axle injury. Safely raise and adequately support the
components can occur. Remove and install end yokes vehicle so that it will remain stable and in place
and flanges by following the recommended procedures before attempting to remove an axle.
in the appropriate Carraro axle service manual.
WARNING: Wait for the hydraulic fluid to cool
• DO NOT reuse oil or grease seals.
before servicing any hydraulic component. Hot
hydraulic fluid can cause severe burns.
CLEANING: Clean parts with machined or ground sur-
faces (such as gears, bearings, and shafts) with emul- WARNING: Relieve hydraulic pressure before
sion cleaners or petroleum-based cleaners. DO NOT servicing any hydraulic component. Escaping
steam clean internal components and the interior of the hydraulic fluid under pressure can penetrate
planetary hub and axle housing. Water can cause corro- the skin, causing serious injury.
sion of critical parts. Rust contamination in the lubricant
can cause gear and bearing failure. Remove old gasket The front and rear axle assemblies differ in that the front
material from all surfaces. axle assembly is equipped with a park-brake mechanism
and limited-slip feature; the rear axle has neither. The
steps below outline a typical axle removal procedure,
DRYING: Use clean, lintless towels to dry components suitable for either the front or the rear axle assembly.
after cleaning. DO NOT dry bearings by spinning them Cleanliness is of extreme importance. Before attempting
with compressed air. This can damage mating surfaces to remove the axle, thoroughly clean the vehicle. Avoid
due to lack of lubrication. After drying, lightly coat compo- spraying water or cleaning solution on the stabilizer sole-
nents with oil or a rust-preventive chemical to help pro- noids and other electrical components. If using a steam
tect them from corrosion. If storing components for a cleaner, seal all openings before steam cleaning.
prolonged period, wrap them in wax paper.

Model 3606 • Origin 10/99 5-5

 Section 5

Vehicle frame
1 3
4
2 5
6
15
13 4
13 7
12 5
12
5 3
2
14
3 1
4
8
15 Rear axle
5 3
6
4
1 2 12
16 Bushing
7 8 (four incl. w/axle) 11 9
7
10
14

Front axle Support (ref.)

(trunion)

9
7
10 12

11
MS0680
Support (ref.)
(trunion)

1. Self-tapping lube fitting, 1/8" 7. Flat hardened washer, 7/8" 13. Hex-lock elastic nut, 3/4"
2. Self-align bearing, 1-1/2" ID 8. Cylinder anchor 14. Hex-head capscrew,
3. Cylinder-mount pin, 1.5" diameter 9. Anchor plate M10-1,5 x 16 mm
4. Hex-lock nut, 5/16-18 10. Hex-lock nut, 7/8-9 15. Cylinder
5. Hex-head capscrew, 11. Hex-head capscrew, 16. Bushing
5/16-18 x 3-1/2" 3/4-10 x 5-1/2" Grade 8
6. Hex-head capscrew, 12. Flat hardened washer, 3/4"
7/8-9 x 12"

Figure 5–2. Axle to frame mounting configuration.

5-6 Model 3606 • Origin 10/99

 Axles, Wheels and Tires

IMPORTANT: Clear the work area of all debris, unnec- 11. Four bushings (item 16, Fig. 5–2) help locate the axle
essary personnel, etc. Allow sufficient space to raise the supports to the vehicle frame; tap the front and rear
vehicle and to remove the axle. supports with a hammer as required to separate the
1. Park the vehicle on a firm, level surface. Level the supports from the bushings. Adjust the jack, hoist or
vehicle, ground the attachment, place the travel overhead crane and sling supporting the axle as
select lever in NEUTRAL (N), engage the park brake required to free the axle from the frame and bushings.
switch, straighten all wheels and shut the engine 12. Remove the axle from the vehicle using the jack,
OFF. Allow the hydraulic fluid to cool. hoist or overhead crane and sling supporting the
2. If the axle will be disassembled after removal, place a axle. DO NOT raise or otherwise disturb the vehicle
suitable receptacle under the axle drain plug. while removing the axle. Balance the axle and
Remove the drain plug and allow the axle oil to drain prevent it from tipping, turning or falling while
into the receptacle. Transfer the used axle oil into a removing it from beneath the vehicle. Place the axle
suitable covered container and label the container as on a suitable support or holding stand.
used oil. Dispose of properly.
B. Axle Inspection, Internal Service and Repair
3. Label, disconnect and cap the steering and brake
lines at the axle. Wipe up any spilled oil. Detailed axle service instructions (covering axle, brakes
and wheel-end safety, repair, disassembly, reassembly,
4. Block the front and rear of both tires on the axle that
adjustment and troubleshooting information) are pro-
is not being removed. Ensure that the vehicle will
vided in the Carraro Model 26.25M Maintenance and
remain in place during axle removal before proceeding.
Repair Manual, part number CA355027 (front axle with
5. Raise the vehicle using a suitable jack or hoist. Place park brake) and CA355028 (rear axle without park brake).
suitable supports beneath the frame and lower the
The axle should be checked, serviced and repaired only
vehicle onto the supports. Ensure that the vehicle will
by experienced service technicians who are aware of all
remain in place during axle removal.
safety instructions and particular component features.
6. Support the axle that is being removed with a
suitable jack, hoist or overhead crane and sling. C. Installation
DO NOT raise the axle or the vehicle.
The front and rear axle assemblies differ in that the front
7. Mark and remove both wheel and tire assemblies axle assembly is equipped with a park-brake mechanism
from the axle that is being removed. and limited-slip feature; the rear axle has neither. The
Note: The wheel and tire assemblies must be re- steps below outline a typical axle installation procedure,
installed later with the directional tread pattern “arrows” suitable for either the front or the rear axle assembly.
facing in the direction of forward travel. 1. Before proceeding, ensure that the vehicle will
8. Mark the axle driveshaft flange yoke and unbolt it remain in place during axle installation. Block the
from the axle. front and rear of both tires on the axle that is already
installed on the vehicle.
Note: The drive shaft assembly is a balanced assembly.
2. If applicable, raise the vehicle using a suitable jack or
Mark the yoke and axle so that these components can be
hoist. Place suitable supports beneath the frame and
returned to their original positions when reinstalled. The
lower the vehicle onto the supports, allowing enough
yokes at each end of the drive shaft must be in the same
room for axle installation. Ensure that the vehicle will
plane to help prevent excessive vibration (Fig. 5–3).
remain in place during axle installation.
9. Remove the 5/16-18 x 3-1/2" hex-head capscrew 3. Using a suitable jack, hoist or overhead crane and
(item 5, Fig. 5–2) and 5/16-18 hex-lock nut (4) sling, remove the axle from its support or holding
securing the lower position 1-1/2" diameter cylinder- stand. Balance the axle and prevent it from tipping,
mount pin (3) to the cylinder (15). Tap out the cylinder turning or falling while positioning it beneath the
mount pin, and move the cylinder (15) to prevent it vehicle. DO NOT raise or otherwise disturb the
from interfering with axle removal. vehicle while installing the axle. Keep the axle
10. Remove the 3/4-10 x 5-1/2" Grade 8 hex-head supported and balanced on the jack, hoist or
capscrews (11), 3/4-10 hex-lock elastic nuts (13), overhead crane and sling throughout the installation
and 3/4" hardened flat washers (12) securing the procedure.
front and rear axle supports (rotating trunnions) to
the vehicle frame.

Model 3606 • Origin 10/99 5-7

 Section 5

4. Four bushings (Fig. 5–2) help locate the axle

supports on the vehicle frame. Insert the bushings Align yokes in same plane as shown
into the holes on the front and rear axle supports. Angled
(note angled notch in yoke)
Align the bushings and supports with the frame. notch
Raise the axle as required to align the supports with
the frame.
5. Install the 3/4-10 x 5-1/2" Grade 8 hex-head
capscrews (item 11), new 3/4-10 hex-lock elastic nuts
(13), and 3/4" hardened flat washers (12) securing
the front and rear axle supports to the vehicle frame.
Straight
Torque to 250 lb/ft (340 Nm).
edge
6. If required, attach the cylinder anchor (8) and anchor
plate (9) to the axle with 7/8-9 x 12" hex-head
capscrews (6), 7/8" hardened flat washers (7), and
new 7/8-9 hex-lock nuts (10). Torque to 380 lb/ft (515
Nm). MS0690

Note: Always use new lock nuts to help ensure proper Figure 5–3. Align yokes in the same plane as shown.
fastening.
10. Install the wheel and tire assemblies.
7. Move the cylinder (15) into position on the axle
cylinder anchor (8). Insert a 1.5" diameter cylinder- Note: The wheel and tire assemblies must be installed
mount pin (3) through the cylinder (15) and cylinder with the directional tread pattern “arrows” facing in the
anchor (8). Secure the cylinder-mount pin (3) with a direction of forward travel (Fig. 5–4 and Fig. 5–6).
5/16-18 x 3-1/2" hex-head capscrew (5) and a new
5/16-18 hex-lock nut (4). Torque to 18 lb/ft (24 Nm). Tread “arrows”
Note: Always use new lock nuts to help ensure proper
fastening.
8. Apply multi-purpose grease through the self-tapping must face forward
lube fitting (1) to lubricate the self-align bearing (2)
and the cylinder-mount pin (3).
Sidewall arrow
9. If reinstalling an axle previously removed from the
vehicle, position the driveshaft flange yoke on the
axle according to the alignment marks made earlier. points forward
If installing a new axle, note the position of the
driveshaft yoke at the transfer case. Align the
driveshaft yoke on the axle in the same plane as the
yoke on the transfer case (Fig. 5–3).
Note: The drive shaft assembly is a balanced assembly.
The yokes at each end of the drive shaft must be in the
same plane to help prevent excessive vibration (Fig. 5–3).

a n d Ti r e
el
As
Whe

s’y

Sidewall arrow points forward;

left-side wheel and tire shown.
MS0700

Figure 5–4. The tread “arrows” must point

in the direction of forward travel (also see Fig. 5–6).

5-8 Model 3606 • Origin 10/99

 Axles, Wheels and Tires

11. Torque the lug nuts to 370 lb/ft (500 Nm) using the 18. Start the engine. Turn the steering wheel several
alternating pattern depicted in Fig. 5–5. times lock to lock, operate the frame tilt function
1 several times in both directions, and check the
10
function of the brakes. Check for hydraulic leaks and
tighten or repair as necessary.
5
7 5.2.2 Axle Service and Troubleshooting
Detailed axle service instructions (covering axle, brakes
and wheel-end safety, repair, disassembly, reassembly,
adjustment and troubleshooting information) are pro-
vided in the Carraro Model 26.25M Maintenance and
3 4 Repair Manual, part number CA355027 (limited-slip front
axle with park brake) and CA355028 (rear axle).
The axle should be checked, serviced and repaired only
by experienced service technicians who are aware of all
safety instructions and particular component features.

6 8
5.3 WHEELS AND TIRES
WARNING: Risk of serious personal injury or
9 2 OS0740 death. Mismatched tire sizes, ply ratings or mix-
Figure 5–5. Lug nut torque sequence. ing of tire types (radial tires with bias-ply tires)
may compromise vehicle stability and may
12. Carefully remove the jack, hoist or overhead crane result in vehicle tipover.
and sling supporting the axle.
13. Carefully raise the vehicle using a suitable jack or Welded 13.00 - 24 steel wheels are used on this vehicle.
hoist. Remove the supports from beneath the frame The specified size and ply rating (star rating for radial
and lower the vehicle to the ground. tires) for this vehicle is 13.00 - 24, 12 PLY. Make sure the
14. Remove the blocks from the front and rear of both replacement tire is of the same size and ply rating (star
tires on the other axle. rating for radial tires) as all the other tires. A higher ply
rating (star rating for radial tires) can be used, but only
15. Uncap and connect the steering and brake lines at when all four tires have the same ply rating.
their axle fittings.
The tires are filled with air only when the vehicle leaves
Note: Always use new flat-faced O-rings when connect- the factory. Hydrofill (a calcium chloride solution), foam
ing hydraulic fittings on the Model 3606. fill, or other tire-filling substances are not added to the
16. Check wheel end and hydraulic reservoir oil levels. tires as they alter the weight, stability and handling char-
acteristics of the vehicle, especially under load. Large-
17. Reactivate the parking brake on the front axle if it bore valve stems are used to help expedite tire inflation
was deactivated earlier. Refer to Section 2 for and deflation. An inner tube may be used if a tire does
information on parking brake reactivation. not provide an airtight seal. Check tire inflation pressures
WARNING: Avoid prolonged engine operation when the tires are cold. When mounting a tire on the
in closed areas with inadequate ventilation. wheel, the tire must be mounted on the wheel respective
Failure to properly ventilate exhaust fumes can of the directional tread pattern of the tire; this produces a
result in death or severe personal injury. left or right tire and wheel assembly.
The wheel and tire assemblies must be installed with the
WARNING: Risk of serious personal injury. directional tread pattern “arrows” facing in the direction of
Before starting the engine, tighten all hydraulic forward travel (Fig. 5–4 and Fig. 5–6).
connections and remove all tools from the vehi-
cle. NEVER check for leaks using any part of
the human body; use a piece of cardboard or
wood instead. Wear heavy, protective gloves
and eye protection.

Model 3606 • Origin 10/99 5-9

 Section 5

5.3.1 Removing Wheel and Tire Assembly

from Vehicle
WARNING: Risk of serious personal injury.
When removing a wheel and tire assembly from Tread “arrows”
must point forward
the vehicle:
• Position vehicle on a flat, hard surface and
support vehicle with approved jack stands or
suitable supports.
• Use appropriate safety glasses, safety shoes
and appropriate clothing and equipment.
• DO NOT wear rings or jewelry. DO NOT wear
hair or clothing that could become caught in
machinery or pinch points such as those cre-
ated between the tire and the hub.

1. Park the vehicle on a firm, level surface. Level the

vehicle, ground the attachment, place the travel select Install tires onto wheels to
rotate in proper direction
lever in NEUTRAL (N), engage the park brake switch,
straighten all wheels and shut the engine OFF.
2. Loosen but DO NOT remove the lug nuts on the
wheel and tire assembly to be removed. PS0340

3. Place a suitable jack under the axle pad closest to Figure 5–6. Install wheel and tire assemblies with the
the wheel being removed. Raise the vehicle and directional tread pattern “arrows” facing in the direction of
position a suitable support beneath the axle. Allow forward travel (also see Fig. 5–4).
sufficient room to lower the vehicle onto the support
and to remove the wheel and tire assembly.
4. Lower the vehicle onto the support.
5. Remove lug nuts and lug washers in an alternating
pattern (Fig. 5–5).
6. Remove the wheel and tire assembly from the
vehicle.

5-10 Model 3606 • Origin 10/99

 Axles, Wheels and Tires

5.3.2 Wheel Cleaning 5.3.5 Tires

WARNING: Dirt and rust prevent the tire from A. Dismounting Tire from Wheel
seating properly on the wheel, which could
result in an explosive separation. Such explo- WARNING: Risk of serious personal injury.
sions could result in severe personal injury or When removing a tire from a wheel:
death to the tire installer and to those in the • Use safety chains, or place the wheel and
area. tire assembly in a safety cage when deflating
a tire or when inflating a newly mounted tire.
Remove all rust, corrosion, dirt and other foreign material • Deflate tire completely before servicing.
from all metal surfaces. In particular, the bead area (tire- NEVER attempt to unseat the beads of an
to-wheel mounting surface) must be especially clean. inflated tire.
• NEVER re-inflate a tire that has been run flat
5.3.3 Wheel Inspection and Replacement or seriously under-inflated without removing
the tire from the wheel and checking for tire
WARNING: NEVER rework, heat, weld or
and wheel (rim) damage.
braze a wheel rim.
• NEVER hit a tire or wheel rim with a hammer
Clean and inspect the wheel rim before installing or NEVER object.
a new tire. Verify that the wheel rim diameter • NEVER rework, heat, weld or braze a wheel
exactly matches the tire rim diameter molded rim.
into the tire. • Use the appropriate specialty tools and
equipment for mounting a tire to a wheel or
Check all surfaces of the wheel for rust, corrosion,
for dismounting a tire from a wheel, or have
cracks, bent flanges, deep marks or gouges. Replace a
a qualified professional perform the work.
damaged, worn or cracked wheel. NEVER rework, heat,
DO NOT attempt to mount or dismount a
weld or braze a wheel rim.
tire without the proper tools, training and
Inspect the valve core and stem. Replace the entire valve equipment.
if either component is damaged.
B. Wheel Inspection and Replacement
5.3.4 Installing Wheel and Tire Assembly
onto Vehicle WARNING: Clean and inspect the wheel rim
IMPORTANT: The wheel and tire assemblies must be before installing a new tire. Verify that the wheel
installed with the directional tread pattern “arrows” facing rim diameter exactly matches the tire rim diam-
in the direction of forward travel (Fig. 5–4). eter molded into the tire.
Inspect the inside of the tire for dirt, foreign
1. Position wheel onto studs on wheel end of axle.
material, loose cords, cuts, penetrating objects,
2. Install wheel lug washers. and other damage. DO NOT use tires with
3. Install lug nuts and tighten in an alternating pattern irreparable damage.
(Fig. 5–5). Torque to 370 lb/ft (500 Nm).
Replace any tire that is worn or cut through the cords.
When replacing a tire, follow the recommendations of the
tire manufacturer.

C. Tire and Wheel Lubrication

WARNING: Risk of serious personal injury.

Use an approved tire-mounting lubricant only.
NEVER use antifreeze, silicones or petroleum-
based lubricants.

Prior to mounting the tire on the rim, apply a suitable

lubricant to the bead-seat area of the wheel rim and tire
bead. Use a lubricant specified by the wheel and tire
manufacturers.

Model 3606 • Origin 10/99 5-11

 Section 5

D. Mounting Tire onto Wheel extension hose with a clip-on air chuck and pressure
gauge to permit the installer to stand at a safe
WARNING: Risk of serious personal injury. distance from the tire. Each tire bead will usually
When mounting a tire onto a wheel: snap or pop into place, indicating that the bead is
• Use the appropriate specialty tools and seated.
equipment for mounting a tire to a wheel or
for dismounting a tire from a wheel, or have a Note: If either bead should fail to seat at 35 psi (241,1
qualified professional perform the work. DO kPa), the tire may be pinched or another source may be
NOT attempt to mount or dismount a tire interfering with proper mounting. DO NOT increase infla-
without the proper tools, training and equipment. tion pressure to seat the beads. Remove the valve core
• Clean and inspect the wheel rim before and completely deflate the tire. Break both beads loose
installing a new tire. Verify that the wheel rim from the rim and inspect the tire, rim and inner tube, if
diameter exactly matches the tire rim diame- applicable. Lubricate the tire bead, install the valve core
ter molded into the tire. and repeat the 35 psi (241,1 kPa) inflation procedure until
• Inspect the inside of the tire for dirt, foreign the beads seat properly.
material, loose cords, cuts, penetrating 10. After the beads have seated, remove the valve core
objects, and other damage.DO NOT use tires and fully deflate the tire, but DO NOT break the bead
with irreparable damage. or separate the tire from the wheel. Re-install the
• Use an approved tire-mounting lubricant valve core and inflate the tire to 65 psi (551 kPa).
only. NEVER use antifreeze, silicones or
petroleum-based lubricants. E. Tire Speed and Road Surface Limitations
• Use safety chains, or place the wheel and
tire assembly in a safety cage when deflating The tires on this vehicle are designed for low-speed oper-
a tire or when inflating a newly mounted tire. ations not to exceed 25 mph (40 km/hr). If the vehicle is
• Inflate the tire to the cold-operating pressure towed at high speeds, high temperatures may develop
recommended by the tire manufacturer. under the tread bars, causing a shifting of the tread bars
and a weakening of the tire material and cord fabric.
1. Read, understand and follow the above warning There may be no visible evidence of this type of damage,
message. but later, a failure can occur. If tires are to operate for any
2. Clean, inspect and repair the wheel if necessary. DO length of time on a paved road, highway or other hard
NOT use a damaged, rusty or cracked wheel. surface, increase pressure in the tire to the maximum
amount recommended by the tire manufacturer to help
3. Orient the tire in the direction of forward travel reduce the chances of damage, or arrange to have the
required. vehicle transported on a flat-bed truck.
4. Lubricate the inner tire and rim beads with an
approved tire-mounting lubricant only. NEVER use
antifreeze, silicones or petroleum-based lubricants.
5. Push the inner bead of the tire over and around as
much of the wheel rim as possible. Use tire irons or a
suitable, commercially available pneumatic tire
installation machine to work the bead completely
over the rim in small increments. Be careful not to
damage the bead.
6. Lubricate the outer tire and rim beads with an
approved tire-mounting lubricant.
7. Starting opposite the valve hole, use tire irons to
work the outer tire bead over the wheel rim. Work the
bead completely over the rim in small increments
(DO NOT damage the bead).
8. Install a new valve stem into the valve stem hole on
the wheel.
9. Center the tire on the wheel. Inflate the tire until it
fully seats on the wheel rim or to 35 psi (241,1 kPa).
DO NOT exceed 35 psi (241,1 kPa). Use an

5-12 Model 3606 • Origin 10/99

 Axles, Wheels and Tires

F. Care and Storage of Tires

Store unmounted tires vertically, standing on their tread.
If stored for an extended period of time, rotate the tires
periodically to help reduce stress concentrations in the
ground contact area of the tread. Tires should not be
stored flat or stacked vertically (“stove piped”) as they will
become squashed and distorted, making mounting diffi-
cult, particularly for tubeless tires.
Store mounted tires as noted above, but reduce the infla-
tion pressure to 10 psi (68,9 kPa).
Store tires indoors in a cool, dark, dry area away from
drafts. Heat and light can cause oxidation on the tire sur-
face, which leads to decomposition (“crazing”) and
weather checking. Never store tires on oily surfaces or in
contact with oil, grease, petroleum-based substances,
antifreeze or solvents. Tires should not be stored near
volatile substances. Tires absorb volatile substances,
which damage and weaken the tire.
Tires should not be stored outside or in direct sunlight. If
there is no other alternative, tires stored outside must be
covered or otherwise protected from sunlight, wind and
rain. Use an unbroken, opaque covering to help protect
tires stored outdoors.
Store tires away from electric motors, generators, arc
welders, etc., as these generate ozone, which attacks
rubber and causes crazing and weather checking.
Exposure to weather will also cause cracking or crazing
of the rubber as well as deterioration of the tire carcass,
particularly where rain water is permitted to accumulate
in the tire.
When extended vehicle storage is anticipated, the vehicle
should be placed on suitable supports with the tires
raised out of ground contact. Inflation pressure in the tire
should then be reduced to 10 psi (68,9 kPa). Keep the
tires out of contact with sunlight, wind and rain as noted
above.
If it is not possible to raise the vehicle, increase tire infla-
tion pressure by 25 percent. Move the vehicle periodically
to change the location of stress concentrations in the tire
ground contact area.

Model 3606 • Origin 10/99 5-13

 Section 5

5-14 Model 3606 • Origin 10/99

 Section 6
Transfer Case and Drive Shafts

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Legend ................................................. 6-2
General Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.1 GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.1.1 Further Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.1 Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.1 Transfer Case Inspection and Service. . . . . . . . . . . . . . . . . . . . 6-4
6.3.2 Transfer Case Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.3 Transfer Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.4 Internal Transfer Case Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.5 Transfer Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4 DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.4 Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.5 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.6 Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.7 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.8 Slip Yokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Model 3606 • Origin 10/99 6-1

 Section 6

Introduction
The Carraro Model TB 420 transfer case is a single- transfer case shaft bearing adjustment is accomplished
speed, mechanical unit designed for heavy-duty during disassembly/reassembly procedures not cov-
industrial use. The transfer case is located beneath the ered in this manual; consult the Carraro manual for
information.
frame of the vehicle, mounted to the engine mount
(subframe), behind the transmission and ahead of the IMPORTANT: To help ensure optimum performance,
the drive shaft assemblies are specially balanced as a
rear axle. unit at the factory. When servicing any flange yoke, slip
yoke or drive shaft tube, order a complete assembly if
Torque (twisting power) is transferred through a single components are bent or damaged. Refer to the Sky
output shaft from the Clark-Hurth T 12000 transmis- Trak International Model 3606 Parts Manual for order-
sion, to the transfer case, and out to the drive axles via ing information.
two drive shafts, one for the front axle, one for the rear
axle. The transfer case is equipped with a set of four The transfer case and drive shafts should be checked
gears having a 1:1 drive ratio. The drive shafts are of and repaired only by experienced service technicians
industrial-duty, welded-steel, tube-type design, sup- who are aware of all safety instructions and particular
ported by Cardan-type cross and bearing tapered roller component features.
bearing assemblies (universal joints) secured to flanges
and slip yokes.
Detailed transfer case service instructions covering
repair, disassembly, reassembly, adjustment and trou-
bleshooting information is provided in the Carraro
Model TB 420 Transfer Box Maintenance and Repair
Manual, Carraro part number CA355026. For example,

Legend
1. M12 x 30 Bolt 21. Oil Seal Ring, 58 x 80 x 10 39. Flat Washer, M12
2. Shaft Cover 22. Spacer, 55 x 35 x 17 40. Flange Yoke (see note)
3. O-ring 23. Shim (different thicknesses 41. Cross and Bearing Assembly
4. Shim (different thicknesses available) 42. Tube Assembly (see note)
available) 24. Bolt, M10 x 30 43. Dust Cap Kit
5. Snap Ring 25. Drop Box Cover 44. Slip Yoke (see note)
6. Washer, 51 x 40,2 x 3 26. O-ring 45. Grease Nipple
7. Bearing 27. Bearing 46. Loctite® #242 (blue)
8. Transfer Case Housing 28. Washer, 22 x 26 x 1,5
9. Oil Plug, M22 x 1,5 29. Breather Extension NOTE: To help ensure optimum perfor-
10. Gear, Z=37 30. Washer, 10 x 14 x 1,5 mance, drive shaft assemblies are spe-
11. Bearing 31. Breather, M10 x 1 cially balanced at the factory. When
12. Oil Seal Ring, 55 x 72 x 10 32. Bolt servicing any flange yoke, slip yoke, or
drive shaft tube, order a complete as-
13. Input Shaft 33. Washer, 8 x 12 x 1,5
sembly if components are bent or dam-
14. Gear Pin 34. Output Shaft aged. Refer to the Sky Trak International
15. Plug 35. Bolt, M8 x 22 Model 3606 Parts Manual for ordering in-
16. Ring Nut, M25 x 1,5 36. Cover formation.
17. O-ring 37. Shim (different thicknesses
18. Centering Ring available)
19. O-ring 38. Hex Head Cap Screw,
M12 x 1,75 x 35
20. Flange

6-2 Model 3606 • Origin 10/99

 Transfer Case and Drive Shafts

General Overview

Transfer case turned 90° 13

12
11
10
9

8 15
7 7
10 14
4 56 16
3 18
2 15
7 17
1 10 14 19
21 20
33 22
7 23
37 31 32 10
35 36 24
30 25
29 28 26
7
37 2 27
35 36
11 2
12

34

39
38

40
41
42

43
38 44
39
45
41 46
40

MS0430

Model 3606 • Origin 10/99 6-3

 Section 6

6.1 GENERAL INSTRUCTIONS 6.2.2 Technical Data

IMPORTANT: To help ensure optimum performance, the 1. Transfer Case Type: Carraro Model TB 420
drive shaft assemblies are specially balanced as a unit at the 2. Description: Single-speed transfer case
factory. When servicing any flange yoke, slip yoke or drive shaft 3. Forward Reduction Ratio: 1:1
tube, order a complete assembly if components are bent or 4. Reverse Reduction Ratio: 1:1
damaged. Refer to the Sky Trak International Model 3606 Parts
5. Total Reduction Ratio: 1:1
Manual for ordering information.
6. Parking Brake (front axle): Spring applied, hydraulic
Before performing any inspection, maintenance or service release, wet-brake disc type
operation, thoroughly clean the unit. The transfer case and 7. Input Rotation: Reversible; clockwise and
drive shafts should be checked and repaired only by expe- counter-clockwise
rienced service technicians who are aware of all safety 8. Maximum Input RPM: 3,000
instructions and particular component features. 9. Oil Capacity: 1.5 quarts (1,425 liters)
Use suitable products to thoroughly clean all disassem- 10. Oil Type: SAE 80W90 EP or 80W140,
bled mechanical parts to help prevent personal injury to to comply with API GL4,
API GL5 (respectively),
the worker and damage to the parts. Carefully inspect the
MIL-L-2105 and MIL-L-2105D
integrity of all moving parts (bearings, yokes, tubes, Specifications
gears, shafts, etc.) and fasteners (nuts, bolts, washers, 11. Dry Weight: N/A
etc.) as they are subject to major stress and wear. Always
12. Bearing Preload: 125-130 lb/ft (55-59 Nm),
replace elastic-lined nuts and any damaged, worn, measured without oil seal
cracked, seized, or otherwise improper parts that could ring fitted
affect the safe and proper functioning of the vehicle, (NOTE: Transfer case shaft bearing adjustment procedures
transfer case and drive shafts. are not covered in this manual. Refer to the Carraro Model
TB 420 Transfer Box Maintenance and Repair Manual,
Carraro part number CA355026.)
6.1.1 Further Information
13. Sealing Compounds: Loctite® 518, 540, 638
Detailed transfer case service instructions covering
repair, disassembly, reassembly, adjustment and trouble- 6.3 TRANSFER CASE
shooting information is provided in the Carraro Model TB
420 Transfer Box Maintenance and Repair Manual, Carraro 6.3.1 Transfer Case Inspection and Service
part number CA355026.
Whenever servicing the vehicle, conduct a visual inspec-
tion of the transfer case. A few moments spent doing this
6.2 SPECIFICATIONS
can help prevent further problems and down time later.
Refer to Section 2 General Information, Specifications Inspect the transfer case in its entirety, especially the
and Maintenance Instructions. main casting, for any cracks, dents, or other damage.
Look for oil seepage or leaks around the drive shaft
6.2.1 Serial Number Plate flange mounts. Check all bolts for proper torque.
The Carraro serial number plate is riveted to the rear of While the vehicle is under warranty, Sky Trak Interna-
the transfer case above the center of three cover plates. tional does not recommend the servicing of gears, shafts
Information specified on the serial number plate includes or bearings inside the transfer case. Attempts at disas-
Drop Box Type (TB 420), Serial Number, Carraro refer- sembly of these internal transfer case items may void the
ence number, Oil Specific (oil type), and Ratios (final warranty, cause damage to other parts and to the transfer
gear ratio, 1:1). Write this information down in a conve- case casting (housing) itself. If internal service of the
nient location to use in transfer case correspondence. transfer case is required while still under warranty, return
Serial number plate it to Sky Trak International for replacement with a new
transfer case pursuant to the Sky Trak International war-
ranty and return policy in effect when the vehicle was
purchased.
If service of internal transfer case components is required
and the transfer case is not under warranty, refer to the
Carraro Model TB 420 Transfer Box Maintenance and
Front of vehicle Rear of transfer case Repair Manual, Carraro part number CA355026, or con-
MS0440
sult an authorized Carraro repair center or dealer.
Figure 6–1. Location of Carraro serial number plate.

6-4 Model 3606 • Origin 10/99

 Transfer Case and Drive Shafts

6.3.2 Transfer Case Maintenance IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at
Information regarding checking the transfer case oil
the factory. When servicing any flange yoke, slip yoke, or
level and/or changing the transfer case oil is located in
drive shaft tube, order a complete assembly if components
Section 2.12.13 Transfer Case Oil.
are bent or damaged. Refer to the Sky Trak International
Model 3606 Parts Manual for ordering information.
6.3.3 Transfer Case Removal
4. For reference, mark the transmission input drive shaft
1. Level the vehicle, ground the carriage, place the and flange yoke at the transfer case for return to their
travel select lever in NEUTRAL (N), engage the original positions upon reinstallation (Fig. 6–3).
parking brake switch and shut the engine OFF. Allow Unbolt the flange yokes from the transmission and
the engine to cool. from the transfer box. Move the drive shaft out of the
2. Remove the engine mount rear cover plate (Fig. 6–2). way to allow clearance for transfer case removal.
3. Unbolt and remove the two M8 bolts securing the Mark Position
bulkhead fitting bracket to the transfer case. Safely Trans-
swing the bracket and the hydraulic hoses out of the Transfer Case mission
way to help prevent interference with removing the Mark position
Mark
transfer case and drive shafts. Reinstall the bolts Rear Axle position
securing the left side of the center transfer case
cover plate to the transfer case.
Bottom view facing up MS0710

Engine mount Figure 6–3. Mark the shafts and yokes for return to their
rear cover plate original positions.
5. For reference, mark the front and rear axle output
drive shafts and transfer case for return to their
Engine mount original positions upon reinstallation (Fig. 6–3).
(subframe) Unbolt the flange yokes from the axles and from the
transfer box. Move the drive shaft out of the way to
allow clearance for transfer case removal.
Vehicle 6. Position a transmission jack or suitable lifting device
chassis beneath the transfer case. Operate the jack to
contact and support the transfer case, but DO NOT
jack up or raise the transfer case itself. Secure the
M16 bolt and lock- transfer case to the jack or lifting device with a sling.
washer (4 each) 7. Unbolt the M16 bolts and lock washers (Fig. 6–2)
securing the transfer case to the vehicle chassis.
Bulkhead fitting Carefully lower the transfer case and remove it from
bracket beneath the vehicle.
Engine mount
(subframe)
6.3.4 Internal Transfer Case Repair
Detailed transfer case service instructions covering
M8 bolt (2)
repair, disassembly, reassembly, adjustment and trouble-
shooting information are provided in the Carraro Model
TB 420 Transfer Box Maintenance and Repair Manual,
Reservoir Carraro part number CA355026.

Transfer case
MS0490

Figure 6–2. Transfer case mounting arrangement.

Model 3606 • Origin 10/99 6-5

 Section 6

6.3.5 Transfer Case Installation Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each
IMPORTANT: To help ensure optimum performance, the
drive shaft in both directions. Look for excessive loose-
drive shaft assemblies are specially balanced as a unit at
ness, missing parts, cracks or other damage. Worn or
the factory. When servicing any flange yoke, slip yoke, or
damaged drive shafts (Fig. 6–4) and cross and bearing
drive shaft tube, order a complete assembly if components
assemblies may cause an excessive amount of vibration
are bent or damaged. Refer to the Sky Trak International
or noise.
Model 3606 Parts Manual for ordering information.
1. Secure the transfer case to a suitable transmission
jack or lifting device. Raise the transfer case into
position under the vehicle (see Fig. 6–2), within the Apply Loctite
242 (blue)
engine mount (subframe) and vehicle chassis. Use
Drive shaft
new, case hardened 8.8-rated M16 x 2,0 x 75 mm M12 bolt
Dust cap
bolts and lock washers to fasten the transfer case to Flat washer
the chassis. Torque to 156 lb/ft (210 Nm). Split retaining ring
Felt seal
2. Install the front and rear axle drive shafts to the
Slip yoke
transfer case (according to the alignment marks made
Grease fitting
during removal, unless installing new drive shafts).
Bolt the flange yokes to the transfer case and axles Cross assembly
as required. Use new, Loctite® 242 (blue) coated Bearing assembly
grade 8.8 M12 x 1,75 x 35 mm hex-head capscrews, Flange Retaining ring
flat washers and lockwashers. Torque to 83 lb/ft (113 yoke MS0500
Nm).
Figure 6–4. Drive shaft construction.
3. Install the transmission to transfer case input drive
shaft according to the reference marks made during 1. Individually inspect each cross, the bearing caps and
removal. Bolt the flange yokes to the transfer box and the needle bearings for signs of wear or for missing
to the transmission with new, Loctite® 242 (blue) parts.
coated grade 8.8 M12 x 1,75 x 35 mm hex-head Note: Replace the cross and bearing assembly as a
screws, flat washers and lockwashers. Torque to 83 complete assembly if any parts are worn or missing. If all
lb/ft (113 Nm). parts of the cross and bearing assemblies are in good
4. Move the hydraulic hoses into position and bolt the condition, pack the bearing caps with a premium grade of
bulkhead fitting bracket to the transfer case using two multi-purpose wheel-bearing grease. Reattach the bearing
of the M8 x 22 bolts securing the left side of the cap to the cross, assuring that all needle bearings are
center cover plate to the transfer case. Torque to present. Then, reassemble the cross and bearing assem-
18 lb/ft (25 Nm). bly into the drive shaft yoke.
5. Uncap and connect the hydraulic hoses to the 2. Replace the felt seal if worn or damaged.
reservoir according to the marks made during 3. Replace the entire drive shaft assembly if any flange
removal. yoke, slip yoke, or drive shaft tube is severely dented
6. Install the engine mount rear cover plate. or damaged.
4. Cross assemblies should flex and be free from
6.4 DRIVE SHAFTS excessive binding. A slight amount of drag or
resistance is desirable on a new cross and bearing
6.4.1 Drive Shaft Inspection and Service assembly. Excessive looseness causes unbalance.
Whenever servicing the vehicle, conduct a visual inspec-
tion of the drive shafts and cross and bearing assemblies 6.4.2 Drive Shaft Maintenance
(universal joints, or U-joints). A few moments spent doing Information regarding checking lubricating the grease fit-
this can help prevent further problems and down time tings on the drive shafts is located in Section 2.5.3 Lubri-
later. cation Points (grease fittings).

6-6 Model 3606 • Origin 10/99

 Transfer Case and Drive Shafts

6.4.3 Drive Shaft Removal 5. Turn the yoke over and tap on the exposed end of the
cross until the opposite bearing assembly comes out
IMPORTANT: To help ensure optimum performance, the
of the yoke.
drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke, or 6. Remove the cross from the yoke.
drive shaft tube, order a complete assembly if components 7. Repeat Step 2 through Step 6 to remove the cross
are bent or damaged. Refer to the Sky Trak International and bearing assembly on the other end of the drive
Model 3606 Parts Manual for ordering information. shaft.
Removal of any of the three drive shafts (front, rear, and 8. Mark the shaft and slip yoke so that they can be
transmission-to-transfer box) involves fairly straightforward properly aligned when reassembled. Yokes at both
and simple procedures. A typical removal sequence is ends of the drive shaft must be in the same plane to
outlined below: help prevent excessive vibration.
1. Level the vehicle, ground the carriage, place the 9. Unscrew the dust cap and slide the slip yoke off of
travel select lever in NEUTRAL (N), engage the the drive shaft spline.
parking brake switch and shut the engine OFF.
10. Remove the dust cap, split retaining ring, and felt
2. The drive shaft assembly is a balanced assembly. Mark seal from the shaft assembly.
the yoke and axle, transmission, transfer case, and the
shaft and slip yoke so that these components can be 6.4.5 Drive Shaft Cleaning and Drying
returned to their original positions when reinstalled.
Yokes at both ends of the drive shaft must be in the 1. Disassemble and clean all parts using an approved
same plane to help prevent excessive vibration. cleaning fluid. Allow to dry.

3. Remove the M12 hex-head capscrews (Fig. 6–4) and 2. Remove any burrs or rough spots from any machined
flat washers securing the flange yoke to the transfer surfaces. Re-clean and dry as required.
box.
6.4.6 Drive Shaft Assembly
4. Remove the drive shaft assembly.
1. Install the dust cap (Fig. 6–4), split retaining ring, and
6.4.4 Drive Shaft Disassembly felt seal onto the splines of the drive shaft tube
assembly.
IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at IMPORTANT: Ensure that the reference marks made
the factory. When servicing any flange yoke, slip yoke, or before removal on the drive shaft and slip yoke are
drive shaft tube, order a complete assembly if components aligned. The drive shaft and yokes must be in the same
are bent or damaged. Refer to the Sky Trak International plane to help prevent excessive vibration.
Model 3606 Parts Manual for ordering information. 2. Align the reference marks made before removal on
1. Use an approved, non-flammable cleaning fluid to the drive shaft and slip yoke.
thoroughly clean the drive shaft assembly with a 3. Slide the slip yoke (Fig. 6–4) onto the splines of the
brush. Wipe dry before disassembling. drive shaft and tighten the dust cap securely. DO
2. Place the drive shaft assembly in a bench vise. NOT overtighten or the cap will break.
3. Use a pair of pliers to pinch the ends of the retaining 4. Install the cross and bearing assembly into the yoke.
rings (see Fig. 6–4) securing the cross and bearing 5. Secure the cross and bearing assembly in the yoke
assemblies to the yokes. Remove the retaining rings with retaining rings. Pinch each retaining ring with a
from their grooves in the yokes. pliers and insert them into their grooves in the yoke.
Note: If the retaining rings fail to readily snap out of their
grooves in the yokes, tap the end of the bearing cap
lightly to help relieve pressure against the retaining rings.
4. Use a soft, round drive pin with a flat face
approximately 1/32 of an inch (0,8 mm) smaller than
the hole diameter in the yoke to drive on one end of
the cross and bearing assembly until the opposite
bearing assembly comes out of the yoke.

Model 3606 • Origin 10/99 6-7

 Section 6

6.4.7 Drive Shaft Installation B. Slip Yoke Removal

IMPORTANT: To help ensure optimum performance, the IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke, or the factory. When servicing any flange yoke, slip yoke, or
drive shaft tube, order a complete assembly if compo- drive shaft tube, order a complete assembly if components
nents are bent or damaged. Refer to the Sky Trak Inter- are bent or damaged. Refer to the Sky Trak International
national Model 3606 Parts Manual for ordering Model 3606 Parts Manual for ordering information.
information. To remove a slip yoke:
Installation of any of the three drive shafts (front, rear, 1. Remove the cross and bearing assembly (Fig. 6–4)
and transmission-to-transfer box) involves fairly straight- securing the slip yoke to the flange yoke (see Section
forward and simple procedures. 6.4.4 Drive Shaft Disassembly steps 3 through 6).
To install a drive shaft: 2. Remove the dust cap, split retaining ring, and felt
1. The vehicle must be level, the carriage grounded, the seal from the other end of the slip yoke.
travel select lever in NEUTRAL (N), the parking brake 3. Remove the slip yoke from the drive shaft.
engaged and the engine OFF.
2. Raise the drive shaft assembly into position. The slip- C. Slip Yoke Installation
yoke end of the transmission to transfer case drive
IMPORTANT: To help ensure optimum performance, the
shaft mounts toward the transmission. The slip-yoke
drive shaft assemblies are specially balanced as a unit at
end of an axle drive shaft mounts toward the axle. If
the factory. When servicing any flange yoke, slip yoke, or
reinstalling a drive shaft previously removed, align
drive shaft tube, order a complete assembly if components
the flange yokes according to the alignment marks
are bent or damaged. Refer to the Sky Trak International
made during removal.
Model 3606 Parts Manual for ordering information.
IMPORTANT: Yokes at both ends of the drive shaft must
To install a slip yoke:
be in the same plane to help prevent excessive vibration.
1. Install the dust cap (Fig. 6–4), split retaining ring, and
3. Secure with new, Loctite® 242 (blue) coated grade
felt seal from the other end of the slip yoke.
8.8 M12 x 1,75 x 35 mm hex-head screws, hardened
flat washers and lockwashers. Torque to 83 lb/ft (113 2. Install the slip yoke onto the drive shaft splines.
Nm). 3. Install the cross and bearing assembly securing the
slip yoke to the flange yoke.
6.4.8 Slip Yokes

A. Slip Yoke Inspection

IMPORTANT: 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 if components
are bent or damaged. Refer to the Sky Trak International
Model 3606 Parts Manual for ordering information.
Replace slip yokes (Fig. 6–4) if worn or damaged.

6-8 Model 3606 • Origin 10/99

 Transfer Case and Drive Shafts

6.5 TROUBLESHOOTING This section provides an easy reference guide covering

the most common problems that occur during operation
of the transfer case.

Transfer Case and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Gear teeth worn or grooved. 1. Insufficient lubrication. • Replace gear.
2. Contaminated lubricant. • Use correct lubricant. Fill to correct
level and change at recommended
intervals.
2. Gear teeth overheated 1. Prolonged operation at high • Replace gear.
(check color of gear teeth). temperatures. • Use correct lubricant. Fill to correct
2. Incorrect lubricant. level and change at recommended
3. Low oil level. intervals.
4. Lubricant contaminated.
3. Gear teeth pitted. 1. Intensive use. • Replace gear.
2. Insufficient lubrication. • Use correct lubricant. Fill to correct
3. Lubricant contaminated. level and change at recommended
intervals.
4. Transfer box housing bent 1. Insufficient lubrication. • Replace bearings.
or cracked. 2. Lubricant contaminated. • Use correct lubricant. Fill to correct
3. Intensive use. level and change at recommended
intervals.
4. Normal wear.
• Correct preload.
5. Inadequate bearing preload.
5. Leaks from oil seal ring. 1. Prolonged operation at high • Replace seal, and parent surface,
temperatures. if damaged.
2. Seals fitted incorrectly. • Use correct lubricant. Fill to correct
3. Seal lip damaged. level and change at recommended
4. Lubricant contaminated. intervals.

6. Worn shaft splines. 1. Intensive use. • Replace flanges.

2. Loose nut. • Check shaft splines for excessive
wear; replace as required.
7. Gear tooth fatigue fracture 1. Intensive use. • Replace gear.
(check whether the fracture 2. Continuous overloading. • DO NOT overload.
line is well-defined).
8. Worn inside cup or worn 1. Intensive use. • Replace bearing.
tapered roller bearing. 2. Excessive gear end float. • Check end float.
3. Insufficient lubrication. • Use correct lubricant. Fill to correct
4. Lubricant contaminated. level and change at recommended
intervals.
9. Noise when coasting; even 1. Worn splines on input flange, • Adjust or replace (see
slight transfer case noise gears or shafts. Troubleshooting step 10).
can be heard when vehicle
is coasting.

Model 3606 • Origin 10/99 6-9

 Section 6

Transfer Case and Drive Shaft Troubleshooting

Problem Cause Remedy

10. Noise when driving. 1. Pinion and crown-wheel wear. 1. Replace.
2. Gears and bearings loose. 2. Adjust.
3. Gears and bearings worn. 3. Replace.
4. Excessive eccentricity of gears. 4. Replace.
5. Lack of lubricant. 5. Fill to correct level.
6. Incorrect lubricant. 6. Replace.
11. Intermittent noise. 1. Gear damaged. 1. Replace gear.
2. Cover bolts loose. 2. Tighten to proper torque.
12. Continuous noise. 1. Gear teeth damaged. 1. Replace.
2. Worn bearings. 2. Replace.
3. Shafts or gear splines worn. 3. Replace.
13. Excessive transfer case 1. Incorrect installation. 1. Remove and reinstall correctly.
noise. 2. Incorrect universal joint assembly. 2. Check assembly of the universal
joint and of the flange.
3. Damaged or worn out transfer 3. Check the condition of gears,
case parts. bearings, etc. Replace as
required.
4. Contamination in the transfer case 4. Look for foreign particles. Check
or incorrect assembly of parts. assembly of transfer case
components.
14. Friction noise. 1. Fatigued or worn out transfer case 1. Check the condition of gears,
parts. bearings, etc. Replace as
required.
2. Contamination in the transfer case 2. Look for foreign particles. Check
or incorrect assembly of assembly of the various parts of
components. the transfer case.
15. Vibration or intermittent 1. Incorrect installation. 1. Remove and reinstall correctly.
noise when travelling. 2. Incorrect universal joint assembly. 2. Check assembly of the universal
joint and of the flange.
3. Incorrect use of product. 3. Use product correctly.

6-10 Model 3606 • Origin 10/99

 Section 7
Transmission: Clark-Hurth T 12000

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Legend ................................................. 7-2
General Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1 TRANSMISSION SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2 TRANSMISSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.1 Transmission Performance Specifications . . . . . . . . . . . . . . . . . 7-4
7.2.2 Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2.3 Transmission-related Fuse Ratings, Amps . . . . . . . . . . . . . . . . 7-4
7.3 TOWING A DISABLED VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.1 Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . 7-5
7.5 TRANSMISSION REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5.1 Transmission Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . 7-8
7.5.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . 7-10
7.6 TRANSMISSION TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Model 3606 • Origin 10/99 7-1

 Section 7

Introduction
Instructions in this section pertain mainly to general mission and torque converter are powered by their own
specifications, towing, maintenance information, and internal hydraulic (“transmission fluid”) system, separate
transmission removal and installation procedures. from the vehicle hydraulic system. The transmission is
equipped with an external oil cooler, mounted in the
Internal transmission service instructions and detailed engine heat exchanger (radiator).
specifications are provided in the Clark-Hurth T 12000
The transmission gear (or “speed”) select lever, an electric
Powershift Transmission 3, 4, & 6 Speed Intermediate shift control, is located on the left side of the steering col-
Drop Maintenance and Service Manual, part number SM umn in the operator's cab. Movement of the gear select
T12-3,4,6 ID. lever energizes the selected transmission shift solenoid
valves, which, in turn, direct the transmission fluid under
The Clark-Hurth T 12000 Powershift Transmission used in pressure to the selected forward or reverse valve, and to
this vehicle is available in four-speed (Cummins and Per- the designated range (gear or “speed”) clutch. Several fac-
kins turbocharged engines) and three-speed (Perkins nat- tors, including terrain, loading, engine RPM, axle/wheel-
urally-aspirated engines) configurations. One gear select end gearing and the selected transmission gear determine
lever is used for both applications; of course, a fourth gear actual vehicle speed.
will not be present if the vehicle is equipped with a three- To engage the clutch, the gear select lever is placed in the
speed transmission. The “intermediate drop” designation desired directional (forward or reverse) and range (gear or
refers to the relative top-to-bottom length of the transmis- “speed”) position. Gear select lever movement energizes
sion case, chosen for its compatibility with vehicle chassis the selected direction and range (gear) solenoids, allowing
and operating requirements. Intermediate drop does not transmission fluid under pressure to flow through tubes
refer to an operational RPM shift or drop. and passages to the selected clutch shafts. Oil sealing
The flywheel provides engine input to the transmission rings are located on the clutch shaft; these rings direct oil
and, ultimately, out of the transmission to the transfer case under pressure through a drilled passageway in the shaft
and drive axles. Hydraulic power flows through the trans- to a desired clutch. Hydraulic pressure forces the piston
mission and torque converter, which is attached to the fly- and discs against the back-up plate. Discs, with edge
wheel. The transmission and hydraulic torque converter tangs, clamp against toothed discs on the inner diameter,
operate together to transmit engine power to the axles via enabling the hub and the clutch shaft to lock together and
the transfer case (“drop box”) and drive shafts. The trans- drive as a unit, providing output power.

Legend
1. Dipstick Assembly 17. Screw 33. Speed Sensor Plug Screw
2. Dipstick Tube 18. Converter Housing-to-Plate Gasket 34. Spacer Plate
3. Plug 19. Converter Housing 35. Seat Snap Ring
4. O-ring 20. Temperature Pickup Plug 36. Converter Safety Valve Poppet
5. Sensor Port Plug 21. Lock Washer 37. Drain Back Port Plug
6. Oil Level Plug 22. Screw 38. Spacer Plate-to-Transmission Case
7. Oil Level Plug O-ring 23. Screw Dowel Pin
8. Transmission Case 24. Plug 39. Spacer Plate-to-Transmission Case
Gasket
9. Tube and Screen Assembly 25. Plug
40. Transmission Case-to-Spacer Plate
10. Oil Supply Tube Seal Ring 26. Screw Screw
11. Oil Supply Tube Retainer Clip 27. Screw 41. Filler Plug
12. Seal Washer 28. Safety Valve Seat 42. Air Breather
13. Clip Retainer Screw Nut 29. Safety Valve Spring 43. Transmission Gasket and Sealing Kit
14. Clip Retainer Screw Washer 30. Poppet Washer (services entire transmission)
15. Retainer Clip Screw 31. Sensor O-ring
16. Magnetic Drain Plug 32. Sensor Port Plug

7-2 Model 3606 • Origin 10/99

 Transmission

General Overview

42 1

33
32
31
25 2
3
41
40 4
21

38
4
3
4
35 36
39 3
25
34 24
33 5
6
32 31
7
6
37 7

21
8
12 16
26 17

28
10
21
30 29 9
27 21 15
26 14

3 11
12
3 13
4 24
4
3
4 25

18

21
23 43
43

21 19
21 PF0760
22
22
20
4
4 3 PS0010

Model 3606 • Origin 10/99 7-3

 Section 7

7.1 TRANSMISSION SERIAL NUMBER 7.2.2 Transmission Lubrication

The transmission serial number plate (Fig. 7–1) is A. Transmission Fluid
located on the engine side of the transmission at the bot-
tom right, toward the hydraulic fluid reservoir (tank). Infor- Complete transmission fluid information is found in Sec-
mation specified on the serial number plate includes the tion 2.5.6 Transmission.
transmission model number, the transmission serial num-
ber and other data. Information on the serial number B. Transmission Fluid (Oil) Capacity
plate is required in correspondence regarding the trans- Capacity w/ filter change ... 3.4 gal (12,9 l)
mission. Filter .................................. 1.5 qt (1,4 l)

7.2.3 Transmission-related Fuse Ratings, Amps

• Display Panel ..................7.5
• Neutral Relay/Starter ......7.5
• Neutral Sense .................7.5

Front • Transmission Solenoids ..7.5

of vehicle • Transmission Relay .........7.5

7.3 TOWING A DISABLED VEHICLE

Towing a disabled vehicle should only be attempted as a
Serial number last resort, after exhausting all other options. Follow the
plate MS0720 instructions in Section 2.13.1 Towing A Disabled Vehicle.
Figure 7–1. The transmission serial number plate is Make every effort to repair the vehicle, and move it under
located on the engine side of the transmission at the bot- its own power, before using the emergency towing proce-
tom right, near the hydraulic fluid reservoir (tank). dures outlined in Section 2.13.1.
To prepare the vehicle for towing, the parking brake
7.2 TRANSMISSION SPECIFICATIONS mechanisms at the front axle must be disabled. This will
General transmission specifications are found in Section allow the front wheels to rotate freely during emergency
2 General Information, Specifications and Maintenance towing. See Section 2.13.2 Disabling the Parking Brakes
Instructions. Transmission fluid information is found in and Section 2.13.3 Reactivating the Parking Brakes to
Section 2.5.6 Transmission. reactivate the parking brakes after towing and repair.
IMPORTANT: After the vehicle has been towed to a
7.2.1 Transmission Performance Specifications secure location, reactivate the parking brake. Carefully
follow the procedures from start to finish. Consult your
Performance criteria is based on full throttle engine
local Sky Trak distributor or the Sky Trak Service Depart-
speed unless otherwise specified or not applicable. The
ment if you are unsure about any part of the procedure,
four-speed transmission is used with Cummins and Per-
or for specific instructions for your particular situation.
kins turbocharged engines. The three-speed transmis-
sion is used with Perkins naturally-aspirated engines
only. Lubrication chart

Travel Speed (standard tires, no load)

4-SPEED 3-SPEED Maintenance chart
First gear 4.3 m.p.h. 4.2 m.p.h.
(6,9 km/hr) (6,8 km/hr)
Second gear 9.1 m.p.h. 9.2 m.p.h.
(14,6 km/hr) (14,8 km/hr)
Third gear 15.3 m.p.h. 17.7 m.p.h.
(24,6 km/hr) (28,5 km/hr) OS1170
Fourth gear 20.8 m.p.h. N/A Figure 7–2. The lubrication and maintenance charts
(if equipped) (33,5 km/hr) are located inside the engine cover.

7-4 Model 3606 • Origin 10/99

 Transmission

7.4 TRANSMISSION MAINTENANCE Periodically

Periodically, depending on operating conditions and other
7.4.1 Maintenance Introduction factors, back flush the transmission oil cooler, which is
part of the radiator (Fig. 7–3). ALWAYS back flush the
WARNING: To help avoid severe burns, DO
transmission oil cooler after removing the transmission
NOT attempt this procedure when the engine,
for repair or replacement. The transmission oil cooler out-
cooling, and hydraulic systems are hot. Wait
let hose, routed to the lower radiator fitting, is located on
until they have cooled before proceeding.
the right or hydraulic reservoir side of the transmission.
• Exercise extreme care to help avoid skin
The transmission oil cooler inlet hose, routed to the
rashes, fire hazards and inhalation of harmful
upper radiator fitting, is located on the left or boom side
vapors when using solvent and caustic
of the transmission, just below the position occupied by
cleaners.
the main hydraulic pump (refer to Section 8A.5.3 Perkins
• Exercise extreme care when using a steam
Engine Radiator and Oil Cooler Replacement, or to Sec-
cleaner to help avoid burns.
tion 8B.5.3 Cummins Engine Radiator and Oil Cooler
IMPORTANT: These instructions cover only the routine Replacement for replacement procedures). Disconnect
maintenance of the transmission. Refer to the Clark- and back flush the oil cooler portion of the radiator with
Hurth T 12000 Powershift Transmission 3, 4, & 6 Speed oil and compressed air until all foreign material is
Intermediate Drop Maintenance and Service Manual, removed. If necessary, remove the radiator from the vehi-
part number SM T12-3,4,6 ID for information on trans- cle and clean the oil cooler circuit using oil, compressed
mission diagnosis and internal component replacement. air and steam.
Cleanliness is of extreme importance. Before attempting IMPORTANT: DO NOT use flushing compounds for
any repairs, thoroughly clean the exterior of the transmis- cleaning purposes.
sion to help prevent dirt from entering while performing
maintenance checks and procedures. CUMMINS ENGINES
Radiator
Section 7.4.2 Transmission Maintenance Schedule pro-
vides a suggested maintenance schedule with refer- Inlet
ences to pertinent procedures and instructions in this hose
manual. To help prevent transmission problems before
Outlet hose
they occur, follow the maintenance schedule.
Note: Lubrication and Maintenance Chart decals are
located inside the engine compartment cover (see
Fig. 7–2). These decals contain a general maintenance
schedule that should be followed to maintain the vehicle Outlet
in good operating condition (refer to Section 2 General Inlet hose
Information, Specifications and Maintenance Instruc- hose
tions). The same schedule information is presented in
PS0740
Section 2.12.10 Transmission Oil and Filter with a
detailed account of how to perform the procedures.
PERKINS ENGINES Inlet
hose Radiator
7.4.2 Transmission Maintenance Schedule
Complete transmission maintenance information is
located in Section 2.12.10 Transmission Oil and Filter.
• At ten hour intervals, check the transmission oil level
(see Section 2.12.10 Transmission Oil and Filter). Outlet
• When the vehicle completes its first 50 hours of use, hose
change the transmission filter. Change the filter only;
DO NOT change the transmission oil and the filter at
the first 50 hour maintenance level (see Section
2.12.10 Transmission Oil and Filter). Inlet
hose
• At 1,000 hour intervals, change the transmission oil
and filter (see Section 2.12.10 Transmission Oil and
PS0750
Filter).
Figure 7–3. Transmission oil cooler hose routings.

Model 3606 • Origin 10/99 7-5

 Section 7

7.5 TRANSMISSION REPLACEMENT

IMPORTANT: To help ensure safety and optimum per- Transmission
formance, replace the transmission if it is damaged. filter
Refer to the Sky Trak International Model 3606 Parts Temperature • Transmission
switch dipstick
Manual for ordering information.
Cleanliness is of extreme importance. Before attempting
to remove the transmission, thoroughly clean the exterior
of the transmission to help prevent dirt from entering dur- Transmission
ing the replacement process. Avoid spraying water or mount
cleaning solution onto or near the transmission shift sole- bracket boss
noids and other electrical components.

7.5.1 Transmission Removal

Transmission
drain plug
WARNING: Risk of severe personal injury. OS1010
NEVER lift a transmission alone; enlist the help
Figure 7–4. Place a suitable receptacle
of at least one assistant or use a suitable hoist
under the transmission drain plug.
or overhead crane and sling.
10. Remove the main hydraulic pump from the
1. Level the vehicle, ground the attachment, place the transmission.
travel select lever in Neutral (N), turn the wheels fully
to the left, and engage the parking brake switch. 11. Label, disconnect and cap the transmission oil cooler
inlet and outlet lines at the transmission. The
2. Attach Accident Prevention Tags (see Section 1 transmission oil cooler outlet hose (Fig. 7–3), routed
Safety) to the ignition keyswitch and to the steering to the lower radiator fitting, is located on the right or
wheel. hydraulic reservoir side of the transmission. The
3. Unlock and open the engine compartment cover. transmission oil cooler inlet hose, routed to the upper
Allow the engine, transmission and hydraulic fluid to radiator fitting, is located on the left or boom side of
cool. the transmission, just below the position occupied by
4. Disconnect the battery negative (-) ground terminal to the main hydraulic pump.
help prevent the engine from starting accidentally.
5. Place a suitable receptacle under the transmission Frame (ref.)
drain plug (Fig. 7–4). Remove the transmission 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. Clean and reinstall the
transmission drain plug.
6. Disconnect the fuel run solenoid connection on the
top of the engine so the pump will not accidentally
operate, causing engine crankshaft rotation.
7. Remove the front engine cover plate (Fig. 7–5) from
the vehicle frame.
8. Remove the engine air cleaner assembly and the
Front engine
bracket supporting the air cleaner inlet hose at the cover plate
turbocharger assembly on turbocharged engines. MS0740

Cover the air inlet to the turbo assembly on Cummins Figure 7–5. Engine front cover plate location.
engines. On Perkins naturally-aspirated engines,
cover the air intake. 12. Wipe up any spilled hydraulic and transmission oil.
9. Label, disconnect and cap the inlet and outlet hoses 13. Label and disconnect the transmission shift solenoid
at the main hydraulic pump, mounted to the wiring harness connectors. Move the wiring harness
transmission. safely out of the way.

7-6 Model 3606 • Origin 10/99

 Transmission

IMPORTANT: To help ensure optimum performance, the barring tool to prevent the flywheel from turning while
drive shaft assemblies are specially balanced as a unit at removing the capscrews and washers.
the factory. Mark the drive shaft yoke at the transmission 18. Obtain four M12 x 80 mm capscrews with several
for return to its original position. washers each, as needed, and thread one capscrew/
14. Mark the transmission to transfer case drive shaft washer set into the tapped holes of each
yoke at the transmission-mounting flange. Remove transmission mount bracket boss (Fig. 7–4).
the M12 hex-head capscrews and lock washers 19. Connect an engine lift strap or sling to the M12 x
securing the flange yoke to the transmission. Lower 80mm capscrews, and to a suitable hoist or overhead
the transmission end of the drive shaft safely to the crane. Avoid sling contact with the transmission shift
ground, out of the way of the transmission. solenoids and the two modulation valve assemblies
15. FOR CUMMINS ENGINES: Working from beneath mounted on the top of the transmission. Operate the
the vehicle, on the left or boom side of the engine, hoist or crane to remove slack from the sling, but DO
just behind the engine-to-chassis mount bracket, NOT raise the transmission at this time.
remove the rubber hole plug and metal cover plate. IMPORTANT: Mark a capscrew locating hole on the
The plate covers a flywheel inspection hole transmission converter housing and the engine flywheel
(Fig. 7–6) on the engine. housing to aid in reinstallation, as the sides of the trans-
FOR PERKINS ENGINES: Remove the starter. mission case do not align vertically with the engine or
Remove the rubber hole plug above and to the left of with the chassis (Fig. 7–7).
the starter opening.

Rubber plug hole

Mark
Engine flywheel
inspection hole

Boom side
engine mount

M S0760
Figure 7–7. Mark a capscrew locating hole on the trans-
MS0750 mission converter housing and engine flywheel housing.
Figure 7–6. Cummins engine flywheel inspection hole. 20. Remove the twelve M10 x 1,5 x 30mm PC8.8 hex-
IMPORTANT: The engine flywheel and the transmission head capscrews and M10 lock washers securing the
drive plate are factory-balanced units. Mark the flywheel transmission to the engine. Separate the
and the transmission drive plate for return to their original transmission from the engine.
positions during re-installation. WARNING: Risk of personal injury. The trans-
16. Insert an engine barring tool into the rubber plug hole mission may move while hoisting it out of the
opening (Fig. 7–6, Cummins engine shown). If an chassis. Carefully move the transmission and
engine barring tool is not available, use a pry bar or adjust the sling as needed. Keep fingers,
other suitable device to alternately turn and bar the hands, legs and other body parts clear of the
engine flywheel. The tool will be used to advance, transmission.
then lock, the flywheel to permit removal of the
capscrews and washers securing the transmission 21. Carefully remove the transmission from the vehicle.
drive plate to the flywheel. Avoid causing damage to the transmission and to the
drive plate. Reposition the lift strap as needed to
17. Working through the flywheel inspection hole on the adjust for load shifting during transmission removal.
engine (Fig. 7–6, Cummins engine shown), remove
the eight 3/8-24 NF x 1-3/4" Grade 8 hex-head 22. Lift the transmission clear of the vehicle and lower it
capscrews (Cummins engine) or 3/8-24 NF x 2" onto suitable supports or secure it to a stand built
Grade 8 hex-head capscrews (Perkins engine) and especially for transmission or engine service. Secure
the eight 3/8" washers securing the transmission the transmission so that it will not move or fall.
drive plate to the engine flywheel. Use the engine

Model 3606 • Origin 10/99 7-7

 Section 7

23. Remove any external transmission components as

Flywheel
required, including the transmission temperature
housing
switch (Fig. 7–4). Flywheel
24. Remove the transmission oil filter and dispose of
properly. Clean the filter mounting surface.
The transmission is now ready for inspection and/or further
service. Refer to the Clark-Hurth T 12000 Powershift
Transmission 3, 4, & 6 Speed Intermediate Drop Mainte- Gap Gap
nance and Service Manual, part number SM T12-3,4,6
ID for information on transmission diagnosis and internal
Guide studs
component repair or replacement.

7.5.2 Transmission Inspection

and Internal Repair
MA0391
The charging pump and flywheel housing may require Figure 7–8. Engine flywheel housing guide studs.
removal for inspection and further transmission disas-
sembly. Mark the housing for return to its original position 5. Use a hoist or overhead crane and sling attached to
as the sides of the transmission case do not align verti- the M12 x 80mm capscrews. Raise and position the
cally with the engine or with the chassis (Fig. 7–10). transmission within the chassis. DO NOT mount or
align the transmission with the engine using the two
Refer to the Clark-Hurth T 12000 Powershift Transmis-
M10 x 1,5 x 63,5 mm guide studs (dowels) at this
sion 3, 4, & 6 Speed Intermediate Drop Maintenance and
time.
Service Manual, part number SM T12-3,4,6 ID for infor-
mation on transmission diagnosis and internal component IMPORTANT: The flywheel and the torque converter are
repair or replacement. If replacing the entire transmis- factory-balanced units. If applicable, align the flywheel
sion, transfer the transmission temperature switch to the and the torque converter with the orientation marks made
replacement transmission. The gear shift solenoids are during the removal procedure.
included with a new transmission. 6. Working through the engine flywheel inspection and
access hole on Cummins engines (Fig. 7–6), or
7.5.3 Transmission Installation through the starter mount hole on Perkins engines,
rotate and align a flywheel screw hole with a
WARNING: Risk of severe personal injury. transmission drive plate weld nut. Obtain and thread
NEVER lift a transmission alone; enlist the help a 3/8-24 NF x 4" threaded stud, to serve as a drive
of at least one assistant or use a suitable hoist plate locating stud, through the flywheel screw hole
or overhead crane and sling. and into the drive plate weld nut (Fig. 7–9).

WARNING: The transmission must be properly Flywheel 4" locating Converter

installed using fasteners of correct size and Access housing stud housing
grade torqued to their specified value. hole
Drive plate
1. Clean all mating surfaces on both the engine and the mounting
transmission prior to assembly. screw hole

2. Obtain and thread four M12 x 80 mm capscrews with

2-1/2" guide stud
several washers each, as needed, into each
transmission mount bracket boss (Fig. 7–4) to aid in
Flywheel
transmission installation. Drive
plate
3. Temporarily thread two M10 x 1,5 x 63,5mm guide
studs into the engine flywheel housing (Fig. 7–8).
These will be used as alignment dowels. 2-1/2" guide stud

4. Notice the gaps between the upper and lower halves MA0401
of the transmission-to-engine bolt circle (Fig. 7–9). Figure 7–9. Flywheel and drive plate locating studs.
Use the gaps as an aid in installation, as the sides of
the transmission case do not align vertically with the 7. Position the transmission onto the two M10 x 1,5 x
engine or with the chassis (Fig. 7–10). 63,5 mm guide studs (Fig. 7–8).

7-8 Model 3606 • Origin 10/99

 Transmission

8. Begin securing the transmission to the flywheel 12. When all eight capscrews and washers are installed,
housing with M10 lock washers and M10 x 1,5 x 30 mm torque the capscrews to 26-29 lb/ft (35-39 Nm). This
PC8.8 hex-head capscrews. Remove the two M10 x will require torquing each screw and rotating the
1,5 x 63,5 mm guide studs (dowels) after several engine flywheel until all eight of the capscrews are
capscrews and washers are installed. When tightened.
installing the washers and capscrews, tighten bolts 13. Remove the hoist or overhead crane and sling.
evenly in stages and assure that the transmission
converter housing installs evenly against the engine 14. Continue making hook-ups of previously
flywheel housing. disconnected items, hoses, etc. Before attaching the
main pump hose, fill the pump with hydraulic fluid by
Note: If the transmission is not aligned properly with the hand to prime it.
engine, the torque converter will angle against the drive
15. Clean the transmission oil filter mounting surface.
plate and damage will occur when the engine is started.
16. Apply a clean film of clean 10W motor oil to the new
9. When all twelve capscrews and washers are filter gasket. Install the new filter and torque 20-25 lb/ft
installed, torque each capscrew to 37 lb/ft (50 Nm). (27-34 Nm).
10. Remove the 3/8-24 NF x 4" threaded stud, serving as
Note: 10W motor oil is recommended in most climates;
a drive plate locating stud (Fig. 7–9), and install a
however, 5W20 motor oil may be substituted for use in
3/8-24 NF flywheel-to-drive plate capscrew with a
conditions -30°F to 70°F (-34°C to 21°C) only.
3/8" lock washer in place of the stud. Partially, but not
completely, tighten the capscrew. 17. Transmission oil may be added through either the fill
plug or dipstick holes. Remove the fill plug or dipstick
Note: Due to different flywheel thicknesses, different fly-
and add approximately 3.4 gallons (12,9 liters) of
wheel-to-drive plate capscrews are used. For the Cummins
10W motor oil. Check the oil level by taking
engine, 3/8-24 NF x 1-3/4" Grade 8 hex-head capscrews
intermittent dipstick readings as outlined in Checking
are used. For the Perkins engine, 3/8-24 NF x 2" Grade 8
the Transmission Oil Level. DO NOT overfill.
hex-head capscrews are used. Use Loctite® #242 (blue)
Reinstall the fill plug or dipstick when finished.
on all flywheel bolts.
18. Coat the drive shaft yoke-to-transmission M12-1,75 x
3/8" fasteners 35 mm hex-head capscrews with Loctite® #242
(blue). Install the yoke with the capscrews and
hardened M12 flat washers. Torque the capscrews to
83 lb/ft (112,5 Nm).
19. Connect the wiring harness terminals to the
transmission solenoids.
20. Remove the caps and install the transmission oil
cooler inlet and outlet lines at the transmission (Fig.
7–3). The transmission oil cooler outlet hose, routed
to the lower radiator fitting, is located on the right or
hydraulic reservoir side of the transmission. The
transmission oil cooler inlet hose, routed to the upper
M10 fasteners radiator fitting, is located on the left or boom side of
MS0770 the transmission, just below the position occupied by
Figure 7–10. Transmission to engine fasteners. the main hydraulic pump.
11. Insert an engine barring tool into the sight plug hole 21. Attach the main hydraulic pump to the transmission.
(Fig. 7–6, Cummins engine shown) and advance the Align the splined pump drive shaft with the
flywheel to the next screw hole and drive plate weld transmission drive and secure the pump to the
nut. Continue installing and partially tightening the transmission with 1/2-13 x 1-1/2" hex-head
remaining capscrews and washers and rotating the capscrews, 1/2" lock washers and 1/2" plain washers.
flywheel and drive plate. Torque capscrews to 75 lb/ft (102 Nm).
22. Uncap and install the hydraulic inlet and outlet hoses
on the main hydraulic pump.
23. Install the engine air cleaner assembly and the
bracket supporting the air cleaner inlet hose at the
turbocharger assembly on turbocharged engines.

Model 3606 • Origin 10/99 7-9

 Section 7

24. Attach the front engine cover plate (Fig. 7–5) to the 8. Back flush the transmission oil cooler portion of the
vehicle frame. Secure with 5/16-18 x 1" hex-head radiator with oil and compressed air until all foreign
capscrews, 5/16" lock washers and 5/16" flat material is removed. Flushing in the direction of
washers. Torque capscrews to 18 lb/ft (24 Nm). normal oil flow does not adequately clean the cooler.
25. Connect the fuel run solenoid connector on the top of If needed, remove the radiator from the vehicle.
the engine near the radiator. IMPORTANT: DO NOT use flushing compounds for
26. Wipe up any spilled fluids. Dispose of properly. cleaning purposes.

27. Connect the battery negative (-) ground terminal at 9. Reassemble all components and fill the transmission
the battery. with clean, fresh 10W motor oil through the filler
opening until oil comes up to the FULL port on the
7.5.4 After Transmission Service or transmission housing.
Replacement 10. Remove the UPPER check plug. Fill the transmission
with oil until oil runs from the UPPER oil hole.
Refer to the Clark-Hurth T 12000 Powershift Transmis-
Replace the filler and the level plug.
sion 3, 4, & 6 Speed Intermediate Drop Maintenance and
Service Manual, part number SM T12-3,4,6 ID for infor- 11. Run the engine for two minutes at idle (1,000 - 1,100
mation on servicing the transmission after overhaul or rpm) rpm to help prime the torque converter and the
repair. In general: transmission oil lines.
1. Check transmission oil level and add oil as required. 12. Recheck the level of the fluid in the transmission with
the engine running at idle (1,000 - 1,100 rpm).
2. Install a new transmission filter.
13. Add 10W motor oil as necessary to bring the fluid
3. Check the torque on the drive shaft yoke retaining
level up until it begins to run freely from the UPPER
bolts. Tighten these M12 bolts to 156 lb/ft (212 Nm).
oil level check plug hole. Install the oil level plug.
4. Wear suitable eye protection. When an overhauled or Recheck the oil level when it reaches operating
repaired transmission is installed, thoroughly clean temperature (180-200°F, or 83-94°C).
the oil cooler lines to and from the transmission.
14. Recheck all drain plugs, lines, connections, etc., for
5. Drain and flush the entire system. leaks and tighten where necessary.
6. Disconnect and clean all transmission lines
(Fig. 7–3). When possible, remove transmission lines
from the vehicle for cleaning.
7. Thoroughly clean transmission filter screens and
cases, and replace transmission filter elements.

7-10 Model 3606 • Origin 10/99

 Transmission

7.6 TRANSMISSION TROUBLESHOOTING This section provides an easy reference guide covering
the most common problems that occur during operation
of the transmission.

Transmission Troubleshooting

Problem Cause Remedy

1. Low clutch pressure. 1. Low oil level. 1. Fill to the proper level.
2. Clutch pressure regulating valve 2. Clean the valve spool and
stuck open. housing.
3. Faulty charge pump. 3. Replace the pump.
4. Broken or worn clutch shaft or 4. Replace sealing rings.
piston sealing rings.
5. Clutch piston bleed valve stuck 5. Clean bleed valve thoroughly.
open.
2. Low converter charging 1. Low oil level. 1. Locate the break and/or stop the
pump output. leaks.
2. Suction screen plugged. 2. Clean the suction pump.
3. Defective oil pump. 3. Replace the pump.
3. Overheating. 1. Worn oil sealing rings. 1. Remove, disassemble and
rebuild the converter assembly.
2. Clogged radiator. 2. Clean radiator.
3. Worn oil pump. 3. Replace the pump.
4. Low oil level. 4. Fill to the proper level.
4. Noisy converter. 1. Worn oil pump. 1. Replace the pump.
2. Worn or damaged bearings. 2. Disassemble the converter and
determine which bearing is worn
or damaged.
5. Lack of power. 1. Low engine RPM causes 1. Adjust the engine RPM check
converter stall. governor.
2. Worn oil sealing rings. 2. Remove, disassemble and
rebuild the converter assembly.
3. Worn oil pump. 3. Replace the pump.
4. Low oil level. 4. Fill to the proper level.
Note: For further information, refer to:
Clark-Hurth T 12000 Powershift Transmission
3, 4, & 6 Speed Intermediate Drop
Maintenance and Service Manual
part number SM T12-3,4,6 ID.

Model 3606 • Origin 10/99 7-11

 Section 7

7-12 Model 3606 • Origin 10/99

 Section 8A
Engine: Perkins 1004 Series

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2
Legend ................................................. 8A-2
General Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
8A.1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
8A.2 PERKINS ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-6
8A.3 PERKINS SPECIFICATIONS AND MAINTENANCE INFORMATION . . . 8A-6
8A.4 PERKINS ENGINE STANDARD PRACTICES . . . . . . . . . . . . . . . . . . . . . 8A-6
8A.5 PERKINS ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8A-6
8A.5.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
8A.5.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
8A.5.3 Perkins Engine Radiator and Oil Cooler Replacement . . . . . . . 8A-7
8A.6 PERKINS ENGINE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8A-10
8A.7 PERKINS ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-10
8A.7.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-12
8A.7.2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-12
8A.7.3 Fuel Level Sender and Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . 8A-13
8A.7.4 Fuel Lift Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-13
8A.7.5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-14
8A.7.6 Venting Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . 8A-14
8A.7.7 Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-14
8A.7.8 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-15
8A.8 PERKINS ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8A-15
8A.9 PERKINS ENGINE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-16
8A.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-16
8A.9.2 Engine Disassembly, Inspection, and Service. . . . . . . . . . . . . . 8A-19
8A.9.3 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-19
8A.10 PERKINS ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-22
8A.11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-23

Model 3606 • Origin 10/99 8A-1

 Section 8A

Introduction
DISCLAIMER AND SCOPE

These instructions are written for worldwide use. In A gradual running in (break in) of a new engine is not
territories where legal requirements govern engine necessary. Full load can be applied to a new engine as
smoke emission, noise, safety factors, etc., apply all soon as the engine is put into service and the coolant
instructions, data and dimensions provided herein in temperature is at least 140° F (60°C). Extended light-
load operation during the early life of the engine is not
such a way that after maintenance, service and repair recommended. DO NOT run the engine at high, no-load
of the engine, engine operation does not violate local speeds. DO NOT apply an overload to the engine.
regulations.
Throughout this section, the left or right side of the
IMPORTANT: These instructions cover only the routine engine is as viewed from the flywheel end.
maintenance, removal, installation and troubleshooting
of the engine. Refer to the local Perkins Engine Distrib-
utor and the applicable Perkins or Perkins Phaser/
Detroit Diesel Phaser/1000 Series engine service man-
ual for assistance with comprehensive engine diagno-
sis, repair and component replacement.

Legend
1. Perkins 1004-series Engine 12. Flat Narrow Washer, 7/16" 21. Hex-lock Elastic Nut, 5/8-11
2. Fan Belt 13. Hex-head Capscrew, 22. Engine Oil Filter
3. Ten-blade, 18"-Suction Fan 7/16-14 X 3-1/4", Grade 8 23. Starter
4. Alternator, 65 Amp 14. Hex-head Capscrew, 24. Front Right Side Engine Mount
5/8-11 X 4", Grade 8
5. Hex-lock Elastic Nut, 7/16-14 25. Hex-head Capscrew,
15. Flat Narrow Washer, 5/8" 1/4-20 X 3/4"
6. Rebound Washer, 7/16"
16. Engine Mount 26. Starter Relay
7. Rear Left Side Engine Mount
17. Front Left Side Engine Mount 27. Hex-lock Elastic Nut, 1/4-20
8. Engine Mount
18. Hex-head Capscrew, 28. Rear Right Side Engine Mount
9. Hex-head Capscrew, M12-1,75 X 40 mm Pc 8,8
3/8-16 X 1-1/2, Grade 5 29. Engine Block Heater
19. Lockwasher, M12
10. Flat Narrow Washer, 3/8"
20. Rebound Washer, 5/8"
11. Hex-lock Elastic Nut, 3/8-16

8A-2 Model 3606 • Origin 10/99

 Perkins Engine

General Overview

29
3
Flange nuts supplied w/ engine

28 2
26
25

1
27

20
9
5
4 6

24
11
10 7

8
10
22
9

21
20
11 19
10 18

17

16
10
9

Engine mount subframe (ref.)

(includes hydraulic reservoir)

12
15
13
Front of vehicle Torque to 60 lb/ft (81 Nm)
14
Torque to 180 lb/ft (244 Nm)
MS1000

Figure 8A–1. Perkins engine general overview.

Model 3606 • Origin 10/99 8A-3

 Section 8A

8A.1 SAFETY INFORMATION Engine Coolant (anti-freeze/anti-boilover)

WARNING: DO NOT remove the radiator cap

General Vehicle Operation
while the engine and coolant are hot. Hot cool-
WARNING: Before attempting to start the ant under pressure is dangerous and can injure
engine and/or operate the vehicle, read the the eyes and cause severe burns.
owners/operators manual. • Cooling system corrosion inhibitors contain
• Before operating the engine and/or the vehi- alkali (chemicals that break down organic
cle, install guards and clear all personnel from substances such as skin and eye tissue). DO
the immediate area. NOT swallow. Avoid prolonged or repeated
• Check that the brakes are fully functional. contact with corrosion inhibitors. In case of
• DO NOT exceed the stability limits of the vehi- skin con-tact, immediately wash affected area
cle. with soap and water. In case of contact with
• Allow only ONE person to have control of the eyes, immediately flood eyes with large
engine and the vehicle amounts of water for a minimum of 15 min-
utes. Obtain medical assistance immediately.
Preparation Keep corrosion inhibitors out of the reach of
children.
WARNING: Wear protective glasses and pro- • DO NOT use salt water or other corrosive liq-
tective shoes. uid in the cooling system.
• Verify that the work area is capable of sup-
porting the weight of the vehicle and the Rotating Parts and Fan Blades
torque created by any suspended load.
• DO NOT work on an engine or a vehicle that WARNING: Keep away from parts which
is supported ONLY by a hoist or lift jacks. Use rotate; the fan blades can appear invisible when
blocks or suitable stands. the fan is rotating.
DO NOT pull or pry on the fan blades. This
Engine Operation practice will cause fan failure. Use only
approved methods and tools for manually rotat-
WARNING: Operate the engine in a well-venti- ing the engine.
lated area only. Assure that engine operation
will not produce a concentration of toxic emis- Battery
sions.
• DO NOT operate the engine in the presence WARNING: Keep sparks and fires away from
of a fuel spill or gas leak. Such combustible batteries. Batteries produce hydrogen gas,
vapors, when drawn into the engine, can which can explode and cause severe personal
cause engine over-acceleration, explosion, injury and property damage.
fire and extensive personal injury and prop- Battery fluid can burn the skin and injure the
erty damage. Before operating in any hazard- eyes. If you come in contact with battery acid,
ous environment, consult a recognized flush the affected area with large amounts of
authority (such as the engine distributor) on water and obtain medical assistance immedi-
engine operation in hazardous environments. ately.
• DO NOT smoke or operate the engine during
refueling. Engine Oil

Cleaning WARNING: Engine oil can cause skin disor-

ders and other personal injury. Avoid prolonged
WARNING: When using steam cleaners and or repeated contact with both new and used
pressure washers, wear protective glasses, engine oil.
gloves and clothing to help prevent personal
injury. Diesel Fuel

WARNING: NEVER use gasoline or other WARNING: Diesel fuel can cause skin irrita-
flammable materials for cleaning parts. Use tion. Use gloves or protective hand lotion when
only approved cleaning solvents. working on the fuel system

8A-4 Model 3606 • Origin 10/99

 Perkins Engine

Engine Repair Parts

WARNING: Before beginning any adjustments WARNING: Always use factory-approved fas-
or repairs, place a DO NOT OPERATE tag in teners and parts. DO NOT use other than fac-
the operator’s compartment and on the con- tory-approved fasteners and parts when
trols, and disconnect the battery negative replacement is necessary.
cable.
• DO NOT operate, clean, lubricate or adjust
the engine without proper training.
• NEVER attempt to perform an adjustment or
repair that is not understood.
• Before servicing, relieve pressure in fuel, oil,
coolant and hydraulic lines. Obtain medical
assistance immediately if a high-pressure jet
of fuel, oil, coolant or hydraulic fluid strikes the
skin.
• DO NOT permit loose clothing, hair, etc., near
moving parts.
• Keep away from parts which rotate; fan
blades can appear invisible when the fan is
rotating.
• To help prevent burns, avoid contact with com-
ponents that remain hot after power is turned
off or disconnected.
• Some of the gaskets on the engine obtain
asbestos. Breathing asbestos dust is danger-
ous to health and may cause severe bodily
harm. Avoid creating dust and follow local
directives for handling and disposing of mate-
rials that contain asbestos.

Model 3606 • Origin 10/99 8A-5

 Section 8A

8A.2 PERKINS ENGINE SERIAL NUMBER DO NOT steam clean the following parts:

The Perkins 1004-series engine serial number is • Electrical Components

stamped on a label which is fastened to the side of the • Wiring
engine block, toward the vehicle hydraulic reservoir. • Injectors
Information contained in the serial number is required in
correspondence regarding the engine. • Fuel Pump
• Belts and Hoses
Perkins serial number location
• Bearings
During reassembly and inspection, thoroughly clean all
parts, and, where present, remove burrs and scales.
Gaskets and O-rings
Front of vehicle
NEVER re-use a gasket or O-ring. Use new gaskets and
O-rings. Thoroughly clean sealing surfaces before install-
ing a new gasket or O-ring. Always install new flat-faced
O-rings when servicing hydraulic fittings. Cover any open
ports of high-precision components (such as fuel system
equipment) exposed by removal or disassembly to help
MS3010 prevent the entry of foreign material.
Figure 8A–2. Perkins engine serial number label location. Capscrews and Metric Parts
Supply the engine serial number when communicating When replacing capscrews, always use a capscrew of
about an engine or engine components. the same size and strength as the capscrew being
replaced. Incorrect capscrews cause engine damage.
8A.3 PERKINS SPECIFICATIONS Return capscrews removed from the engine to their origi-
AND MAINTENANCE INFORMATION nal locations.
Engine, coolant and oil specifications and maintenance The Perkins 1004 series engine uses parts that are of
information appear in Section 2 General Information, metric dimensions. Metric capscrews are described, in
Specifications, and Maintenance Instructions. millimeters, in terms of major thread diameter, distance
between threads, and overall length.
Note: Detailed Perkins engine service instructions (cov-
Metric capscrew dimensions:
ering disassembly, inspection, internal repair, assembly,
adjustment and troubleshooting information) are pro- M8 x 1,25 - 25
vided in the appropriate Perkins engine service manual. Length, in millimeters
Distance between threads, in millimeters
8A.4 PERKINS ENGINE STANDARD Major thread diameter, in millimeters
PRACTICES
Verify that the correct type of part is used at all times.
Left and Right Sides of the Engine
8A.5 PERKINS ENGINE COOLING SYSTEM
Throughout this section, the left or right side of the
engine is as viewed from the flywheel end. The Perkins engine cooling system is a closed, pressur-
ized system that consists of coolant passages in the
Cleanliness engine, plus the oil cooler, thermostat, water pump,
hoses, radiator and radiator overflow bottle. The engine
Cleanliness is very important during engine repair. Con- is cooled by the circulation of coolant through passages
tamination of the engine during repair will reduce the life in the cylinder block and head. Circulation is by thermo-
of an engine. Thoroughly clean the engine and engine siphon action, assisted by an impeller-type water pump,
compartment area before attempting to service or repair driven by a fan belt from the crankshaft pulley. The water
the engine. pump bearings are prepacked with a special grease and
do not require service. Replace a faulty water pump.
General engine cooling specifications and maintenance
procedures are listed in Section 2 General Information,
Specifications, and Maintenance Instructions.

8A-6 Model 3606 • Origin 10/99

 Perkins Engine

8A.5.1 Radiator Pressure Cap WARNING: NEVER remove the radiator cap
The cooling system is designed to use a radiator pres- while the engine is hot. The cooling system is
sure cap to help prevent the coolant from boiling. In addi- under pressure. Hot coolant can cause severe
tion, the pressure helps to eliminate the formation of burns or eye injury. Wear protective clothing
steam pockets within the engine and ensures coolant cir- and safety glasses.
culation throughout all coolant passageways of the
4. Drain approximately two quarts (2 liters) of coolant.
engine. For a 210° F (99° C) system, use a 7 psi Slowly turn the radiator cap to the first stop and allow
(48 kPa) radiator cap. An incorrect or malfunctioning cap any pressure to escape. Remove the radiator cap.
can result in the loss of coolant and a hot-running engine. Place a funnel at the base of the radiator to channel
the drained coolant into a container. Open the
Thermostat radiator drain plug or petcock and allow the coolant to
drain into the funnel. Transfer the coolant into a
properly labeled container. Save for reuse later or
dispose of properly. Close the radiator drain plug or
Thermostat petcock.
housing 5. Remove the setscrews securing the water outlet
connection to the engine, and remove the water
outlet connection and thermostat gasket.
MS1090 6. Remove the thermostat and clean the gasket
Figure 8A–3. Perkins 1004-series engine surfaces. DO NOT let any debris into the thermostat
thermostat housing (typical). opening while the thermostat is removed.
IMPORTANT: Always use the correct thermostat.
8A.5.2 Thermostat Replacement NEVER operate the engine without a thermostat, or
Before considering thermostat replacement, check the engine damage will result.
coolant level, fan belt tension and dash panel tempera- 7. Install the thermostat, gasket and water outlet
ture gauge. If the engine seems to take a long time to connection. Secure with the setscrews removed
warm up, the thermostat (Fig. 8A–3) may be stuck in the earlier. Tighten the setscrews.
open position and requires replacement. If the engine
8. Fill the cooling system. Run the engine to operating
runs hot, check the temperature of the upper radiator
temperature. Visually check for leaks with the engine
hose. If the hose is not hot, the thermostat may be stuck
running. Check the coolant level in the overflow bottle
in the closed position. If the engine has overheated, per-
and fill, or drain, as necessary.
formance may suffer, indicating other damage including a
leaking cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
8A.5.3 Perkins Engine Radiator
and Oil Cooler Replacement
To replace the thermostat:
Before considering radiator or oil cooler replacement for
1. Level the vehicle, ground the attachment, place the other than obvious damage, conduct a cooling system
travel select lever in NEUTRAL (N), engage the pressure test, check the coolant specific gravity, coolant
parking brake switch and shut off the engine. level, fan belt tension and dash panel temperature
WARNING: DO NOT attempt this procedure gauge. If the engine runs hot, check the temperature of
when the engine is hot. Wait for the engine, the upper radiator hose. If the hose is not hot, the ther-
muffler, and tailpipes to cool down before pro- mostat may be stuck in the closed position. If the engine
ceeding. Failure to do so could result in severe has overheated, performance may suffer, indicating other
burns damage including a leaking cylinder head gasket,
cracked cylinder head or block, and/or other internal
2. Unlatch, unlock and open the engine cover. Allow the engine damage.
engine to cool before proceeding. Draining the
cooling system while the engine is hot can cause
cracks in the engine block.
3. Disconnect the negative (-) battery cable.

Model 3606 • Origin 10/99 8A-7

 Section 8A

39 33
1
34 37 38
36
30
32 8
31
4 35
30
29
28
Front of vehicle
27
2
3

4
5

19 6
24 8 7
Engine (ref.)
26
17

18
19
24 20
25 21 22
10 12
7
9
16 11
23
13
15 13
14

7
14
Engine subframe (ref.)

PS0490

1. Bulb seal 15. Sheet 28. Radiator cap, 13 psi (89,6 kPa)
2. Bulb seal molding 16. Hex-head capscrew, 29. Narrow flat washer, 5/16"
3. Radiator baffle assembly 3/8-16 x 1-1/2 Grade 5 30. Lockwasher, 5/16"
4. Foam baffle 17. Rubber mount 31. Hex-head capscrew,
5. Oil cooler 18. Radiator shroud 5/16-18 x 3/4" Grade 5
6. Radiator mount ring 19. Radiator hose clamp (radiator) 32. Overflow tank, 3 qt. (incl. item 33)
7. Rebound washer, 3/8" 20. Hex-head capscrew, 33. Cap w/tether
1/4-20 x 3/4" 34. Right radiator bracket assembly
8. Hex-lock elastic nut, 5/16-18
21. Narrow flat washer, 1/4" 35. Well nut
9. Radiator mount bushing
22. Baffle 36. Wide flat washer, 1/4"
10. Spacer
23. Hex-lock elastic nut, 1/4-20 37. Lockwasher, 1/4"
11. Left radiator bracket
24. Radiator hose clamp (engine) 38. Hex-head capscrew,
12. Hex-socket head shoulder bolt,
3/8 x 1-1/2 x 5/16-18 25. Radiator input hose 1/4-20 x 1-1/2
13. Wide flat washer, 3/8" 26. Radiator return hose 39. Fan warning decal
14. Hex-lock elastic nut, 3/8-16 27. Radiator assembly (incl. item 28)

Figure 8A–4. Perkins engine radiator and oil cooler.

8A-8 Model 3606 • Origin 10/99

 Perkins Engine

To remove the radiator and oil cooler:

1. Level the vehicle, ground the attachment, place the
Inlet
travel select lever in NEUTRAL (N), engage the Radiator
hose
parking brake switch and shut off the engine.
Remove the ignition key. Secure accident prevention
tags to both the steering wheel and the ignition
switch.
WARNING: DO NOT attempt this procedure
when the engine is hot. Wait for the engine,
muffler, and tailpipes to cool down before pro- Outlet
ceeding. Failure to do so could result in severe hose
burns.

2. Unlatch, unlock and open the engine cover. Allow the

engine to cool before proceeding. Draining the
cooling system while the engine is hot can cause Inlet
cracks in the engine block. hose
3. Disconnect the negative (-) battery cable.
PS0750
WARNING: NEVER remove the radiator cap
Figure 8A–5. Transmission hose routings.
while the engine is hot. The cooling system is
under pressure. Hot coolant can cause severe 10. Working above the radiator, remove two 5/16-18 x
burns or eye injury. Wear protective clothing 3/4" Grade 5 hex-head capscrews (item 31,
and safety glasses. Fig. 8A–4), 5/16" lockwashers (30) and 5/16" narrow
flat washers (29) securing the radiator (27) at the
4. Place a suitable container beneath the radiator upper mounting tabs to the radiator shroud (18). The
petcock. Slowly turn the radiator cap to the first stop radiator shroud contains 5/16" weld nuts that retain
and allow any pressure to escape. Remove the the capscrews.
radiator cap.
11. Working below the radiator, remove two 5/16-18 x
5. Place a funnel at the base of the radiator to channel 3/4" Grade 5 hex-head capscrews (31), 5/16"
the drained coolant into the container. Open the lockwashers (30) and 5/16" narrow flat washers (29)
radiator drain plug or petcock and allow the coolant to securing the radiator at the lower mounting tabs to
drain into the funnel. Transfer the coolant into a the radiator shroud (18).
properly labeled container. Dispose of properly if
coolant needs to be replaced. Close the radiator 12. Working from beneath the radiator, remove two 3/8-
drain plug or petcock. 16 hex-lock elastic nuts (14), 3/8" rebound washers
(7) and rubber mounts (17) secured to the welded
6. Loosen clamps (items 19 and 24, Fig. 8A–4) on the studs on the bottom of the radiator.
radiator return (lower) hose (26). Work the hose off
the radiator. Position the hose out of the way to allow 13. At the sides of the radiator, remove the 3/8 x 1-1/2 x
radiator removal, or remove the hose from the 5/16-18 hex-socket head shoulder bolts (12), spacers
engine. Inspect the hose and replace if necessary. (10), 3/8" rebound washers (7), radiator mount
bushings (9), radiator mount rings (6), and 5/16-18
7. Loosen clamps (19 and 24, Fig. 8A–4) on the radiator hex-lock elastic nuts (8) securing the radiator at its
input (upper) hose (25). Work the hose off the side mounting tabs to the radiator brackets (8 and
radiator. Position the hose out of the way to allow 34). Carefully remove the radiator from the vehicle.
radiator removal, or remove the hose from the
engine. Inspect the hose and replace if necessary. 14. At the bottom of the hydraulic system oil cooler (Fig.
8A–6), disconnect and cap the 90° elbow. Remove
8. Loosen the fan belt and remove the fan (item 3, Fig. and discard the flat-faced O-ring seal. Disconnect
8A–1). Remove the four hex-head capscrews (not and cap the 3/4" I.D. x 28" hose.
shown) and lockwashers (not shown) securing the
fan (3) to the engine water pump. 15. Remove the six 1/4-20 x 1-1/2" hex-head capscrews
(38, Fig. 8A–4), 1/4" lockwashers (37), 1/4" flat wide
9. At the radiator, disconnect and cap the transmission washers (36) and well nuts (35) securing the radiator
inlet and outlet hoses (Fig. 8A–5). baffle assembly (3) to the oil cooler (5).

Model 3606 • Origin 10/99 8A-9

 Section 8A

16. Remove the oil cooler (Fig. 8A–6). on the bottom of the radiator. Torque to 31 lb/ft
(42 Nm).
Oil cooler 9. Working below the radiator, install two 5/16-18 x 3/4"
Grade 5 hex-head capscrews (31), 5/16"
lockwashers (30) and 5/16" narrow flat washers (29)
securing the radiator at the lower mounting tabs to
3/4" I.D. x 28" hose
the radiator shroud (18). Torque to 18 lb/ft (24 Nm).
10. Working above the radiator, install two 5/16-18 x 3/4"
Grade 5 hex-head capscrews (31), 5/16"
lockwashers (30) and 5/16" narrow flat washers (29)
securing the radiator at the upper mounting tabs to
O-Ring the radiator shroud (18). The radiator shroud
90° Elbow contains 5/16" weld nuts that retain the capscrews.
Torque to 18 lb/ft (24 Nm).
Reservoir
11. Uncap and connect the transmission inlet and outlet
SS1150 hoses (Fig. 8A–5).
12. Install the fan (item 3, Fig. 8A–1) on the water pump
Figure 8A–6. Perkins oil cooler hose routings.
pulley on the front of the engine. Secure with four
17. Remove, inspect and replace the seal bulb (1), seal hex-head capscrews (not shown) and lockwashers
bulb moulding (2), and foam baffles (4) as required. (not shown). Install the fan belt.
13. Install clamps (19 and 24, Fig. 8A–4) on the radiator
Radiator and Oil Cooler Installation input (upper) hose (25). Work the hose onto both the
1. Install the seal bulb (item 1, Fig. 8A–4), seal bulb engine and then the radiator. Tighten the clamps.
moulding (2), and foam baffles (4) as required. 14. Install clamps (19 and 24) on the radiator return
2. Position the oil cooler (5) within the radiator assembly (lower) hose (26). Work the hose onto both the
baffle (3). engine and then the radiator. Tighten the clamps.
3. Install the six 1/4-20 x 1-1/2" hex-head capscrews Fill the cooling system. Run the engine to operating tem-
(38, Fig. 8A–4), 1 /4" lockwashers (37), 1/4" flat wide perature. Visually check for leaks with the engine run-
washers (36) and well nuts (35) securing the radiator ning. Check the coolant level in the overflow bottle and
baffle assembly (3) to the oil cooler (5). Torque to 9 fill, or drain, as necessary.
lb/ft (12 Nm).
4. At the bottom of the hydraulic system oil cooler 8A.6 PERKINS ENGINE
(Fig. 8A–6), install a new flat-faced O-ring seal in the ELECTRICAL SYSTEM
90° elbow and secure the elbow fitting to the cooler. Refer to Section 10 Electrical System for information cov-
Use a back-up wrench and torque the elbow fitting to ering the Perkins engine electrical system, including the
155-165 lb/ft (210-224 Nm). starter, alternator and primary wiring.
5. Secure the 3/4" I.D. x 28" hose (Fig. 8A–6) to the oil
cooler. 8A.7 PERKINS ENGINE FUEL SYSTEM
6. Carefully place the radiator into position at the oil The Perkins engine fuel system includes a fuel tank (item
cooler. As required, place two foam baffles (item 4, 36, Fig. 8A–7), fuel level sender (21) and dash panel
Fig. 8A–4) between the radiator and the oil cooler. gauge, fuel strainer (8), fuel lift pump, fuel filter (14), and
7. At the sides of the radiator, install the 3/8 x 1-1/2 x fuel supply and return lines.
5/16-18 hex-socket head shoulder bolts (item 12, The threaded fuel filler (29) has a keyed fuel cap (31) and
Fig. 8A–4), spacers (10), 3/8" rebound washers (7), permits entry of diesel fuel into the tank. The fuel level
radiator mount bushings (9), radiator mount rings (6), sender (21) and dash panel gauge are described in Sec-
and 5/16-18 hex-lock elastic nuts (8) securing the tion 10 Electrical System. A fuel supply hose (9) carries
radiator at its side mounting tabs to the radiator fuel from the tank to the engine lift pump and then under
brackets (11 and 34). pressure to the fuel filter (14). Filtered fuel is directed to
8. Working from beneath the radiator, install two 3/8-16 the fuel injection pump and to the individual fuel injectors.
hex-lock elastic nuts (14), 3/8" rebound washers (7) Surplus fuel at the fuel injector pump is returned to the
and rubber mounts (17) secured to the welded studs tank via the fuel return hose (15).

8A-10 Model 3606 • Origin 10/99

 Perkins Engine

8 6
6 10
6 7
5 9
11
4
10
1

10 6 Cab panel (ref.)

12 3
2

13
32
14 30
31
15
29
6
28
30

6
23 25 27 33
10 24
22 23 6
16 21 26 34
20 6 6
19 35

18 36
38
Front of vehicle 6
17 17

37 MS1130

1. Fuel/water separator 14. Fuel filter 27. Beaded hose tee

2. Hex-head capscrew, 15. Fuel return hose 28. Fuel breather hose
5/16-18 x 1-1/4"
16. 90° hose barb elbow, #5-6P* 29. Fuel filler
3. Flat narrow washer, 5/16" 30. U-type muffler clamp, 2"
17. 90° hose barb elbow, #10-6P*
4. Hex-lock elastic nut, 5/16-18 31. Fuel cap w/keys (incl. Item 32)
5. Tube union, 5/16"-13/32" 18. Fuel breather hose
32. Keys (set of two)
6. Hose clamp, SAE Type F 19. Hose barb coupling, #6-6P*
33. Upper hose clamp, SAE Type F
7. Fuel hose, 3/8" x 4" 20. Square head black plug, MI #6P*
34. Fuel filler hose
8. Fuel strainer 21. Fuel sender w/ gasket
35. Lower hose clamp, SAE Type F
9. Fuel tank-to-engine hose, 3/8" x 68" 22. Fuel sender cover
36. Fuel tank
10. Mini hose clamp, 7/32" diameter 23. Lockwasher, #10
37. Gasket
11. Fuel hose, 5/16" x 18" 24. Pan-head screw, #10-24 x 3/4"
38. Pipe thread sealant w/Teflon®, 8oz;
12. Tube union, 1/4"-5/16" 25. Pan-head screw, #10-24 x 5/8" use w/ ALL threaded fittings
13. Fuel filter assembly (incl. Item 14) 26. Fuel breather hose

Figure 8A–7. Perkins engine fuel system.

Model 3606 • Origin 10/99 8A-11

 Section 8A

8A.7.1 Diesel Fuel 8A.7.2 Fuel Tank

Fuel represents a major portion of vehicle operating The fuel tank (item 36, Fig. 8A–7) is located directly
costs and therefore must be used efficiently. Always use beneath the operator’s cab.
a premium brand of high-quality, clean diesel fuel. Low
cost, inferior fuel can lead to poor performance and A. Removal
expensive engine repair.
The operator’s cab must be partially removed in order to
Note: Use only diesel fuel designed for diesel engines. remove the fuel tank. Follow the directions for removing
Some heating fuels contain harmful chemicals that can the operator’s cab in Section 4 Cab, Covers and Mirrors,
seriously affect engine efficiency and performance. then remove the fuel tank.
IMPORTANT: Due to the precise tolerances of diesel If a leaking fuel tank is suspected, check that all fuel tank
injection systems, keep the fuel clean and free of dirt and inlets and outlets are not the cause of the leak before
water. Dirt and water in the fuel system can cause severe removing the cab and the fuel tank from the vehicle.
damage to both the injection pump and the injection noz-
zles. B. Disassembly
Use ASTM No. 2 D fuel with a minimum cetane rating of 1. Remove the four #10-24 x 3/4" pan-head screws
40. No. 2 diesel fuel gives the best economy and perfor- (item 24, Fig. 8A–7), the #10-24 x 5/8" pan-head
mance under most operating conditions. Fuels with Cet- screw (25), and the five #10 lockwashers (23)
ane numbers higher than 40 may be needed in high securing the fuel sender cover (22) and fuel sender
altitudes or extremely low ambient temperatures to help with gasket (21) to the fuel tank.
prevent misfiring and excessive smoking. 2. Remove the black MI #6P square-head plug (20), the
Inform the owner/operator of the vehicle to use No. 2 D #6-6P hose barb coupling (19), the #5-6P 90° hose
diesel fuel, unless ambient temperatures are below 32° F barb elbow (16) and both #10-6P 90° hose barb
(0° C). When temperatures are below 32° F (0° C), a elbows (17).
blend of No. 1 D and No. 2 D fuels, known as “winterized”
No. 2 D, may be used. C. Cleaning and Drying
Note: No. 1 D fuel may be used, however, fuel economy If contaminated fuel or foreign material is in the tank, the
will be reduced. tank can usually be cleaned. Replace a leaking or dam-
aged tank. DO NOT attempt to repair, plug or patch a
WARNING: DO NOT mix gasoline or alcohol leaking or damaged fuel tank. The tank is manufactured
with diesel fuel. The mixture can cause an using an injection molding process and cannot be
explosion. repaired.
Use a low-sulfur content fuel with a cloud point (the tem- To clean the fuel tank:
perature at which wax crystals form in diesel fuel) at least 1. Have a dry chemical (Class B) fire extinguisher near
10° below the lowest expected fuel temperature. the work area.
The viscosity of the fuel must be kept above 1.3 cen- WARNING: NEVER drain or store fuel in an
tistrokes to provide adequate fuel system lubrication. open container due to the possibility of explo-
Note: When using diesel fuel with a sulfur content below sion or fire. Discard the fuel in an approved
1.3 percent, the filter change interval must be reduced by manner.
75 hours. The use of fuel with a sulfur content above 1.3
percent is not recommended. 2. Invert and tilt the tank from side to side. Safely drain
any fuel into a suitable container. Dispose of properly.
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes. Invert
the tank, tilt it from side to side, and drain the water.
4. If necessary, add a diesel fuel emulsifying agent to
the tank. Refer to the manufacturer’s instructions for
the correct emulsifying agent-to-water mixture ratio.
Refill the tank with water, and agitate the mixture for
10 minutes. Drain the tank completely.

8A-12 Model 3606 • Origin 10/99

 Perkins Engine

5. Refill the fuel tank with water until it overflows.

Completely flush the tank with water. Empty the tank
and allow it to dry completely. Fuel lift pump

D. Inspection
1. Inspect the fuel tank thoroughly for any cracks, slices,
leaks or other damage. Replace a leaking or
damaged tank. DO NOT attempt to repair, plug or
patch a leaking or damaged fuel tank. The tank is
manufactured using an injection molding process and
cannot be repaired.
2. With the fuel tank removed from the vehicle, plug all Priming lever
openings except one elbow fitting. Install the elbow OA0332
fitting and apply approximately 1 to 1-1/2 psi (7 to 10
kPa) of air pressure through the elbow. Check the Figure 8A–8. Typical fuel lift pump.
tank for leaks by applying a soap solution to the
exterior of the tank, or by submerging the tank in To Check Pressure with Pump in Position:
water and looking for bubbles to appear at the 1. Fit a 0 to 10 psi (0 to 0,69 bar) pressure gauge to the
cracked or damaged area. pump outlet. Ensure that there are no leaks at the
connections between the gauge and the pump.
E. Assembly and Replacement
2. Crank the engine for 10 seconds and note the
1. Install the fuel sender with gasket (item 21, maximum gauge pressure. If the maximum gauge
Fig. 8A–7) and the fuel sender cover (22) to the fuel pressure is less than 4.5 psi (0,31 kgf/cm2 or
tank. Secure with four #10-24 x 3/4" pan-head 31 kN/m2), replace the pump.
screws (24), and four #10 lockwashers (23). 3. Stop cranking the engine and time how long it takes
2. Coat threads with Teflon® (38) and install the black for the pressure to drop to half the maximum
MI #6P square-head plug (20), the #6-6P hose barb pressure noted. If less than 30 seconds elapses,
coupling (19), the #5-6P 90° hose barb elbow (16) replace the pump.
and both #10-6P 90° hose barb elbows (17).
3. Replace the fuel tank in the cab mount subframe. A. Fuel Lift Pump Removal
Attach the fuel level gauge wire to the #10-24 x 5/8" 1. Clean debris from around the lift pump.
pan-head screw (25), slide a #10 lockwasher (23)
2. Disconnect the fuel lines.
onto the screw and secure the screw to the fuel tank
at the fuel sender cover. 3. Remove the capscrews, gasket, and fuel lift pump.
4. Reconnect the fuel hoses and follow the directions in
B. Cleaning and Drying
Section 4 Cab, Covers and Mirrors to replace the
other fuel system components and the cab. Clean the exterior of the pump with mineral spirits and
blow dry with compressed air.
8A.7.3 Fuel Level Sender and Gauge Note: Parts replacement is not practical. The fuel lift
The fuel level sender and gauge assembly is described in pump is serviced as an entire assembly.
Section 10 Electrical System.
C. Fuel Lift Pump Installation
8A.7.4 Fuel Lift Pump Testing 1. Clean the mounting surface on the cylinder block.
To test the diaphragm, remove the fuel inlet line from the 2. Install the fuel lift pump with a new gasket. Install and
lift pump (Fig. 8A–8). Block the fuel inlet with a finger and torque the capscrews to 18 lb/ft (24 Nm).
operate the priming lever. A properly operating pump will
provide suction that will remain until the finger is removed 3. Connect the fuel lines.
from the inlet. To test pump performance, disconnect the
outlet line from the fuel lift pump to the fuel filter and
rotate the engine; a spurt of fuel should occur for every
two engine revolutions.

Model 3606 • Origin 10/99 8A-13

 Section 8A

8A.7.5 Fuel Filter To test a fuel injector:

Refer to Section 2 General Information, Specifications, 1. Remove the fuel injector from the cylinder head.
and Maintenance Instructions for information on remov- 2. Invert the fuel injector with the nozzle facing out, then
ing and replacing the fuel filter (item 1, Fig. 8A–7). retighten the unions.
3. Loosen the unions of the other fuel injector pipes (to
8A.7.6 Venting Air from the Fuel System help avoid the possibility of the engine starting).
Refer to Section 2 General Information, Specifications,
and Maintenance Instructions, paragraph 2.12.7 D, Vent- WARNING: KEEP CLEAR of spraying fuel.
ing Air from the Fuel System. Diesel fuel will spray when venting high pres-
sure lines. The fuel pressure is sufficient to
penetrate the skin and cause serious bodily
8A.7.7 Fuel Injectors
injury. Wear protective clothing and safety
The Perkins engine uses closed nozzle hole-type injec- glasses.
tors (or “atomizers”). The injectors have different part
numbers for different engine ratings. The Perkins fuel 4. Operate the starter to turn the engine over until fuel
injector code (stamped on the fuel injector body) identify sprays from the nozzle. Examine the shape of the
the injector. spray. If the spray is unduly “wet” or “streaky”, or
obviously sprays to one side, or if the nozzle
IMPORTANT: Use only the specified injector for the
“dribbles” fuel, it may only be necessary to probe the
engine.
nozzle holes to remove blockage.
During the injection cycle, high pressure from the injec-
IMPORTANT: DO NOT attempt to adjust injection pres-
tion pump rises to the operating (or “pop”) pressure,
sure without a testing pump and pressure gauge. It is
which causes the needle valve in the injector to lift. Fuel
impossible to accurately adjust the setting of fuel injec-
is then injected into the cylinder. A shimmed spring is
tors without the proper equipment.
used to force the needle valve closed as the injection
pressure drops below the pop pressure to seal off the A perfect fuel injector, when tested by pumping fuel
nozzle after injection. Failure of the needle valve to lift through it in the open air, gives a short “pinging” sound as
and to close at the correct time, or a needle valve that is the fuel emerges from the holes. After the fuel injector
stuck open, can cause the engine to misfire and produce has been in service for some time, the pinging changes
low power. Fuel leaking from the open nozzle can cause to a crackling sound. It is not until the fuel injector sounds
a fuel knock, poor performance, smoke, poor fuel econ- “dead” that its condition is likely to affect the running of
omy, and rough running. the engine.

A. Locating Faulty Fuel Injectors B. Injector Replacement

A faulty fuel injector can cause: Preparatory steps:

• Misfiring • Thoroughly clean around the injector(s)
• Knocking • Disconnect the high-pressure fuel line(s)
• Overheating • Disconnect the fuel drain manifold
• Loss of power IMPORTANT: The injector must not rotate in the bore of
the cylinder head or damage to the cylinder head will
• Smoky (black) exhaust
occur. If rust has formed on the hold-down nut, soak the
• Increased fuel consumption nut with rust-penetrating solvent for a minimum of three
The particular faulty fuel injector(s) may be determined minutes. Then, tap the injector body with a drift pin to
by releasing the pipe union nut on each fuel injector in help loosen any rust.
turn, with the engine running at a fast “tick-over.” If, after
slackening a pipe union nut, the engine revolutions To Replace a Fuel Injector:
remain constant, a faulty fuel injector has been identified. 1. Remove the fuel leak-off pipe.
2. Remove the high-pressure pipe union nuts from the
fuel injector and fuel injection pump and release the
pipe.
3. Remove the fuel injector flange nuts and remove the
fuel injector and seat washer.

8A-14 Model 3606 • Origin 10/99

 Perkins Engine

4. Place the new fuel injector and new seat washer into
position. DO NOT misalign the fuel injector. Tighten
the flange nuts evenly in small increments up to a 1. Exhaust pipe
final torque of 14 lb/ft (19 Nm). 2. Exhaust gasket 1

3. Heavy-duty T-bolt
WARNING: KEEP CLEAR of spraying fuel.
band clamp
Diesel fuel will spray when venting high pres- 2
4. Exhaust bellows
sure lines. The fuel pressure is sufficient to
5. Exhaust pipe
penetrate the skin and cause serious bodily
injury. Wear protective clothing and safety 6. Heavy-duty muffler
clamp, 2-1/2"
glasses.
7. Exhaust muffler
5. Connect the high-pressure fuel pipe. Torque the nut 8. Exhaust tail pipe 3
to 15 lb/ft (20 Nm).
6. Connect the fuel leak-off pipe. 4
7. Run the engine and check for fuel and air leakage.
8. Bleed the fuel system in accordance with the 8 Secure to 6 3
band clamp
instructions in Section 2 General Information,
on vehicle 5
Specifications, and Maintenance Instructions.
7

8A.7.8 After Fuel System Service

1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system (see Section 2 General 6

Information, Specifications, and Maintenance 6

Instructions, paragraph 2.12.7 D).
PS0140
3. Fill the fuel tank with fresh, clean diesel fuel as
Figure 8A–9. Perkins engine exhaust system.
required.
When replacing the muffler, also replace the tail pipe.
8A.8 PERKINS ENGINE EXHAUST SYSTEM Before assembling components, use exhaust system
sealer at all slip joint connections.
WARNING: Exhaust fumes contain carbon
monoxide, a colorless, odorless gas which is When installing exhaust system components, allow suffi-
fatal when inhaled in a confined area. Avoid cient clearance between the components and other vehi-
breathing exhaust fumes and prevent engine cle pipes, hoses and wiring that could be adversely
operation from becoming a cause of toxic emis- affected by excessive heat.
sions. When installing an exhaust system, provide for parts
Exhaust system components reach high tem- expansion when the system is hot.
peratures and can cause severe burns. DO Whenever performing service on the vehicle, check the
NOT come into contact with hot exhaust system condition of the exhaust system. Check the entire
components. exhaust system for broken, damaged, missing or mispo-
The exhaust system (Fig. 8A–9) is supported by the sitioned parts, open seams, holes, loose connections
engine and the vehicle frame to help minimize the trans- and other deterioration which could permit exhaust
fer of noise and vibration into the operator’s cab. The tail fumes to seep into the operator’s cab. Correct any dam-
pipe directs exhaust fumes to the right side of the vehicle, aged areas immediately.
away from the cab.
Annoying rattles and noise vibrations in the exhaust sys-
tem are usually caused by misalignment of parts. When
aligning the system, leave all capscrews and nuts slightly
loose until all parts are properly aligned, then tighten all
fasteners working from the front of the system to the rear.

Model 3606 • Origin 10/99 8A-15

 Section 8A

8A.9 PERKINS ENGINE REPLACEMENT

Removal and installation of the engine can be done with Radiator Cap
or without the transmission attached. For information on
removing the transmission from, and installing it to, the Fitting on Neck of
engine, refer to Section 7 Transmission. Radiator Fill Tube
Coolant
8A.9.1 Engine Removal Overflow
Bottle
WARNING: To avoid severe burns, DO NOT
attempt to remove the engine when the engine, Hose from
cooling system and hydraulic system are hot. Bottom of
Wait until all parts and systems are cool before Overflow
proceeding. Bottle
Radiator
1. Level the vehicle, ground the attachment, place the Drain
travel select lever in NEUTRAL (N), engage the (petcock
parking brake switch and shut off the engine. Allow removed)
the engine, cooling system and hydraulic system to
cool. Funnel
2. Label and disconnect the negative (-) battery ground
cable at the battery (Fig. 8A–10) Also, disconnect the OS0472

negative lead from at the starter mounting bolt. Figure 8A–11. Drain the radiator.
Auxiliary
function 5. Remove either the fan or the radiator to help prevent
valve damage to the radiator when the engine is removed.
6. Detach and remove the air cleaner (Fig. 8A–12).
Loosen the clamp securing the air intake hose to the
Battery engine panel. Remove the hose from the engine
panel (ref.).
Hydraulic 7. If equipped with a turbocharger, loosen the air
temperature cleaner mount band assembly (Fig. 8A–12) securing
sending unit the air cleaner hose to the turbocharger engine
Hydraulic intake. Remove the hose from the turbocharger
fluid level intake, and cover the intake to help prevent debris,
sending unit etc. from entering the opening.
8. Unscrew the clamp securing the air cleaner body
Negative (-) cable
OS1040 (Fig. 8A–12) to the mount plate on the engine.
Remove the air cleaner assembly in its entirety. Place
Figure 8A–10. Disconnect the negative (-) battery cable.
it in a secure location.
3. Remove the hood with the help of at least one 9. If equipped with a turbocharger, disconnect the
assistant (refer to Section 4 Cab, Covers and turbocharger-to-exhaust connection, secured with a
Mirrors). stainless steel V-band clamp. Cover the exhaust
4. Position a suitable container beneath the radiator opening to help prevent debris, etc. from entering.
(Fig. 8A–11). Remove the radiator cap and open the
radiator drain petcock. Allow the coolant to drain into
the container. At the engine, loosen the upper and
lower radiator hose clamps. Pry the hoses away from
the engine.

8A-16 Model 3606 • Origin 10/99

 Perkins Engine

11. Label and disconnect the alternator wire connector

Turbo mount (Fig. 8A–13) and both alternator ground wires.
21
18 20 Ground
22
19 Natural mount wires
20 Alternator
20 20 Engine (ref.)
19 21
18 22
16 14 15 17 21
20
5
19

4
16 14 15

6 Wire connector
MS1560

Figure 8A–13. Label and disconnect the alternator wire

3 connector and both ground wires.
2
12. Disconnect (unplug) the hydraulic fluid level indicator
7 lead (Fig. 8A–10 and Fig. 8A–14) and the hydraulic
12 8 temperature sending unit lead (Fig. 8A–10) from the
10 wiring harness connector.
11 9
13 1 Hydraulic fluid
level sending
unit lead
Engine
12 harness
lead
Engine Front of
panel (ref.) vehicle
PS0480

1. Air cleaner assembly 15. Flat narrow washer, 5/16"

(incl. items 2-6) 16. Air cleaner mount
2. Body assembly band assembly
3. Safety filter 17. Hex-head capscrew,
4. Primary filter M10-1,5 x 60 mm PC 8,8
(Natural only)
5. Cover assembly or MS3020

6. Vactuator valve M10-1,5 x 60 mm PC 8,8 Figure 8A–14. Disconnect the hydraulic fluid
7. Heavy-duty T-bolt clamp (Turbo only) level indicator lead.
8. Air cleaner hose 18. Lockwasher, M10
13. Label and disconnect the wires at the main ground
9. Heavy-duty T-bolt clamp 19. Air cleaner mount plate
stud (Fig. 8A–15),
10. Close nipple, #2 20. Spacer, 0.40" Engine
11. Vacuum switch 21. Spacer, 0.710" Ground mount
12. Hose clamp, SAE Type F 22. Hex-lock elastic nut, stud support
5/16-18
13. Air intake hose
14. Hex-head capscrew,
5/16-18 x 3/4"

Figure 8A–12. Perkins air cleaner.

10. Disconnect the exhaust pipe (Fig. 8A–9) from the
exhaust bellows, secured with a heavy-duty T-bolt
band clamp. Cover the exhaust opening to help
prevent debris, etc. from entering.
Tube clip
MS1410

Figure 8A–15. Disconnect wires at the main ground stud.

Model 3606 • Origin 10/99 8A-17

 Section 8A

14. At the starter, label and disconnect the positive (+) drive shaft must be in the same plane to help prevent
battery cable. excessive vibration (Fig. 8A–26).
15. Label and disconnect the engine water temperature 17. Working from beneath the vehicle, label and
switch lead (Fig. 8A–16), engine oil pressure switch disconnect all engine wire harness leads (refer to
lead, and transmission temperature lead. Section 10 Electrical System as required for detailed
Engine water views of harness leads). Remove plastic tie wraps as
temperature switch required to allow access to the wiring harness and
Engine oil wire leads.
pressure switch
18. Disconnect the engine wiring harness bulkhead
connector from the cab wiring harness bulkhead
Transmission connector along the vehicle frame.
temperature
19. Label and disconnect the wiring harness at the steer
switch
select valve.
20. Label and disconnect the wiring connectors at the
auxiliary function valve solenoids (Fig. 8A–10 and
Fig. 8A–17), located near the battery. Move all wiring
out of the way to allow engine removal.

Auxiliary function valve

(also see Fig. 8A-10)

MS1570
G
PB
PB

Figure 8A–16. Label and disconnect the engine water

temperature and oil pressure switch leads, MS1420

and the transmission temperature lead. Figure 8A–17. Disconnect the wiring at the auxiliary
function valve solenoids.
16. If removing the engine and transmission as a unit:
• Place a suitable container beneath the hydraulic 21. Working from the side of the vehicle, disconnect the
reservoir side of the radiator. Disconnect the fuel return line (Fig. 8A–18) at the fuel injector pump.
transmission cooler hoses at the radiator and cap
Fuel injector distributor Fuel return line
the connectors to help prevent excess fluid
drainage. Secure the hoses out of the way on top
of the engine.
• Move the container beneath the transmission.
Disconnect and cap the inlet and outlet hoses at
the main hydraulic pump. Disconnect the pump
inlet hose from the hydraulic reservoir and cover
the opening to help prevent debris, etc. from
entering the pump. Move the hoses out of the way
to allow engine and transmission removal.
• Label and disconnect all transmission wire leads.
• Mark the transmission and transmission driveshaft OS0731
flange yoke. Disconnect the transmission-to
Figure 8A–18. Disconnect the fuel return line to
transfer case driveshaft at the transmission flange
the fuel injector distributor.
yoke. Secure the U-joints with tape. Lower the
driveshaft to the ground. 22. Disconnect the fuel inlet line at the fuel lift pump (Fig.
8A–20).
Note: The drive shaft assembly is a balanced assembly.
Mark the yoke and transmission so that these compo-
nents can be returned to their original positions when the
transmission is reinstalled. The yokes at each end of the

8A-18 Model 3606 • Origin 10/99

 Perkins Engine

Engine
Fuel lift pump
lift plates

Fuel inlet line

OA0332

Figure 8A–19. Fuel inlet line to lift pump connection.

23. Mark the location of the throttle cable at its engine
mount bracket (Fig. 8A–20).
24. Disconnect the throttle cable at the bracket above the
MS1110
starter (Fig. 8A–20).
Figure 8A–21. Engine lift plates.
25. At the hydraulic fluid reservoir, disconnect the engine
harness wire lead (Fig. 8A–10 and Fig. 8A–22) from 27. In four locations, remove the nuts, washers and
the hydraulic fluid-level sending unit. capscrews securing the engine mounts (Fig. 8A–1) to
26. Connect a suitable engine hoist to the engine lift the hydraulic reservoir/engine mount subframe.
plates (Fig. 8A–21). 28. Begin removing the engine from the vehicle with the
hoist or overhead crane.
29. As the engine is lifted away and removed, reposition
Two washers the debris shield at the base of the radiator to prevent
Engine mount
Jam nut bracket damage and allow engine removal. Avoid damaging
(above starter) the oil filter and oil filter housing.
30. Carefully lift the engine out and away from the
Stop and throttle lever vehicle. Place the engine safely onto ground
supports, or in a suitable engine stand. DO NOT rest
Throttle
the engine on its oil pan, or damage will occur.
cable
8A.9.2 Engine Disassembly, Inspection, and
Service
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Perkins
Clamp
INJECTOR PUMP 1004 series service manual. Several special engine ser-
vice tools are required to properly service the Perkins
engine. Contact the local Perkins parts distributor for fur-
ther information.
Clevis, clevis pin
and cotter pin
8A.9.3 Engine Installation
MA0201
Removal and installation of the engine can be done with
Figure 8A–20. Throttle cable connection at engine. or without the transmission attached. For information on
installing the transmission to the engine, refer to Section
7 Transmission.
1. Place the engine mounts (items 8 and 16, Fig. 8A–1)
into the appropriate locations within the hydraulic
reservoir/engine mount subframe on the vehicle.

Model 3606 • Origin 10/99 8A-19

 Section 8A

2. Attach a suitable engine hoist to the engine lift plates 10. Connect the fuel return line to the fuel injector
(Fig. 8A–21). distributor (Fig. 8A–24).
3. Carefully install the engine onto the engine mounts Fuel injector distributor Fuel return line
(items 7, 8, 16, 17, 24 and 28, Fig. 8A–1). Make sure
the bracket-type engine mounts align properly with
the engine mounts in the subframe.
4. In four locations, install the nuts, washers and
capscrews securing the engine mounts (Fig. 8A–1) to
the hydraulic reservoir/engine mount subframe.
Torque the 7/16-14 x 3-1/4" Grade 8 capscrews to 60
lb/ft (81 Nm). Torque the 5/8-11 x 4" Grade 8
capscrews to 180 lb/ft (244 Nm).
5. Install the fan and/or radiator as required.
6. Connect the engine harness and hydraulic fluid-level OS0731

sending unit leads (Fig. 8A–22). Figure 8A–24. Connect the fuel return line to
Hydraulic fluid the fuel injector distributor.
level sending
unit lead 11. Connect the engine wiring harness leads to the steer
Engine select valve leads (Fig. 8A–25).
harness Steer select valve
lead
Front of
vehicle Connect

Engine
wiring
harness
leads
Connect
MS3020
MS1400
Figure 8A–22. Connect the engine harness lead to the
hydraulic fluid level sending unit lead. Figure 8A–25. Connect the engine wiring harness leads to
the steer select valve leads.
7. Secure the throttle cable (Fig. 8A–20) to the bracket
located just above the starter. 12. Connect the engine wiring-harness bulkhead
connector to the bulkhead receptacle.
8. Connect the throttle cable at the engine mount
bracket (Fig. 8A–20). 13. Working from beneath the vehicle, connect all engine
wire harness leads as necessary (refer to Section 10
9. Connect the fuel inlet line to the fuel lift pump
Electrical System for detailed views of each
(Fig. 8A–23).
component). Secure the harness with tube clips and
Fuel lift pump plastic tie wraps as required to prevent the wiring
harness and wire leads from hanging below the
vehicle and from coming into contact with moving
Fuel inlet line parts.
14. If the engine and transmission were NOT installed as
a unit, attach the transmission to the engine at this
time. Refer to Section 7 Transmission.
Note: The drive shaft is a balanced assembly. The yokes
at each end of the drive shaft must be in the same plane
to help prevent excessive vibration (Fig. 8A–26).

OA0332

Figure 8A–23. Fuel inlet line to lift pump connection.

8A-20 Model 3606 • Origin 10/99

 Perkins Engine

27. Attach the upper and lower radiator hoses (Fig. 8A–
Align yokes in same plane as 4) to the engine water pump (and to the radiator, if
Angled necessary) and secure with hose clamps.
shown (note angled notch in yoke)
notch
28. Open the radiator cap (Fig. 8A–4) and fill the radiator
with a 50/50 mixture of water and ethylene glycol.
More coolant will need to be added later. Replace
and tighten the radiator cap.
29. Install the hood with the help of at least one assistant
(refer to Section 4 Cab, Covers and Mirrors).
Straight 30. Connect the positive (+) battery cable at the starter,
edge then at the battery.
31. Connect the negative (-) battery ground cable lead to
the starter mounting bolt.
32. Check that all hydraulic system, electrical system,
MS1120
cooling system, fuel system, and exhaust system
connections are correctly and tightly connected.
Figure 8A–26. Align yokes in the same plane as shown.
33. From within the cab, lightly depress the throttle pedal
15. Coat the M12 transmission driveshaft yoke retaining (Fig. 8A–27) to full-throttle position. As needed,
capscrews with Loctite #242 (blue), install adjust the limit-stop screw until it touches the pedal.
lockwashers and torque to 83 lb/ft (112,5 Nm). Tighten the locknut to 120 to 125 lb/in (13,6 to 14,1
16. Connect all transmission wire leads at the shift Nm).
solenoids. 34. Have an assistant stand by with a Class B fire
17. Connect the hydraulic system inlet and outlet hoses extinguisher. Start and idle the engine.
at the main hydraulic pump. Connect the inlet hose to 35. Check for leaks from the engine, main hydraulic
the hydraulic reservoir if necessary. Refer to Section pump and lines, transmission, hydraulic reservoir and
9 Hydraulic System as required. fuel tank. Check the levels of all fluids and lubricants.
18. Connect the transmission hoses to the radiator (Fig. Fill as required.
8A–6).
19. Connect the engine coolant temperature and oil Throttle
pressure switch leads (Fig. 8A–16). Limit-stop pedal
screw
20. Connect the positive (+) battery cable at the starter.
21. Attach all wiring harness connectors and leads (refer
to Section 10 Electrical System as required for Locknut
detailed views of harness leads).
22. Connect the alternator wire leads (Fig. 8A–13).
Cab floor
23. Connect the exhaust pipe (Fig. 8A–9) to the exhaust
bellows. Secure with a heavy-duty T-bolt band clamp.
For turbocharged engines, connect the turbocharger
exhaust connection. Secure with a stainless steel V- MA0191

band clamp. Figure 8A–27. Adjust the throttle limit-stop screw.

24. Secure the air cleaner mount band assembly (Fig. IMPORTANT: During the full throttle check:
8A–12) and mount plate to the engine with the • DO NOT operate any hydraulic function;
necessary fasteners. • DO NOT steer or apply any pressure to
25. Install the air cleaner assembly (Fig. 8A–12) in its the steering wheel;
entirety. Install the air cleaner hose to the • Keep the transmission in NEUTRAL (N).
turbocharger intake port. Secure the air cleaner hose 36. Obtain and connect an appropriate engine analyzer
with a heavy-duty T-bolt clamp. or tachometer. Check the engine rpm at full throttle. If
26. Install the air intake hose (Fig. 8A–12) at the engine the rpm is not 2600 to 2800 rpm, readjust the throttle
panel. Tighten the SAE Type F clamp to secure the limit-stop screw at the throttle pedal within the cab.
air intake hose to the engine panel.

Model 3606 • Origin 10/99 8A-21

 Section 8A

37. Purge the hydraulic system of air by operating all 11. Remove the exhaust pipe. Seal the manifold with
boom functions through their entire range of motion waterproof tape.
several times. Check the hydraulic oil level. 12. Disconnect the battery and store it safely, in a fully
38. Check for proper operation of all components. charged condition. Before the battery is put into
39. Turn the engine OFF. storage, give the battery terminals a protection
against corrosion with a light coating of dielectric
grease or petroleum jelly.
8A.10 PERKINS ENGINE STORAGE
13. Seal the vent pipe of the fuel tank or the fuel filler cap
If the engine is properly protected and stored according with waterproof tape.
to the following recommendations, no corrosion damage
will normally occur. Perkins Engine Company, Inc. and 14. Remove and store the fan drive belt.
Sky Trak International are not responsible for any dam- Note: Before starting the engine after storage, operate
age that occurs in relation to a service storage period. the starter motor with one of the fuel-run solenoid wires
Use the following procedures immediately upon remov- disconnected until oil pressure shows on the oil pressure
ing engine from service if being stored for an extended gauge, or until the low oil-pressure warning light goes
period of time. out.
1. Clean the outside of the engine.
2. When using a preservative fuel, drain the fuel system
and fill with the preservative fuel. When not using
preservative fuel, keep the fuel system charged with
regular fuel, which, along with the fuel filter, will have
to be drained and discarded at the end of the storage
period.
3. Run the engine to operating temperature. Correct
any fuel, fluid, oil or air leaks. Stop the engine and
drain the oil.
4. Replace the oil filter.
5. Fill the crankcase (sump) to the FULL mark on the
dipstick with new, clean oil or with an approved
preservative fluid. If a preservative fluid is used, it
must be drained and replaced with regular lubricating
oil before the engine is returned to service.
6. Drain the cooling system. To provide protection
against corrosion, fill the cooling system with a
coolant containing a corrosion inhibitor. If frost
protection is needed, use the appropriate mixture of
antifreeze and water. If frost protection is not
required, use an appropriate mixture of water with an
approved corrosion mixture.
7. Run the engine for a short period to distribute
lubricating oil and coolant throughout the engine.
8. Clean out the engine breather pipe (where fitted) and
seal the end of the pipe.
9. Remove the fuel injectors and spray clean engine
lubricating oil into cylinder bores, four ounces (118,3
ml) of lubricating oil divided evenly between the four
cylinders.
10. Remove the air filter and any pipe installed between
the air filter and the induction manifold. Seal the
manifold with waterproof tape.

8A-22 Model 3606 • Origin 10/99

 Perkins Engine

8A.11 TROUBLESHOOTING
Items 1 through 60 in the Key cover both naturally-aspi- pertain to naturally-aspirated engines only. Items 61
rated and turbocharged engines. There are no items that through 64 cover turbocharged engines ONLY.

Trouble Possible Causes (see key, below)

Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61*, 63*
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61*, 63*, 64*
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63*
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61*, 63*
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62*
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57, 64*
Excessive Crankcase 25, 31, 33, 34, 45, 55, 60
Pressure
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12
Key to Possible Causes
1. Battery capacity low 24. Exhaust pipe restriction 47. Damaged fan
2. Bad electrical connection 25. Leaking cylinder head gasket 48. Faulty engine mounting
3. Faulty starter motor 26. Overheating 49. Incorrectly aligned flywheel housing
4. Incorrect grade of lubricating oil 27. Cold running or incorrectly aligned flywheel
5. Low cranking speed 28. Incorrect tappet adjustment 50. Faulty thermostat
6. Fuel tank empty 29. Sticking valves 51. Restriction in water jacket
7. Faulty stop control operation 30. Incorrect high pressure pipes 52. Loose fan belt
8. Blocked fuel feed line 31. Worn cylinder bores 53. Choked radiator
9. Faulty fuel lift pump 32. Pitted valves and seats 54. Faulty water pump
10. Choked fuel filter 33. Broken, worn or sticking piston ring(s) 55. Choked breather pipe
11. Restriction in air cleaner 34. Worn valve stems and guides 56. Damaged valve stem oil deflectors
12. Air in fuel system 35. Over-full air cleaner (if fitted)
13. Faulty fuel injection pump 36. Worn or damaged bearings 57. Coolant level too low
14. Faulty fuel injectors or incorrect type 37. Insufficient oil in sump 58. Blocked sump strainer
15. Incorrect use of cold start equipment 38. Inaccurate gauge 59. Broken valve spring
16. Faulty cold start equipment 39. Oil pump worn 60. Exhauster or vacuum pipe leak
17. Broken fuel injection pump drive 40. Pressure relief valve sticking open *For turbocharged engines:
18. Incorrect fuel pump timing 41. Pressure relief valve sticking closed 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 42. Broken relief valve spring 62. Turbo lubricating oil seal leak
20. Poor compression 43. Faulty suction pipe 63. Turbo induction system leaks
21. Blocked fuel tank vent 44. Choked oil filter 64. Turbo waste-gate operating
22. Incorrect grade of fuel 45. Piston seizure / pick up improperly (if equipped)
23. Sticking throttle or restricted 46. Incorrect piston height
movement

Model 3606 • Origin 10/99 8A-23

 Section 8A

8A-24 Model 3606 • Origin 10/99

 Section 8B
Engine: Cummins 4BT3.9

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2
Legend ................................................. 8B-2
General Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
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.5.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7
8B.5.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7
8B.5.3 Cummins Engine Radiator and Oil Cooler Replacement . . . . . 8B-7
8B.6 CUMMINS ENGINE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8B-10
8B.7 CUMMINS ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10
8B.7.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-11
8B.7.2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-12
8B.7.3 Fuel Level Sender and Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . 8B-13
8B.7.4 Fuel Lift Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-13
8B.7.5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-13
8B.7.6 Venting Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . 8B-13
8B.7.7 Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-13
8B.7.8 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-15
8B.8 CUMMINS ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8B-15
8B.9 CUMMINS ENGINE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-16
8B.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-16
8B.9.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . 8B-20
8B.9.3 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-20
8B.10 CUMMINS ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-22
8B.11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-23

Model 3606 • Origin 10/99 8B-1

 Section 8B

Introduction
DISCLAIMER AND SCOPE A gradual running in (break in) of a new engine is not
necessary. Full load can be applied to a new engine as
These instructions are written for worldwide use. In soon as the engine is put into service and the coolant
territories where legal requirements govern engine temperature is at least 140° F (60°C). Extended light-
smoke emission, noise, safety factors, etc., apply all load operation during the early life of the engine is not
recommended. DO NOT run the engine at high, no-
instructions, data and dimensions provided herein in
load speeds. DO NOT apply an overload to the engine.
such a way that after maintenance, service and repair
Throughout this section, the left or right side of the
of the engine, engine operation does not violate local
engine is as viewed from the flywheel end.
regulations.

IMPORTANT: These instructions cover only the routine

maintenance, removal, installation and troubleshooting
of the engine. Refer to the local Cummins Engine Dis-
tributor and the applicable Cummins engine service
manual for assistance with comprehensive engine diag-
nosis, repair and component replacement.

Legend
1. Cummins 4BT3.9 Turbo Engine 17. Engine Mount 31. Front Right-side Engine Mount
2. Fan Belt 18. Hex-head Capscrew, 32. Rear Right-side Engine Mount
3. Suction Fan, 18" 3/8-16 x 1-1/4 Grade 5 33. Engine Oil Filter
19. Narrow Flat Washer, 3/8"
4. Hex-head Capscrew, 34. Flat-face Elbow, 90°, #12 ORB x
M10-1,5 x 90 mm 20. Hex-lock Elastic Nut, 3/8-16 #12
5. Lockwasher, M10 21. Narrow Flat Washer, 7/16" 35. Oil Filter Bracket
6. Alternator Fan 22. Hex-head Capscrew, 36. Lockwasher, 1/4"
7. Alternator, 65 Amp 7/16-14 x 3-1/4" Grade 8
37. Hex-head Capscrew,
8. Flat-face Straight Connector, 23. Hex-head Capscrew, 1/4-20 x 5/8"
#10 ORB x #12 5/8-11 x 4" Grade 8
38. Hex-head Capscrew,
9. Flat-face Elbow Swivel, #12 24. Narrow Flat Washer, 5/8" M12-1,75 x 25 mm
10. Remote Oil Filter Hose Assembly 25. Hex-head Capscrew, 39. Starter
3/8-16 x 1-1/2 Grade 5
11. Tie Wrap 40. Starter Relay Mount
26. Engine Mount
12. Hex-lock Elastic Nut, 7/16-14 41. Hex-lock Elastic Nut, 1/4-20
27. Front Left-side Engine Mount
13. Rebound Washer, 7/16" 42. Starter Relay
28. Hex-head Capscrew,
14. Lockwasher, M12 M12-1,75 x 40 mm PC 8,8 43. Hex-head Capscrew,
15. Hex-head Capscrew, 1/4-20 x 3/4"
29. Rebound Washer, 5/8"
M12-1,75 x 30 mm PC 8,8
30. Hex-lock Elastic Nut, 5/8-11
16. Rear Left-side Engine Mount

8B-2 Model 3606 • Origin 10/99

 Cummins Engine

General Overview
Left side of engine (on right side of vehicle)

40
41

39
14 42
38
35 37 43
36
34
Front of
34 engine
10
10 3
33
Front of 1
vehicle 4

2 5
15 14

32
28 12
6
14 7 13
8 14
31 15
20 16
19
9 17
19
18

11
30 10
29
20 14
19 28
27
26
19
25

Front of vehicle

21
24
Engine mount subframe (ref.) 22
(includes hydraulic reservoir) Torque to 60 lb/ft (81 Nm)
23
MS1140 Torque to 180 lb/ft (244 Nm)

Figure 8B–1. Cummins engine general overview.

Model 3606 • Origin 10/99 8B-3

 Section 8B

8B.1 SAFETY INFORMATION Engine Coolant (anti-freeze/anti-boilover)

WARNING: DO NOT remove the radiator cap

General Vehicle Operation
while the engine and coolant are hot. Hot cool-
WARNING: Before attempting to start the ant under pressure is dangerous and can injure
engine and/or operate the vehicle, read the the eyes and cause severe burns.
owners/operators manual. • Cooling system corrosion inhibitors contain
• Before operating the engine and/or the vehi- alkali (chemicals that break down organic
cle, install guards and clear all personnel from substances such as skin and eye tissue). DO
the immediate area. NOT swallow. Avoid prolonged or repeated
• Check that the brakes are fully functional. contact with corrosion inhibitors. In case of
• DO NOT exceed the stability limits of the vehi- skin con-tact, immediately wash affected area
cle. with soap and water. In case of contact with
• Allow only ONE person to have control of the eyes, immediately flood eyes with large
engine and the vehicle. amounts of water for a minimum of 15 min-
utes. Obtain medical assistance immediately.
Preparation Keep corrosion inhibitors out of the reach of
children.
WARNING: Wear protective glasses and pro- • DO NOT use salt water or other corrosive liq-
tective shoes. uid in the cooling system.
• Verify that the work area is capable of sup-
porting the weight of the vehicle and the Rotating Parts and Fan Blades
torque created by any suspended load.
• DO NOT work on an engine or a vehicle that WARNING: Keep away from parts which
is supported ONLY by a hoist or lift jacks. Use rotate; the fan blades can appear invisible
blocks or suitable stands. when the fan is rotating.
DO NOT pull or pry on the fan blades. This
Engine Operation practice will cause fan failure. Use only
approved methods and tools for manually rotat-
WARNING: Operate the engine in a well-venti- ing the engine.
lated area only. Assure that engine operation
will not produce a concentration of toxic emis- Battery
sions.
• DO NOT operate the engine in the presence WARNING: Keep sparks and fires away from
of a fuel spill or gas leak. Such combustible batteries. Batteries produce hydrogen gas,
vapors, when drawn into the engine, can which can explode and cause severe personal
cause engine over-acceleration, explosion, injury and property damage.
fire and extensive personal injury and prop- Battery fluid can burn the skin and injure the
erty damage. Before operating in any hazard- eyes. If you come in contact with battery acid,
ous environment, consult a recognized flush the affected area with large amounts of
authority (such as the engine distributor) on water and obtain medical assistance immedi-
engine operation in hazardous environments. ately.
• DO NOT smoke or operate the engine during
refueling. Engine Oil

Cleaning WARNING: Engine oil can cause skin disor-

ders and other personal injury. Avoid prolonged
WARNING: When using steam cleaners and or repeated contact with both new and used
pressure washers, wear protective glasses, engine oil.
gloves and clothing to help prevent personal
injury. Diesel Fuel

WARNING: NEVER use gasoline or other WARNING: Diesel fuel can cause skin irrita-
flammable materials for cleaning parts. Use tion. Use gloves or protective hand lotion when
only approved cleaning solvents. working on the fuel system.

8B-4 Model 3606 • Origin 10/99

 Cummins Engine

Engine Repair Parts

WARNING: Before beginning any adjustments WARNING: ALWAYS use factory-approved

or repairs, place accident prevention tags in the fasteners and parts. DO NOT use other than
operator’s compartment and on the controls, factory-approved fasteners and parts when
and disconnect the battery negative cable. replacement is necessary.
• DO NOT operate, clean, lubricate or adjust
the engine without proper training.
• NEVER attempt to perform an adjustment or
repair that is not understood.
• Before servicing, relieve pressure in fuel, oil,
coolant and hydraulic lines. Obtain medical
assistance immediately if a high-pressure jet
of fuel, oil, coolant or hydraulic fluid strikes the
skin.
• DO NOT permit loose clothing, hair, etc., near
moving parts.
• Keep away from parts which rotate; fan
blades can appear invisible when the fan is
rotating.
• To help prevent burns, avoid contact with com-
ponents that remain hot after power is turned
off or disconnected.
• Some of the gaskets on the engine obtain
asbestos. Breathing asbestos dust is danger-
ous to health and may cause severe bodily
harm. Avoid creating dust and follow local
directives for handling and disposing of mate-
rials that contain asbestos.

Model 3606 • Origin 10/99 8B-5

 Section 8B

8B.2 CUMMINS ENGINE SERIAL NUMBER DO NOT steam clean the following parts:

The Cummins 4BT3.9 serial number is stamped on the • Electrical Components

front of the engine block, near the fan pulley. Information • Wiring
contained in the serial number is required in correspon- • Injectors
dence with the engine manufacturer.
• Fuel Pump
• Belts and Hoses
• Bearings
4BT3.9
1137-X0865
During reassembly and inspection, thoroughly clean all
Front of parts, and, where present, remove burrs and scales.
vehicle Gaskets and O-rings
NEVER re-use a gasket or O-ring. Use new gaskets and
O-rings. Thoroughly clean sealing surfaces before install-
Serial number
location
ing a new gasket or O-ring. ALWAYS install new flat-
faced O-rings when servicing hydraulic fittings.
Cover any open ports of high-precision components
(such as fuel system equipment) exposed by removal or
disassembly to help prevent the entry of foreign material.
MS1150
Capscrews and Metric Parts
Figure 8B–2. Cummins engine serial number location.
When replacing capscrews, ALWAYS use a capscrew of
Supply the engine serial number and/or data tag informa- the same size and strength as the capscrew being
tion when communicating about an engine or engine replaced. Incorrect capscrews can result in engine dam-
components. age. Return capscrews removed from the engine to their
original locations.
8B.3 CUMMINS SPECIFICATIONS AND The Cummins 4BT3.9 engine uses parts that are of met-
MAINTENANCE INFORMATION ric dimensions. Metric capscrews are described, in milli-
Engine, coolant and oil specifications and maintenance meters, in terms of major thread diameter, distance
information appear in Section 2 General Information, between threads, and overall length.
Specifications, and Maintenance Instructions. Metric capscrew dimensions:
Note: Detailed Cummins engine service instructions M8 x 1,25 - 25
(covering disassembly, inspection, internal repair, assem- Length, in millimeters
bly, adjustment and troubleshooting information) are pro- Distance between threads, in millimeters
vided in the appropriate Cummins engine service Major thread diameter, in millimeters
manual.
Verify that the correct type of part is used at all times.
8B.4 CUMMINS ENGINE STANDARD
PRACTICES 8B.5 CUMMINS ENGINE COOLING
SYSTEM
Left and Right Sides of the Engine The Cummins engine cooling system is a closed, pres-
Throughout this section, the left or right side of the surized system that consists of coolant passages in the
engine is as viewed from the flywheel end. engine, plus the oil cooler, thermostat, water pump,
hoses, radiator and radiator overflow bottle. The engine
Cleanliness is cooled by the circulation of coolant through passages
in the cylinder block and head. Circulation is by thermo-
Cleanliness is very important during engine repair. Con- siphon action, assisted by an impeller-type water pump,
tamination of the engine during repair will reduce the life driven by a fan belt from the crankshaft pulley. The water
of an engine. Thoroughly clean the engine and engine pump bearings are prepacked with a special grease and
compartment area before attempting to service or repair do not require service. Replace a faulty water pump.
the engine. General engine cooling specifications and maintenance
procedures are listed in Section 2 General Information,
Specifications, and Maintenance Instructions.

8B-6 Model 3606 • Origin 10/99

 Cummins Engine

8B.5.1 Radiator Pressure Cap WARNING: NEVER remove the radiator cap
The cooling system is designed to use a radiator pres- while the engine is hot. The cooling system is
sure cap to help prevent the coolant from boiling. In addi- under pressure. Hot coolant can cause severe
tion, the pressure helps to eliminate the formation of burns or eye injury. Wear protective clothing
steam pockets within the engine and ensures coolant cir- and safety glasses.
culation throughout all coolant passageways of the
4. Drain approximately two quarts (2 liters) of coolant.
engine. For a 210° system, use a 7 psi (48 kPa) radiator Slowly turn the radiator cap to the first stop and allow
cap. An incorrect or malfunctioning cap can result in the any pressure to escape. Remove the radiator cap.
loss of coolant and a hot-running engine. Place a funnel at the base of the radiator to channel
the drained coolant into a container. Open the
radiator drain plug or petcock and allow the coolant to
drain into the funnel. Transfer the coolant into a
properly labeled container. Dispose of properly.
Close the radiator drain plug or petcock.
5. Remove the fan drive belt. Loosen the alternator link
capscrew on the bottom of the alternator. Remove
the alternator mounting capscrew and lower the
alternator.
MS1160 6. Remove the three capscrews securing the
Figure 8B–3. Typical Cummins engine thermostat housing. thermostat housing (Fig. 8B–3) to the engine.
7. Remove the thermostat and clean the gasket
8B.5.2 Thermostat Replacement surfaces. DO NOT let any debris into the thermostat
Before considering thermostat replacement, check the opening while the thermostat is removed.
coolant level, fan belt tension and dash panel tempera- IMPORTANT: ALWAYS use the correct thermostat.
ture gauge. If the engine seems to take a long time to NEVER operate the engine without a thermostat, or
warm up, the thermostat may be stuck in the open posi- engine damage will result.
tion and requires replacement. If the engine runs hot,
8. Install the thermostat, engine lift bracket, gasket and
check the temperature of the upper radiator hose. If the
thermostat housing. Secure with the three capscrews
hose is not hot, the thermostat may be stuck in the
removed earlier. Torque to 18 lb/ft (24 Nm).
closed position. If the engine has overheated, perfor-
mance may suffer, indicating other damage including a 9. Raise the alternator and install the mounting
leaking cylinder head gasket, cracked cylinder head or capscrew. Torque to 32 lb/ft (43 Nm).
block, and/or other internal engine damage. 10. Install the fan drive belt, then fill the cooling system.
To replace the thermostat: Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
1. Level the vehicle, ground the attachment, place the
coolant level in the overflow bottle and fill, or drain, as
travel select lever in NEUTRAL (N), engage the
necessary.
parking brake switch and shut off the engine.
WARNING: DO NOT attempt this procedure 8B.5.3 Cummins Engine Radiator
when the engine is hot. Wait for the engine, and Oil Cooler Replacement
muffler, and tailpipes to cool down before pro- Before considering radiator or oil cooler replacement for
ceeding. Failure to do so could result in severe other than obvious damage, conduct a cooling system
burns. pressure test, check the coolant specific gravity, coolant
2. Unlatch, unlock and open the engine cover. Allow the level, fan belt tension and dash panel temperature
engine to cool before proceeding. Draining the gauge. If the engine runs hot, check the temperature of
cooling system while the engine is hot can cause the upper radiator hose. If the hose is not hot, the ther-
cracks in the engine block. mostat may be stuck in the closed position. If the engine
has overheated, performance may suffer, indicating other
3. Disconnect the negative (-) battery cable. damage including a leaking cylinder head gasket,
cracked cylinder head or block, and/or other internal
engine damage.

Model 3606 • Origin 10/99 8B-7

 Section 8B

83
77
78 44
81 82
80
73
76 51
75
47 79
74
73
72
Front of vehicle 71
45
46

63 47
48
70
49
Engine (ref.) 51 50
68
61
62
63
69 64
65
68 66 53 55
50
52
60
54
67 56
59 56
57

50
58
Engine subframe (ref.)

PS0370

44. Bulb seal 58. Hex-lock nut, 3/8-16 71. Radiator assembly (incl. item 72)
45. Bulb seal molding 59. Sheet 72. Radiator cap, 13 psi (89,6 kPa)
46. Radiator baffle assembly 60. Hex-head capscrew, 73. Narrow flat washer, 5/16"
47. Foam baffle 3/8-16 x 1-1/2 Grade 5 74. Lockwasher, 5/16"
48. Oil cooler 61. Rubber mount 75. Hex-head capscrew,
49. Radiator mount ring 62. Radiator shroud 5/16-18 x 3/4" Grade 5
50. Rebound washer, 3/8" 63. Radiator hose clamp (radiator) 76. Overflow tank, 3 qt. (incl. item 77)
51. Hex-lock elastic nut, 5/16-18 64. Hex-head capscrew, 77. Cap w/tether
1/4-20 x 3/4" 78. Right radiator bracket assembly
52. Radiator mount bushing
65. Narrow flat washer, 1/4" 79. Well nut
53. Spacer
66. Baffle 80. Wide flat washer, 1/4"
54. Left radiator bracket
67. Hex-lock elastic nut, 1/4-20 81. Lockwasher, 1/4"
55. Hex-socket head shoulder bolt,
3/8 x 1-1/2 x 5/16-18 68. Radiator hose clamp (engine) 82. Hex-head capscrew,
56. Wide flat washer, 3/8" 69. Radiator return hose 1/4-20 x 1-1/2
57. Hex-lock elastic nut, 3/8-16 70. Radiator input hose 83. Fan warning decal

Figure 8B–4. Cummins engine radiator and oil cooler.

8B-8 Model 3606 • Origin 10/99

 Cummins Engine

To replace the radiator and oil cooler:

1. Level the vehicle, ground the attachment, place the Radiator
travel select lever in NEUTRAL (N), engage the
parking brake switch and shut off the engine.
Inlet
Remove the ignition key. Secure accident prevention hose
tags to the steering wheel and ignition switch.
Outlet hose
WARNING: DO NOT attempt this procedure
when the engine is hot. Wait for the engine,
muffler, and tailpipes to cool down before pro-
ceeding. Failure to do so could result in severe
burns. Outlet
Inlet hose
2. Unlatch, unlock and open the engine cover. Allow the
hose
engine to cool before proceeding. Draining the
cooling system while the engine is hot can cause PS0740
cracks in the engine block.
Figure 8B–5. Transmission hose routings.
3. Disconnect the negative (-) battery cable.
10. Working above the radiator, remove two 5/16-18 x
WARNING: NEVER remove the radiator cap 3/4" Grade 5 hex-head capscrews (item 75, Fig. 8B–
while the engine is hot. The cooling system is 4), 5/16" lockwashers (74) and 5/16" narrow flat
under pressure. Hot coolant can cause severe washers (73) securing the radiator at the upper
burns or eye injury. Wear protective clothing mounting tabs to the radiator shroud (62). The
and safety glasses. radiator shroud contains 5/16" weld nuts that retain
the capscrews.
4. Place a suitable container beneath the radiator
petcock. Slowly turn the radiator cap to the first stop 11. Working below the radiator, remove two 5/16-18 x
and allow any pressure to escape. Remove the 3/4" Grade 5 hex-head capscrews (75), 5/16"
radiator cap. lockwashers (74) and 5/16" narrow flat washers (73)
securing the radiator at the lower mounting tabs to
5. Place a funnel at the base of the radiator to channel the radiator shroud (62).
the drained coolant into the container. Open the
radiator drain plug or petcock and allow the coolant to 12. Working from beneath the radiator, remove two 3/8-
drain into the funnel. Transfer the coolant into a 16 hex-lock nuts (58), 3/8" rebound washers (50) and
properly labeled container. Dispose of properly if rubber mounts (61) secured to the welded studs on
coolant needs to be replaced. Close the radiator the bottom of the radiator.
drain plug or petcock. 13. At the sides of the radiator, remove the 3/8 x 1-1/2 x
6. Loosen clamps (items 63 and 68, Fig. 8B–4) on the 5/16-18 hex-socket head shoulder bolts (55), spacers
radiator return (lower) hose (69). Work the hose off (53), 3/8" rebound washers (50), radiator mount
the radiator. Position the hose out of the way to allow bushings (52), radiator mount rings (49), and 5/16-18
radiator removal, or remove the hose from the hex-lock elastic nuts (51) securing the radiator at its
engine. Inspect the hose and replace if necessary. side mounting tabs to the radiator brackets (54 and
78). Carefully remove the radiator from the vehicle.
7. Loosen clamps (63 and 68, Fig. 8B–4) on the radiator
input (upper) hose (70). Work the hose off the 14. At the bottom of the oil cooler (Fig. 8B–6), use
radiator. Position the hose out of the way to allow wrench and a back-up wrench to disconnect the 90°
radiator removal, or remove the hose from the elbow. Cap the elbow. Remove and discard the flat-
engine. Inspect the hose and replace if necessary. faced O-ring seal. Disconnect and cap the 3/4" I.D. x
28" hose.
8. Loosen the fan belt and remove the fan (item 1, Fig.
8B–1). Remove the four M10-1,5 x 90 mm hex-head 15. Remove the six 1/4-20 x 1-1/2" hex-head capscrews
capscrews (4) and M10 lockwashers (5) securing the (item 82, Fig. 8B–4), 1/4" lockwashers (81), 1/4" flat
fan (3) to the engine. wide washers (80) and well nuts (79) securing the
radiator baffle assembly (46) to the oil cooler (48).
9. Disconnect and cap the transmission inlet and outlet
hoses (Fig. 8B–5).

Model 3606 • Origin 10/99 8B-9

 Section 8B

16. Remove the oil cooler (Fig. 8B–6). 9. Working below the radiator, install two 5/16-18 x 3/4"
Grade 5 hex-head capscrews (75), 5/16"
lockwashers (74) and 5/16" narrow flat washers (73)
Oil cooler securing the radiator at the lower mounting tabs to
the radiator shroud (62). Torque to 18 lb/ft (24 Nm).
10. Working above the radiator, install two 5/16-18 x 3/4"
3/4" I.D. x 28" hose Grade 5 hex-head capscrews (75), 5/16"
lockwashers (74) and 5/16" narrow flat washers (73)
securing the radiator at the upper mounting tabs to
the radiator shroud (62). The radiator shroud
contains 5/16" weld nuts that retain the capscrews.
O-Ring Torque to 18 lb/ft (24 Nm).
Reservoir 90° Elbow 11. Uncap and connect the transmission inlet and outlet
hoses (Fig. 8B–5).
12. Install the fan (item 3, Fig. 8B–1) on the water pump
SS1150 pulley on the front of the engine. Secure with four
M10-1,5 x 90 mm hex-head capscrews (4) and M10
Figure 8B–6. Cummins oil cooler hose routings. lockwashers (5). Torque to 37 lb/ft (50 Nm). Install the
17. Remove, inspect and replace the seal bulb (item 44, fan belt.
Fig. 8B–4), seal bulb moulding (45), and foam baffles 13. Install clamps (63 and 68, Fig. 8B–4) on the radiator
(47) as required. input (upper) hose (70). Work the hose onto both the
engine and then the radiator. Tighten the clamps.
Radiator and Oil Cooler Installation 14. Install clamps (63 and 68) on the radiator return
1. Install the seal bulb (item 1, Fig. 8B–4), seal bulb (lower) hose (69). Work the hose onto both the
moulding (45), and foam baffles (47) as required. engine and then the radiator. Tighten the clamps.
2. Position the oil cooler (48) within the radiator 15. Fill the cooling system. Run the engine to operating
assembly baffle (46). temperature. Visually check for leaks with the engine
running. Check the coolant level in the overflow bottle
3. Install the six 1/4-20 x 1-1/2" hex-head capscrews
and fill, or drain, as necessary.
(82, Fig. 8B–4), 1 /4" lockwashers (81), 1/4" flat wide
washers (80) and well nuts (79) securing the radiator
baffle assembly (46) to the oil cooler (48). Torque to 9 8B.6 CUMMINS ENGINE ELECTRICAL
lb/ft (12 Nm). SYSTEM
4. At the bottom of the hydraulic system oil cooler (Fig. The Cummins engine electrical system, including the
8B–6), install a new flat-faced O-ring seal in the starter, alternator and primary wiring, is described in
elbow and secure the hose to the cooler. Use a back- Section 10 Electrical System.
up wrench and torque to 155-165 lb/ft (210-224 Nm).
5. Secure the 3/4" I.D. x 28" hose (Fig. 8B–6) to the oil 8B.7 CUMMINS ENGINE FUEL SYSTEM
cooler. The Cummins engine fuel system includes a fuel tank
6. Carefully place the radiator into position at the oil (item 24, Fig. 8B–7), fuel level sender (9) and dash panel
cooler. As required, place two foam baffles (item 4, gauge, fuel strainer (5), fuel lift pump (ref.), fuel filter (1),
Fig. 8B–4) between the radiator and the oil cooler. and fuel supply and return lines.
7. At the radiator sides, install the 3/8 x 1-1/2 x 5/16-18 The threaded fuel filler (17) has a keyed fuel cap (19) and
hex-socket head shoulder bolts (55), spacers (53), 3/ permits entry of diesel fuel into the tank.
8" rebound washers (50), radiator mount bushings The fuel level sender (9) and dash panel gauge are
(52), radiator mount rings (49), and 5/16-18 hex-lock described in Section 10 Electrical System.
elastic nuts (51) securing the radiator at its side
mounting tabs to the radiator brackets (54 and 78). A fuel supply hose (6) carries fuel from the tank to the
engine lift pump (ref.) and then under pressure to the fuel
8. Working from beneath the radiator, install two 3/8-16 filter (1). Filtered fuel is directed to the fuel injection pump
hex-lock nuts (58), 3/8" rebound washers (50) and and to the individual fuel injectors. Surplus fuel at the fuel
rubber mounts (61) secured to the welded studs on injector pump is returned to the tank via the fuel return
the bottom of the radiator. Torque to 31 lb/ft (42 Nm). hose (30).

8B-10 Model 3606 • Origin 10/99

 Cummins Engine

Front of vehicle
1

Engine rotated Cab panel (ref.)

2 3 180° for clarity

4
20
18 19
3
5
Fuel lift pump
3 17
(ref.) 3
6
29 16 18

3
3

30 13 12 21
11 15
11
10 3 22
3 9
28 14
8 3 3
7 23
25

Front of vehicle
27

3 24
25

31
26
MS1170

1. Fuel filter 11. Lockwasher, #10 23. Lower hose clamp, SAE Type F
2. Straight barb connector, #6-4P 12. Pan-head screw, #10-24 x 3/4" 24. Fuel tank
3. Hose clamp, SAE Type F 13. Pan-head screw, #10-24 x 5/8" 25. 90° hose barb elbow, #10-6P,
4. Fuel hose, 3/8" x 10" 14. Fuel breather hose use with Item 31
5. Fuel strainer 15. Beaded hose tee 26. Gasket
6. Fuel tank-to-engine hose, 3/8" x 85" 16. Fuel breather hose 27. Fuel breather hose
7. Hose barb coupling, #6-6P, 17. Fuel filler 28. 90° hose barb elbow, #5-6P,
use with Item 31 18. U-type muffler clamp, 2" use with Item 31
8. Square-head black plug, MI#6, 19. Fuel cap w/keys (incl. Item 20) 29. Mini hose clamp, 7/32" diameter
use with Item 31
20. Keys (set of two) 30. Fuel return hose
9. Fuel sender w/gasket
21. Upper hose clamp, SAE Type F 31. Pipe thread sealant w/Teflon®, 8oz;
10. Fuel sender cover use w/ ALL threaded fittings
22. Fuel filler hose
Figure 8B–7. Cummins engine fuel system.

8B.7.1 Diesel Fuel IMPORTANT: Due to the precise tolerances of diesel

injection systems, keep the fuel clean and free of dirt and
Fuel represents a major portion of vehicle operating
water. Dirt and water in the fuel system can cause severe
costs and therefore must be used efficiently. ALWAYS
damage to both the injection pump and the injection noz-
use a premium brand of high-quality, clean diesel fuel.
zles. Use ASTM No. 2 D fuel with a minimum cetane rat-
Low cost, inferior fuel can lead to poor performance and
ing of 40. No. 2 diesel fuel gives the best economy and
expensive engine repair.
performance under most operating conditions. Fuels with
Note: Use only diesel fuel designed for diesel engines. Cetane numbers higher than 40 may be needed in high
Some heating fuels contain harmful chemicals that can altitudes or extremely low ambient temperatures to help
seriously affect engine efficiency and performance. prevent misfiring and excessive smoking.

Model 3606 • Origin 10/99 8B-11

 Section 8B

Inform the owner/operator of the vehicle to use No. 2 D To clean the fuel tank:
diesel fuel, unless ambient temperatures are below 32° F 1. Have a dry chemical (Class B) fire extinguisher near
(0° C). When temperatures are below 32° F (0° C), a the work area.
blend of No. 1 D and No. 2 D fuels (known as "winterized"
No. 2 D) may be used. WARNING: NEVER drain or store fuel in an
open container due to the possibility of explo-
Note: No. 1 D fuel may be used, however, fuel economy
sion or fire. Discard the fuel in an approved
will be reduced.
manner.
WARNING: DO NOT mix gasoline or alcohol
2. Invert and tilt the tank from side to side. Safely drain
with diesel fuel. The mixture can cause an
any fuel into a suitable container. Dispose of properly.
explosion.
3. Clean the fuel tank with a high-pressure washer, or
Use a low-sulfur content fuel with a cloud point (the tem- flush the tank with hot water for five minutes. Invert
perature at which wax crystals form in diesel fuel) at least the tank, tilt it from side to side, and drain the water.
10° below the lowest expected fuel temperature. The vis- 4. If necessary, add a diesel fuel emulsifying agent to
cosity of the fuel must be kept above 1.3 centistrokes to the tank. Refer to the manufacturer’s instructions for
provide adequate fuel system lubrication. the correct emulsifying agent-to-water mixture ratio.
Note: When using diesel fuel with a sulfur content below Refill the tank with water, and agitate the mixture for
1.3 percent, the filter change interval must be reduced by 10 minutes. Drain the tank completely.
75 hours. The use of fuel with a sulfur content above 1.3 5. Refill the fuel tank with water until it overflows.
percent is not recommended. Completely flush the tank with water. Empty the tank
and allow it to dry completely.
8B.7.2 Fuel Tank
The fuel tank (item 24, Fig. 8B–7) is located directly D. Inspection
beneath the operator’s cab. 1. Inspect the fuel tank thoroughly for any cracks, slices,
leaks or other damage. Replace a leaking or
A. Removal damaged tank. DO NOT attempt to repair, plug or
The operator’s cab must be partially removed in order to patch a leaking or damaged fuel tank. The tank is
remove the fuel tank. Follow the directions for removing manufactured using an injection molding process and
the operator’s cab in Section 4 Cab, Covers and Mirrors, cannot be repaired.
then remove the fuel tank. If a leaking fuel tank is sus- 2. With the fuel tank removed from the vehicle, plug all
pected, check that all fuel tank inlets and outlets are not openings except one elbow fitting. Install the elbow
the cause of the leak before removing the cab and the fitting and apply approximately 1 to 1-1/2 psi (7 to 10
fuel tank from the vehicle. kPa) of air pressure through the elbow. Check the
tank for leaks by applying a soap solution to the
B. Disassembly exterior of the tank, or by submerging the tank in
water and looking for bubbles to appear at the
1. Remove the four #10-24 x 3/4" pan-head screws
cracked or damaged area.
(item 12, 8B–7), the #10-24 x 5/8" pan-head screw
(13), and the five #10 lockwashers (11) securing the
E. Assembly and Replacement
fuel sender cover (10) and fuel sender with gasket (9)
to the fuel tank. 1. Install the fuel sender with gasket (item 9, Fig. 8B–7)
2. Remove the black MI #6P square-head plug (8), the and the fuel sender cover (10) to the fuel tank.
#6-6P hose barb coupling (7), the #5-6P 90° hose Secure with four #10-24 x 3/4" pan-head screws (12),
barb elbow (28) and both #10-6P 90° hose barb and four #10 lockwashers (11).
elbows (25). 2. Coat threads with Teflon® (31) and install the black
MI #6P square-head plug (8), the #6-6P hose barb
C. Cleaning and Drying coupling (7), the #5-6P 90° hose barb elbow (28) and
both #10-6P 90° hose barb elbows (25).
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned. Replace a leaking or dam- 3. Replace the fuel tank in the cab mount subframe.
aged tank. DO NOT attempt to repair, plug or patch a Attach the fuel level gauge wire to the #10-24 x 5/8"
leaking or damaged fuel tank. The tank is manufactured pan-head screw (13), slide a #10 lockwasher (11)
using an injection molding process and cannot be onto the screw and secure the screw to the fuel tank
repaired. at the fuel sender cover.

8B-12 Model 3606 • Origin 10/99

 Cummins Engine

4. Reconnect the fuel hoses and follow the directions in 3. Connect the fuel lines.
Section 4 Cab, Covers and Mirrors to replace the
other fuel system components and the cab. 8B.7.5 Fuel Filter
Refer to Section 2 General Information, Specifications,
8B.7.3 Fuel Level Sender and Gauge and Maintenance Instructions for information on remov-
The fuel level sender and gauge assembly is described in ing and replacing the fuel filter (item 1, Fig. 8B–7).
Section 10 Electrical System.
8B.7.6 Venting Air
8B.7.4 Fuel Lift Pump Testing from the Fuel System
Inspect the camshaft lever and return spring for exces- Refer to Section 2 General Information, Specifications,
sive wear. To test the diaphragm, remove the fuel inlet and Maintenance Instructions, paragraph 2.12.7 D, Vent-
line from the lift pump. Block the fuel inlet with a finger ing Air from the Fuel System.
(Fig. 8B–8) and operate the hand plunger. A properly
operating pump will provide suction that will remain until 8B.7.7 Fuel Injectors
the finger is removed from the inlet.
The Cummins engine uses Bosch 17 mm closed nozzle
hole-type injectors. The injectors have different part num-
bers for different engine ratings. The last four digits of the
Vent screw Cummins part number (stamped on the bottom portion of
the injector) identify the injector.
Fuel inlet IMPORTANT: Use only the specified injector for the
line engine.
During the injection cycle, high pressure from the injec-
tion pump rises to the operating (or “pop”) pressure,
which causes the needle valve in the injector to lift. Fuel
is then injected into the cylinder. A shimmed spring is
used to force the needle valve closed as the injection
pressure drops below the pop pressure to seal off the
nozzle after injection. Failure of the needle valve to lift
Hand
and to close at the correct time, or a needle valve that is
plunger
Lift stuck open, can cause the engine to misfire and produce
pump low power. Fuel leaking from the open nozzle can cause
OS1450 a fuel knock, poor performance, smoke, poor fuel econ-
omy, and rough running.
Figure 8B–8. Testing a typical fuel lift pump.

A. Locating Faulty Fuel Injectors

A. Fuel Lift Pump Removal
A faulty fuel injector can cause:
1. Clean debris from around the lift pump.
2. Disconnect the fuel lines. • Misfiring
• Knocking
3. Remove the capscrews, gasket, and fuel lift pump.
• Overheating
B. Cleaning and Drying • Loss of power
Clean the exterior of the pump with mineral spirits and • Smoky (black) exhaust
blow dry with compressed air. • Increased fuel consumption
Note: Parts replacement is not practical. The fuel lift The particular faulty fuel injector(s) may be determined
pump is serviced as an entire assembly. by releasing the pipe union nut on each fuel injector in
turn, with the engine running at a fast “tick-over.” If, after
C. Fuel Lift Pump Installation slackening a pipe union nut, the engine revolutions
1. Clean the mounting surface on the cylinder block. remain constant, a faulty fuel injector has been identified.
2. Install the fuel lift pump with a new gasket. Install and
torque the capscrews to 18 lb/ft (24 Nm).

Model 3606 • Origin 10/99 8B-13

 Section 8B

To test a fuel injector:

1. Remove the fuel injector from the cylinder head. Injector body
2. Invert the fuel injector with the nozzle facing out, then O-ring
retighten the unions. Hold-down nut
3. Loosen the unions of the other fuel injector pipes (to
help avoid the possibility of the engine starting).
WARNING: KEEP CLEAR of spraying fuel.
Diesel fuel will spray when venting high pres-
sure lines. The fuel pressure is sufficient to
penetrate the skin and cause serious bodily
injury. Wear protective clothing and safety
glasses.

4. Operate the starter to turn the engine over until fuel

sprays from the nozzle. Examine the shape of the
spray. If the spray is unduly “wet” or “streaky”, or
obviously sprays to one side, or if the nozzle
“dribbles” fuel, it may only be necessary to probe the
nozzle holes to remove blockage. Protrusion

IMPORTANT: DO NOT attempt to adjust injection pres- Notch

Copper washer
sure without a testing pump and pressure gauge. It is MA1960
impossible to accurately adjust the setting of fuel injec-
Figure 8B–9. Fuel injector.
tors without the proper equipment.
A perfect fuel injector, when tested by pumping fuel 2. Clean the injector nozzle bore.
through it in the open air, gives a short “pinging” sound as 3. Remove the injector hold-down nut from the injector
the fuel emerges from the holes. After the fuel injector body.
has been in service for some time, the pinging changes 4. Apply a light coat of anti-seize compound to the new
to a crackling sound. It is not until the fuel injector sounds injector surface. Avoid getting anti-seize compound
“dead” that its condition is likely to affect the running of into the fuel drain hole.
the engine.
5. Install the hold-down nut on the injector body.
B. Injector Replacement 6. Install a new O-ring into the recessed groove in the
top of the hold-down nut. Make sure the O-ring is not
Preparatory steps:
cut or twisted during installation.
• Thoroughly clean around the injector(s)
7. Apply a light coat of anti-seize compound to the to
• Disconnect the high-pressure fuel line(s) the threads of the injector hold-down nut.
• Disconnect the fuel drain manifold 8. Assemble the injector and new copper washer. Use
IMPORTANT: The injector must not rotate in the bore of only ONE copper washer. A light coat of clean
the cylinder head or damage to the cylinder head will 15W40 engine oil placed between the washer and
occur. If rust has formed on the hold-down nut, soak the the injector will help keep the washer from falling
nut with rust-penetrating solvent for a minimum of three during installation.
minutes. Then, tap the injector body with a drift pin to 9. Install the injector with the protrusion on the side of
help loosen any rust. the nozzle fitting into the notch in the head.
1. Use a 16 mm wrench to prevent the injector body 10. Tighten the hold-down nut and torque to 44 lb/ft
(Fig. 8B–9) from turning. Loosen the hold-down nut (60 Nm).
with a 24 mm box wrench.
11. Install the fuel drain manifold and torque to 6 lb/ft
(8 Nm).
12. Install the high-pressure fuel lines and torque to 18
lb/ft (24 Nm).
13. Run the engine and check for fuel and air leakage.

8B-14 Model 3606 • Origin 10/99

 Cummins Engine

14. Bleed the fuel system in accordance with the

instructions in Section 2 General Information,
Specifications, and Maintenance Instructions. 1. V-band clamp 1
To
2. Exhaust pipe 2 engine
8B.7.8 After Fuel System Service 3. Heavy-duty T-bolt exhaust
band clamp
1. Drain and flush the fuel tank if it was contaminated. 3
4. Exhaust bellows
2. Vent air from the fuel system (see Section 2 General 5. Exhaust pipe
Information, Specifications, and Maintenance 6. Heavy-duty muffler 4
Instructions, paragraph 2.12.7 D). clamp, 2-1/2"
3. Fill the fuel tank with fresh, clean diesel fuel as 7. Exhaust muffler
8. Exhaust tail pipe 3
required.

8B.8 CUMMINS ENGINE EXHAUST Secure to

band clamp 6
SYSTEM on vehicle
8
WARNING: Exhaust fumes contain carbon 7 5
monoxide, a colorless, odorless gas which is
fatal when inhaled in a confined area. Avoid
breathing exhaust fumes and prevent engine
operation from becoming a cause of toxic emis- 6
sions.
6
Exhaust system components reach high tem-
peratures and can cause severe burns. DO
NOT come into contact with hot exhaust sys- PS0130

tem components. Figure 8B–10. Cummins engine exhaust system.

The exhaust system (Fig. 8B–10) is supported by the When installing exhaust system components, allow suffi-
engine and the vehicle frame to help minimize the trans- cient clearance between the components and other vehi-
fer of noise and vibration into the operator’s cab. The tail cle pipes, hoses and wiring that could be adversely
pipe directs exhaust fumes to the right side of the vehicle, affected by excessive heat.
away from the cab. When installing an exhaust system, provide for parts
Annoying rattles and noise vibrations in the exhaust sys- expansion when the system is hot.
tem are usually caused by misalignment of parts. When Whenever performing service on the vehicle, check the
aligning the system, leave all capscrews and nuts slightly condition of the exhaust system. Check the entire
loose until all parts are properly aligned, then tighten all exhaust system for broken, damaged, missing or mispo-
fasteners working from the front of the system to the rear. sitioned parts, open seams, holes, loose connections
When replacing the muffler, also replace the tail pipe. and other deterioration which could permit exhaust
fumes to seep into the operators cab. Correct any dam-
Before assembling components, use exhaust system
aged areas immediately.
sealer at all slip joint connections.

Model 3606 • Origin 10/99 8B-15

 Section 8B

8B.9 CUMMINS ENGINE REPLACEMENT 4. Position a suitable container beneath the radiator
(Fig. 8B–12). Remove the radiator cap and open the
Removal and installation of the engine can be done with radiator drain petcock. Allow the coolant to drain into
or without the transmission attached. For information on the container. At the engine, loosen the upper and
removing the transmission from, and installing it to, the lower radiator hose clamps and pry the hoses away
engine, refer to Section 7 Transmission. from the engine.

8B.9.1 Engine Removal Radiator Cap

WARNING: To avoid severe burns, DO NOT Fitting on Neck of

attempt to remove the engine when the engine, Radiator Fill Tube
cooling system and hydraulic system are hot. Coolant
Wait until all parts and systems are cool before Overflow
proceeding. Bottle

1. Level the vehicle, ground the attachment, place the Hose from
travel select lever in NEUTRAL (N), engage the Bottom of
parking brake switch and shut off the engine. Allow Overflow
the engine, cooling system and hydraulic system to Bottle
cool. Radiator
2. Label and disconnect the negative (-) battery ground Drain
cable at the battery (Fig. 8B–11). Also, disconnect (petcock
the negative lead from at the starter mounting bolt. removed)

Funnel
Auxiliary
function
valve OS0472

Battery Figure 8B–12. Drain the radiator.

5. Detach and remove the air cleaner (Fig. 8B–13).
Hydraulic Loosen the clamp securing the air intake hose to the
temperature
engine panel. Remove the hose at the engine panel.
sending unit
6. Loosen the air cleaner mount band assembly (Fig.
8B–13) securing the air cleaner hose to the
Hydraulic
turbocharger intake on the engine. Remove the
fluid level
sending unit
turbocharger intake hose. Cover the intake to help
prevent debris, etc. from entering.
Negative (-) cable 7. Unscrew the clamp securing the air cleaner body
OS1040
assembly (Fig. 8B–13) to the mount plate on the
Figure 8B–11. Disconnect the negative (-) battery cable. engine. Remove the air cleaner assembly in its
3. Remove the hood with the help of at least one entirety and store securely.
assistant (refer to Section 4 Cab, Covers and
Mirrors).

8B-16 Model 3606 • Origin 10/99

 Cummins Engine

9. Label and disconnect the alternator wire leads (Fig.

Engine (ref.) 8B–14).
14 16 BL
K
15
2L 2
5
19 20 K
K BL
19 BL K
BL K
BL
4 17
B
18 2L
6 D
D-
7
8 Alternator
RN
K/G
PN GR
N
3 10 LT
9 1
MS1600
2
Figure 8B–14. Label and disconnect
12 10 11 the alternator wire leads.
1 10. Disconnect (unplug) the hydraulic fluid level indicator
13 lead (Fig. 8B–11 and Fig. 8B–15) and the hydraulic
temperature sending unit lead (Fig. 8B–11) from the
wiring harness connector.
12
Hydraulic fluid
level sending
Engine unit lead
panel (ref.) Engine
PS0420
harness
1. Air cleaner assembly 13. Air intake hose lead
Front of
(incl. items 2-6) 14. Hex-head capscrew, vehicle
2. Body assembly 5/16-18 x 3/4"
3. Safety filter 15. Flat narrow washer, 5/16"
4. Primary filter 16. Air cleaner mount
5. Cover assembly band assembly
6. Vactuator valve 17. Air cleaner mount plate
7. Heavy-duty T-bolt clamp 18. Hex-lock elastic nut,
5/16-18
8. Air cleaner hose MS3020
19. Hex-head capscrew,
9. T-bolt clamp 3/8-16 x 1-1/4" Grade 5 Figure 8B–15. Disconnect the hydraulic fluid
10. Close nipple, #2 20. Lockwasher, 3/8" level indicator lead.
11. Vacuum switch
12. Hose clamp, SAE Type F 11. Label and disconnect the wires at the main ground
stud (Fig. 8B–16).
Figure 8B–13. Cummins air cleaner. Engine
Ground mount
8. Disconnect the turbocharger exhaust connection, support
stud
secured with a stainless steel V-band clamp, and
cover the exhaust to prevent debris, etc. from
entering. Disconnect the exhaust pipe (Fig. 8B–10)
from the exhaust bellows, secured with a heavy-duty
T-bolt band clamp.

Tube clip
MS1410

Figure 8B–16. Disconnect wires at the main ground stud.

Model 3606 • Origin 10/99 8B-17

 Section 8B

12. Label and disconnect the positive (+) battery cable at 14. If removing the engine and transmission as a unit:
the starter. • Place a suitable container beneath the vehicle
13. Label and disconnect the engine water temperature frame side of the radiator. Disconnect the transmis-
switch lead (Fig. 8B–17), engine oil pressure switch sion cooler hoses at the radiator and cap the con-
lead, and transmission temperature lead. nectors to help prevent excess fluid drainage.
Secure the hoses out of the way on top of the
engine.
• Move the container beneath the transmission.Dis-
connect and cap the inlet and outlet hoses at the
main hydraulic pump. Disconnect the pump inlet
hose from the hydraulic reservoir and cover the
opening to help prevent debris, etc. from entering
the pump. Move the hoses out of the way to allow
engine and transmission removal.
• Label and disconnect all transmission wire leads.
Engine rotated • Mark the transmission and transmission driveshaft
180° for clarity flange yoke. Disconnect the transmission-to transfer
Engine oil case driveshaft at the transmission flange yoke.
pressure switch Secure the U-joints with tape. Lower the driveshaft
to the ground.
Engine water
temperature switch Note: The drive shaft assembly is a balanced assembly.
Mark the yoke and transmission so that these compo-
Transmission nents can be returned to their original positions when the
temperature transmission is reinstalled. The yokes at each end of the
switch drive shaft must be in the same plane to help prevent
excessive vibration (Fig. 8B–23).
15. Working from beneath the vehicle, label and
disconnect all engine wire harness leads (refer to
Section 10 Electrical System as required for detailed
views of harness leads). Remove plastic tie wraps as
required to allow access to the wiring harness and
wire leads.
16. Disconnect the engine wiring harness bulkhead
connector from the cab wiring harness bulkhead
connector along the vehicle frame.

MS1610

Figure 8B–17. Label and disconnect the engine water

temperature and oil pressure switch leads,
and the transmission temperature switch lead.

8B-18 Model 3606 • Origin 10/99

 Cummins Engine

17. Label and disconnect the wiring harness at the steer 21. Mark the location of the throttle cable at its engine
select valve (Fig. 8B–18). mount bracket (Fig. 8B–21).
Steer select valve
Two washers
Jam nut Bracket
Disconnect
(above starter)

Stop and throttle lever

Engine
wiring
harness Throttle
leads cable
Disconnect

MS1400

Figure 8B–18. Label and disconnect the wiring

at the steer select valve. Clamp
18. Label and disconnect the wiring connectors at the INJECTOR PUMP
auxiliary function valve solenoids (Fig. 8B–19). Move
all wiring out of the way to allow engine removal.
Auxiliary function valve Clevis, clevis pin
(also see Fig. 8B-11) and cotter pin

MA0201

Figure 8B–21. Throttle cable connection at engine.

22. Disconnect the throttle cable (Fig. 8B–21) at the
T

G
bracket above the starter.
PB
PB

23. At the hydraulic fluid reservoir, disconnect the engine

OS0731
harness wire lead (Fig. 8B–11) from the hydraulic
fluid-level sending unit.
Figure 8B–19. Disconnect the wiring at the auxiliary
function valve solenoids. 24. Connect a suitable engine hoist to the engine lift
plates (Fig. 8B–22).
19. Working from the side of the vehicle, disconnect the
Engine
fuel return line at the fuel injector pump.
lift plates
20. Disconnect the fuel inlet line (Fig. 8B–20) at the fuel
lift pump.

Fuel inlet
line

MA2030
Fuel lift
pump Figure 8B–22. Typical engine lift plates.
OS1430

Figure 8B–20. Fuel inlet line to lift pump connection.

Model 3606 • Origin 10/99 8B-19

 Section 8B

25. In four locations, remove the nuts, washers and 7. Secure the throttle cable to the bracket (Fig. 8B–21),
capscrews securing the engine mounts (Fig. 8B–1) to located just above the starter.
the hydraulic reservoir/engine mount subframe. 8. Connect the throttle cable (Fig. 8B–21) at the engine
26. Remove either the fan or the radiator to help prevent mount bracket.
damage to the radiator when the engine is removed. 9. Connect the fuel inlet line (Fig. 8B–20) to the fuel lift
27. Begin removing the engine from the vehicle with the pump.
hoist or overhead crane. 10. Connect the fuel return line to the fuel injector pump.
28. As the engine is lifted away and removed, reposition 11. Attach the wiring connectors at the auxiliary function
the debris shield at the base of the radiator to prevent valve solenoids (Fig. 8B–19).
damage and allow engine removal. Avoid damaging
the oil filter and oil filter housing. 12. Connect the wiring harness leads to the steer select
valve leads (Fig. 8B–18).
29. Carefully lift the engine out and away from the
vehicle. Place the engine safely onto ground 13. Connect the engine wiring-harness bulkhead
supports, or in a suitable engine stand. DO NOT rest connector to the bulkhead receptacle along the
the engine on its oil pan, or damage will occur. vehicle frame.
14. Working from beneath the vehicle, connect all engine
8B.9.2 Engine Disassembly, Inspection and wire harness leads (refer to Section 10 Electrical
Service System as required for detailed views of harness
leads). Secure with plastic tube clips and tie wraps as
Engine disassembly, internal inspection, service, repair
required to prevent the wiring harness and wire leads
and assembly procedures are covered in the Cummins
from hanging below the vehicle and from coming into
4BT3.9 service manual. Several special engine service
contact with moving parts.
tools are required to properly service the Cummins
engine. Contact the local Cummins parts distributor for 15. If the engine and transmission were NOT installed as
further information. a unit, attach the transmission to the engine at this
time. Follow the procedure in Section 7
8B.9.3 Engine Installation Transmission.

Removal and installation of the engine can be done with Note: The drive shaft is a balanced assembly. The yokes
or without the transmission attached. For information on at each end of the drive shaft must be in the same plane
installing the transmission to the engine, refer to Section to help prevent excessive vibration (Fig. 8B–23).
7 Transmission. Angled
Align yokes in same plane as shown notch
1. Place the engine mounts (items 17 and 26,
Fig. 8B–1) into the appropriate locations within the (note angled notch in yoke)
hydraulic reservoir/engine mount subframe on the
vehicle.
2. Attach a suitable engine hoist to the engine lift plates
(Fig. 8B–22). Straight
3. Carefully install the engine onto the engine mounts edge
(Fig. 8B–1). Make sure the bracket-type engine
mounts align properly with the engine mounts in the
subframe.
MS1120
4. In four locations, install the nuts, washers and
Figure 8B–23. Align yokes in the same plane as shown.
capscrews securing the engine mounts (Fig. 8B–1) to
the hydraulic reservoir/engine mount subframe. 16. Coat the M12 transmission driveshaft yoke retaining
Torque the 7/16-14 x 3-1/4" Grade 8 capscrews to 60 capscrews with Loctite #242 (blue), install
lb/ft (81 Nm). Torque the 5/8-11 x 4" Grade 8 lockwashers and torque to 83 lb/ft (112,5 Nm).
capscrews to 180 lb/ft (244 Nm). 17. Connect all transmission wire leads.
5. Install the fan and/or radiator as required.
6. At the hydraulic fluid reservoir, connect the engine
harness wire lead (Fig. 8B–11) to the hydraulic fluid-
level sending unit.

8B-20 Model 3606 • Origin 10/99

 Cummins Engine

18. For priming purposes, pour hydraulic oil into the main 32. Check that all hydraulic system, electrical system,
hydraulic pump. Connect the hydraulic system inlet cooling system, fuel system, and exhaust system
and outlet hoses at the main hydraulic pump. If connections are correctly and tightly connected.
necessary, connect the inlet hose to the hydraulic 33. From within the cab, lightly depress the throttle pedal
reservoir. Refer to Section 9 Hydraulic System as (Fig. 8B–24) to full-throttle position. As needed,
required. adjust the limit-stop screw until it touches the pedal.
19. Connect the transmission hoses (Fig. 8B–5) to the Tighten the locknut to 120 to 125 lb/in (13,6 to 14,1
radiator. Nm).
20. Connect the engine coolant temperature switch lead Throttle
(Fig. 8B–17) and oil pressure switch lead (refer to pedal
Section 10 Electrical System for detailed views of
Limit-stop
harness leads).
screw
21. Connect the hydraulic oil pressure and temperature
wiring harness leads (Fig. 8B–11 and Fig. 8B–15).
Locknut
22. Connect the alternator wire leads (Fig. 8B–14), then
connect the positive (+) battery cable to the starter,
then to the battery. DO NOT connect the negative (-)
Cab
lead at this time.
floor
23. Connect the exhaust pipe (Fig. 8B–10) to the exhaust
bellows. Secure with a heavy-duty T-bolt band clamp.
For turbocharged engines, connect the turbocharger
outlet to the exhaust. Secure with a stainless steel V- MA0191
band clamp.
Figure 8B–24. Adjust the throttle limit-stop screw.
24. Secure the air cleaner mount band assembly (Fig.
8B–13) and mount plate to the engine with two 3/8- 34. Have an assistant stand by with a Class B fire
16 x 1-1/4 Grade 5 hex-head capscrews and two 3/8" extinguisher. Start and idle the engine.
lockwashers. 35. Check for leaks from the engine, main hydraulic
25. Install the air cleaner assembly (Fig. 8B–13) in its pump and lines, transmission, hydraulic reservoir and
entirety. Install the air cleaner hose to the fuel tank. Check the levels of all fluids and lubricants.
turbocharger intake port. Secure the air cleaner hose Fill as required.
with a heavy-duty T-bolt clamp. IMPORTANT: During the full throttle check:
26. Install the air intake hose (Fig. 8B–13) at the engine • DO NOT operate any hydraulic function;
panel. Tighten the SAE Type F clamp to secure the • DO NOT steer or apply any pressure to
air intake hose to the engine panel. the steering wheel;
• Keep the transmission in NEUTRAL (N).
27. Attach the upper and lower radiator hoses (Fig. 8B–
4) to the engine water pump (and to the radiator, if 36. Obtain and connect an appropriate engine analyzer
necessary) and secure with hose clamps. or tachometer. Check the engine rpm at full throttle. If
the rpm is not 2600 to 2800 rpm, readjust the throttle
28. Open the radiator cap (Fig. 8B–4) and fill the radiator limit-stop screw at the throttle pedal within the cab.
with a 50/50 mixture of water and ethylene glycol.
More coolant will need to be added later. Replace 37. Purge the hydraulic system of air by operating all
and tighten the radiator cap. boom functions through their entire range of motion
several times. Check the hydraulic oil level.
29. Install the hood with the help of at least one assistant
(refer to Section 4 Cab, Covers and Mirrors). 38. Check for proper operation of all components.

30. Connect the positive (+) battery cable at the starter, 39. Turn the engine OFF.
then at the battery.
31. Connect the negative (-) battery ground cable lead to
the starter mounting bolt. Connect the negative (-)
battery cable at the starter, and the negative frame
ground cable to the frame stud (Fig. 8B–16).

Model 3606 • Origin 10/99 8B-21

 Section 8B

8B.10 CUMMINS ENGINE STORAGE 13. Seal the vent pipe of the fuel tank or the fuel filler cap
with waterproof tape.
If the engine is properly protected and stored according
to the following recommendations, no corrosion damage 14. Remove and store the fan drive belt.
will normally occur. Cummins Engine Company, Inc. and Note: Before starting the engine after storage, operate
Sky Trak International are not responsible for any dam- the starter motor with one of the fuel-run solenoid wires
age that occurs in relation to a service storage period. disconnected until oil pressure shows on the oil pressure
Use the following procedures immediately upon remov- gauge, or until the low oil-pressure warning light goes
ing engine from service if being stored for an extended out.
period of time.
1. Clean the outside of the engine.
2. When using a preservative fuel, drain the fuel system
and fill with the preservative fuel. When not using
preservative fuel, keep the fuel system charged with
regular fuel, which, along with the fuel filter, will have
to be drained and discarded at the end of the storage
period.
3. Run the engine to operating temperature. Correct
any fuel, fluid, oil or air leaks. Stop the engine and
drain the oil.
4. Replace the oil filter.
5. Fill the crankcase (sump) to the FULL mark on the
dipstick with new, clean oil or with an approved
preservative fluid. If a preservative fluid is used, it
must be drained and replaced with regular lubricating
oil before the engine is returned to service.
6. Drain the cooling system. To provide protection
against corrosion, fill the cooling system with a
coolant containing a corrosion inhibitor. If frost
protection is needed, use the appropriate mixture of
antifreeze and water. If frost protection is not
required, use an appropriate mixture of water with an
approved corrosion mixture.
7. Run the engine for a short period to distribute
lubricating oil and coolant throughout the engine.
8. Clean out the engine breather pipe (where fitted) and
seal the end of the pipe.
9. Remove the fuel injectors and spray clean engine
lubricating oil into cylinder bores, four ounces (118,3
ml) of lubricating oil divided evenly between the four
cylinders.
10. Remove the air filter and any pipe installed between
the air filter and the induction manifold. Seal the
manifold with waterproof tape.
11. Remove the exhaust pipe. Seal the manifold with
waterproof tape.
12. Disconnect the battery and store it safely, in a fully
charged condition. Before the battery is put into
storage, give the battery terminals a protection
against corrosion with a light coating of dielectric
grease or petroleum jelly.

8B-22 Model 3606 • Origin 10/99

 Cummins Engine

8B.11 TROUBLESHOOTING
Trouble Possible Causes (see key, below)
Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12

Key to Possible Causes

1. Battery capacity low 23. Sticking throttle or restricted 44. Choked oil filter
2. Bad electrical connection movement 45. Piston seizure / pick up
3. Faulty starter motor 24. Exhaust pipe restriction 46. Incorrect piston height
4. Incorrect grade of lubricating oil 25. Leaking cylinder head gasket 47. Damaged fan
5. Low cranking speed 26. Overheating 48. Faulty engine mounting
6. Fuel tank empty 27. Cold running 49. Incorrectly aligned flywheel housing
7. Faulty stop control operation 28. Incorrect tappet adjustment or incorrectly aligned flywheel
8. Blocked fuel feed line 29. Sticking valves 50. Faulty thermostat
9. Faulty fuel lift pump 30. Incorrect high pressure pipes 51. Restriction in water jacket
10. Choked fuel filter 31. Worn cylinder bores 52. Loose fan belt
11. Restriction in air cleaner 32. Pitted valves and seats 53. Choked radiator
12. Air in fuel system 33. Broken, worn or sticking piston ring(s) 54. Faulty water pump
13. Faulty fuel injection pump 34. Worn valve stems and guides 55. Choked breather pipe
14. Faulty fuel injectors or incorrect type 35. Over-full air cleaner 56. Damaged valve stem oil deflectors
36. Worn or damaged bearings (if fitted)
15. Incorrect use of cold start equipment
37. Insufficient oil in sump 57. Coolant level too low
16. Faulty cold start equipment
38. Inaccurate gauge 58. Blocked sump strainer
17. Broken fuel injection pump drive
39. Oil pump worn 59. Broken valve spring
18. Incorrect fuel pump timing
40. Pressure relief valve sticking open 60. Exhauster or vacuum pipe leak
19. Incorrect valve timing
41. Pressure relief valve sticking closed 61. Turbo impeller damaged or dirty
20. Poor compression
42. Broken relief valve spring 62. Turbo lubricating oil seal leak
21. Blocked fuel tank vent
43. Faulty suction pipe 63. Induction system leaks
22. Incorrect grade of fuel

Model 3606 • Origin 10/99 8B-23

 Section 8B

8B-24 Model 3606 • Origin 10/99

 Section 9
Hydraulic System

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
General Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 HYDRAULIC PRESSURE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4 HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.5 HOSES, TUBE LINES, FITTINGS, ETC. . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.5.1 Hose, Tube, Line and Fitting Replacement . . . . . . . . . . . . . . . . 9-9
9.6 HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.7 HYDRAULIC SYSTEM PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.7.1 Pump, Unloader Valve and Cooling Circuit . . . . . . . . . . . . . . . . 9-12
9.7.2 Pump Failure Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.7.3 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.8 HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.1 Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8.2 Boom Hoist/Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.8.3 Boom Extend/Retract Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.8.4 Frame Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.8.5 Stabil-TRAK Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.8.6 Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.8.7 Attachment Tilt and Slave Cylinder Circuit . . . . . . . . . . . . . . . . 9-48
9.8.8 Joystick Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54
9.8.9 Auxiliary Hydraulics Circuit (optional) . . . . . . . . . . . . . . . . . . . . 9-60
9.9 VALVES AND MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64
9.9.1 Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64
9.9.2 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
9.9.3 Auxiliary Function Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-80
9.9.4 Joystick Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-81
9.9.5 Pilot Select Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-82
9.9.6 Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
9.9.7 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
9.9.8 Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-84
9.9.9 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-85
9.10 CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-86
9.10.1 Attachment Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-87
9.10.2 Slave Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90
9.10.3 Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94

Model 3606 • Origin 10/99 9-1

 Section 9

9.10.4 Hoist/Lower Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-97

9.10.5 Frame Tilt and Stabilizer Cylinders . . . . . . . . . . . . . . . . . . . . . . 9-100
9.10.6 Swing Carriage (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-106
9.10.7 Side Tilt Carriage Cylinder (optional) . . . . . . . . . . . . . . . . . . . . 9-112
9.10.8 Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-116
9.11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-117

Introduction

The hydraulic system consists of fluid, a reservoir, filters, The number one cause of hydraulic component failure is
the gear pump, numerous valves, cylinders and other contamination. Thus, cleanliness and filtration are of the
components that provide vehicle operation and function, utmost importance. Keep the hydraulic fluid as clean as
plus a fluid cooler and all of the related lines, connectors possible to help avoid downtime and repairs.
and hoses. Hydraulic functions are actuated through
interface with electrical system components (such as Dirt and other contaminants that enter the system will
switches, solenoids and sensors); therefore, when a wear away at precision components, ultimately resulting
hydraulic system malfunction is suspected, also consider in their failure. Sand, grit and other contaminants can
the electrical aspect of the particular circuit in question. damage the finely machined surfaces within hydraulic
For further information on electrical components, refer components. Keep the fluid clean and filtered. If
to Section 10 Electrical System in this manual. operating in an exceptionally dirty environment, change
filters and inspect the fluid more often.
The text in this section discusses each hydraulic circuit
and its components, as well as component function and When servicing the system, protect system components
replacement. Comprehensive circuit schematics and from airborne contaminants. Cap or plug hydraulic
exploded view illustrations are used to represent fittings, hoses and tube assemblies. Plug all cylinder
component operation and to aid in performing ports, valves, and the hydraulic reservoir and pump
procedures. A troubleshooting table appears at the openings until installation occurs. Protect threads from
conclusion of this section. contamination and damage.

9-2 Model 3606 • Origin 10/99

 Hydraulic System

General Overview

FRONT ALE ATTACHMENT

TILT
CYLINDER

AUILIARY
COUPLERS
(OPTION)

L R

STEER
CYLINDER

T
BRAKE
VALVE IN
LS

MAIN PUMP

FRAME
TILT UNLOADER
CYLINDER IN VALVE
LS
AUX
P T
R P A B
PRIM

L T
BYPASS STEER
SELECT
VALVE
POER ETEND HYDRAULIC RESERVOIR
STEERING CYLINDER
UNIT
HYDRAULIC
E R
OIL COOLER

JOYSTICK
1 2
T
P
4 3

OPERATORS CAB HOIST

CYLINDER

T
P
PS PBG
L R PSG PB
PP PPG

AUILIARY
FUNCTION
MANIFOLD
RIGHT
LEFT R R SLAVE
SLAVE CYLINDER
CYLINDER
E E
FTR

STEER
CYLINDER
T
P

STABIL-TRAK
CYLINDER

REAR ALE

AU 2
5 6

FORK TILT
RELEASE
IN VALVE
FRAME
FORK
TILT

TILT

ETEND

FRAME TILT
HOIST

ETEND
MAIN
HOIST
CONTROL OUT IN
VALVE

AU 1 A B

PILOT
SELECT
MANIFOLD (OPTIONAL)
AUILIARY
HYDRAULICS
VALVE

VALVE PLATE ASSEMBLY MS1860

Figure 9–1. Major hydraulic system components.

Model 3606 • Origin 10/99 9-3

 Section 9

9.1 SAFETY INFORMATION Hydraulic system maintenance will, at times, require that
the engine be operated. Always follow safety precau-
General tions.

Petroleum-based hydraulic fluids are used in this vehicle.

Temperature increases occur to hydraulic fluid during Manually-operated
operation of various hydraulic functions. A heated petro- Release Valve
leum-based hydraulic fluid presents a considerable fire (for OPTIONAL
hazard, especially when an ignition source is present. Auxiliary Hydraulics)
Hydraulic fluid has a flash point that ranges from 300° to
600° F (150° to 318° C) and an auto-ignition temperature
of 500° to 750° F (262° to 402° C).
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully
examine any deterioration and determine whether any
further use of the component would constitute a hazard.
OS0360
If in doubt, replace the component.
Figure 9–2. Pull the knob on the manually-operated
WARNING: Hot hydraulic fluid can cause release valve located at the rear of the frame to relieve
severe burns. Wait for hydraulic fluid to cool pressure in the auxiliary hydraulic system.
before servicing any hydraulic component.
9.2 SPECIFICATIONS
WARNING: Escaping hydraulic fluid under
pressure can penetrate the skin, causing seri- Refer to Section 2 General Information, Specifications
ous injury. Relieve hydraulic pressure before and Maintenance Instructions for hydraulic system speci-
servicing any hydraulic component. fications.

Note: Residual pressure may remain in hydraulic 9.3 HYDRAULIC PRESSURE DIAGNOSIS
cylinders, hoses, valve bodies, components, etc. If the
Just as vehicle maintenance cannot be performed
hydraulic lines going to or from a component are taught,
without the proper tools and other equipment, hydraulic
slowly, carefully relieve (“bleed off”) pressure.
system maintenance and problem diagnosis cannot be
To relieve hydraulic pressure: properly performed without a hydraulic pressure
On units equipped with AUXILIARY HYDRAULICS, diagnostic kit (Fig. 9–3) and flowmeter kit (Fig. 9–4).
PULL the knob on the manually-operated release valve Sky Trak offers these kits, which include all of the neces-
located at the rear of the frame (Fig. 9–2) beneath the sary fittings, couplers, hoses, gauges and laminated
rear cover. The pressure in the auxiliary system should guide sheets to test hydraulic system pressures and flow
be relieved. The pull knob on the valve is spring loaded rates on Sky Trak vehicles.
and will return when released.
The quick couplers can now be connected or
disconnected between the attachment and the vehicle.
For ALL units, when attempting to disconnect a hydraulic
line, coupler, fitting, or other component, SLOWLY
loosen the part involved. A hissing sound or slow
seepage of hydraulic fluid may occur in most cases. After
the hissing sound has ceased, continue removing the
part. Cap or otherwise block off the part to prevent further
fluid seepage. Wipe up any hydraulic fluid.
WARNING: Risk of severe personal injury. MS1900 MS2040

Before starting the engine, verify that all Figure 9–3. Hydraulic pressure diagnostic kit.
hydraulic connections are properly tightened
and that all tools are removed from the vehicle. Contact Sky Trak or the nearest Sky Trak distributor for
ordering information.

9-4 Model 3606 • Origin 10/99

 Hydraulic System

In general, follow the steps below whenever conducting

pressure checks and performing adjustments:
1. Park the vehicle on a firm, level surface. Engage the
park brake, place the travel select lever in NEUTRAL
(N), level the boom and turn the engine OFF.
2. Pressure tee fittings are conveniently located in each
hydraulic circuit. Install a pressure gauge capable of
measuring at least 10% more pressure than that
which the circuit being checked operates under.
If the vehicle is equipped with optional auxiliary
hydraulics, relieve pressure by pulling the manually-
MS2120 MS2130
operated release valve handle (Fig. 9–2).
Figure 9–4. Flowmeter hydraulic diagnostic kit.
WARNING: Avoid prolonged engine operation
9.3.1 Pressure Checks and Adjustments in closed areas with inadequate ventilation.
Failure to properly ventilate exhaust fumes can
When diagnosing trouble in the hydraulic system, use the
result in death or severe personal injury.
hydraulic testing information on the pages 9-6 and 9-7.
Note: Duplicate pages have been provided on pages 9-8 3. Start the engine. Operate vehicle functions several
through 9-11 in the event the technician needs the infor- times to allow hydraulic oil to reach operating
mation for field use or to laminate and store elsewhere. temperature. The hydraulic oil temperature should be
between 100 and 120° F (38 and 49° C). If a
Keep in mind that what may at first seem to be a hydrau- temperature gauge or thermometer is unavailable,
lic problem could actually be a mechanical or electrical the hydraulic oil reservoir should be warm to the
problem. The true cause of the trouble must be diag- touch.
nosed and cured, or the problem will recur.
4. Refer to Pressure Test Procedures on page 9-7.
The following specifications are important to consider
5. Fully depress the accelerator pedal as required.
when conducting pressure checks and adjustments:
Place and hold the joystick in the position needed to
• In the boom hoist/lower cylinder, the operate the particular vehicle function being checked.
counterbalance valve in the base end of the Continue holding the joystick in position until
cylinder is rated at 4000 psi (276 bar). pressure readings are taken.
• The pop-off emergency relief valve port relief built 6. Check the pressure gauge reading. It should read as
into the working section of the main control valve is specified in the Pressure Readings column on page
rated at 3750 psi (258,75 bar). 9-7. If the reading is not as specified, turn the engine
• If system pressure exceeds 3500 psi (241,5 bar), OFF and check other components in the system.
the main relief valve will open, allowing oil to return Verify that all related hydraulic components and
to the reservoir. electrical switches, sensors, solenoids, etc. are
operating correctly.
• If the return filter becomes plugged, hydraulic oil will
bypass the filter when pressure reaches 25 psi 7. As a last resort, adjust the appropriate relief valve, if
(1,725 bar). applicable. Turning the adjustment screw clockwise
will increase the pressure; turning the screw
counterclockwise will decrease the pressure
WARNING: Avoid prolonged engine operation
in closed areas with inadequate ventilation.
Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.

8. Start the engine and check the pressure again. Turn

the engine OFF, pull the manually-operated release
valve handle on units equipped with the optional
auxiliary hydraulic system, then disconnect or
remove the pressure gauge from the vehicle.

Model 3606 • Origin 10/99 9-5

 Section 9

FRONT AXLE ATTACHMENT

TILT
7
CYLINDER

AUXILIARY
COUPLERS

L R

STEER
CYLINDER

T
1
BRAKE
VALVE IN
LS

MAIN PUMP

6
FRAME
TILT 2 UNLOADER
CYLINDER IN VALVE
LS
AUX
P T
R P A B

PRIM
L T

BYPASS
STEER
SELECT

POWER EXTEND 2a HYDRAULIC RESERVOIR

VALVE

STEERING CYLINDER
UNIT
HYDRAULIC
E R
OIL COOLER

JOYSTICK
1 2
T
P
4 3
3a 4a
OPERATOR'S CAB HOIST
CYLINDER

T
P
PS PBG
4
L R PSG PB
3 PP PPG

5 AUXILIARY
MANIFOLD
RIGHT
LEFT R R SLAVE
SLAVE CYLINDER
CYLINDER
E E
FTR

STEER
CYLINDER
T
P

STABIL-TRAK
CYLINDER

REAR AXLE

2b
AUX 2
5 6
RELEASE
FORK TILT
IN VALVE
FRAME

EXTEND
FORK
TILT

TILT

FRAME TILT
HOIST

EXTEND
2
MAIN
HOIST
CONTROL OUT IN
VALVE

AUX 1 A B

PILOT
SELECT
MANIFOLD (OPTIONAL)
AUXILIARY
HYDRAULICS
VALVE

VALVE PLATE ASSEMBLY

MS1011

9-6 Model 3606 • Origin 10/99

 Hydraulic System

3606 HYDRAULIC TESTING

Engine Information Equipment Needed To Perform Tests
Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm From Hydraulic Diagnostic Test Kit
Full Speed . . . . . . . . . . . . . . . . . . . . . . 2,750 ± 50 rpm
Circuit Gauge Fittings
Hydraulic Oil Information 4,000 PSI Gauge Unit equipped with fittings from factory.
Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46 1 2 3 (275,6 bar)
Capacity - Reservoir . . . . . . . . . . .32.2 gal. (114,7 liter)
Capacity - System . . . . . . . . . . . .59.5 gal. (225,2 liter) 1,000 PSI Gauge
Note: To adjust relief settings or pressure reducing 4 (68,9 bar)
settings, turn the adjustment screw clockwise to
increase pressure or counterclockwise to decrease 1,000 PSI Gauge
pressure. 5 (68,9 bar)

The hydraulic oil temperature for the pump flow test 1,000 PSI Gauge
should be between 100° F (38° C) and 120° F (49° C) 6 (68,9 bar)
(tank hot to the touch) during testing.
4,000 PSI Gauge Requires a male or female quick-
7 (275,6 bar) disconnect coupler with test fitting.

TEST
LOCATION
Hydraulic Pump Flow Test
To check flow readings a flow meter capable of measuring 60 gpm (3,8 ltr/sec) and a load valve capable of
6,000 psi (413,4 bar) will be required (not included with Hydraulic Diagnostic Test Kit).
1
2,000 psi (137,8 bar) load @ Engine Speed of 2,500 ± 25 rpm — Flow rate should be 28 to 32 GPM (1,8 to 2,0 ltr/sec)
STANDBY PRESSURE 250 to 350 psi (17,25 to 24,15 bar) at idle.
2

TEST ADJUST. COMPONENT PRESSURE

PRESSURE TEST PROCEDURES
LOCATION LOCATION DESCRIPTION READINGS
Unloader Valve Main System Relief With engine at FULL throttle, use control lever (“joystick”) to
2 2a 3,500 ± 100 psi lower boom fully. Hold over relief. Check readings. If incorrect,
(241,3 ± 7 bar) adjust or replace cartridge.
Main Control Valve Extend Base With engine at FULL throttle, use control lever (“joystick”) to
Port Relief extend boom fully. Hold over relief. Check readings. If incorrect,
2 2b 3,200 ± 100 psi adjust or replace cartridge.
(220,6 ± 7 bar)
Attachment Tilt 3,700 ± 100 psi CONSULT FACTORY
2 N/A Relief/FORWARD or (255 ± 7 bar)
REARWARD
Auxiliary Manifold Steering Relief With engine at FULL throttle, turn the steering wheel all the way
3 3a 2,500 ± 100 psi to one direction and hold while checking pressure. If pressure
(172,3 ± 7 bar) is not correct, adjust or replace the pressure-reducing cartridge.
Auxiliary Manifold Park Brake Release With engine at idle, switch Park Brake to disengaged position
4 N/A 450 - 700 psi with secondary function held over relief. Check pressure.
(31,0 - 48,2 bar)
Auxiliary Manifold Pilot Pressure With engine at FULL throttle, move joystick to boom retract position.
5 4a 550 ± 100 psi Hold joystick to over relief and check pressure. If pressure is
(37,9 ± 7 bar) not correct, adjust or replace the cartridge in the auxiliary manifold.
Brake Valve 300 psi minimum With engine OFF, depress and hold brake pedal. If pressure is
6 N/A (Manual Brake (20,7 bar) incorrect, check for external leaks. If no leaks are found, refer
Pressure) to service manual brake system information.
Brake Valve 400 psi minimum With engine at idle, depress and hold brake pedal. DO NOT
6 N/A (Service Brake (27,6 bar) turn steering wheel. Check pressure. If pressure is not correct,
Pressure) consult service manual.
Auxiliary With engine at full throttle, auxiliary button on joystick
3,500 ± 100 psi depressed and held, move joystick left or right. Hold joystick to
7 (241,3 ± 7 bar) over relief and check pressure. If pressure is not correct, check
unloader pressure per 2 . If 2 is ok check port reliefs in
aux. valve (consult Factory).

Model 3606 • Origin 10/99 9-7

 Section 9

9.4 HYDRAULIC FLUID

General information and specifications pertaining to • Contamination
hydraulic fluid are found in Section 2 General Informa- Contamination, or dirt, can be any material other than
tion, Specifications and Maintenance Instructions. hydraulic fluid that causes harm or decreases the perfor-
Use only clean, filtered fluid in the hydraulic system. mance of the system. Contaminants include solids, liq-
After servicing or replacing a hydraulic system compo- uids, and gasses. Most contaminants are abrasive in
nent, cycle all vehicle functions several times to remove nature, causing rapid wear or damage to the system.
(purge or “bleed”) air from the hydraulic system. DO NOT • Excessive heat
build maximum pressure at the end of stroke by continu- Excessive heat is a relative thermal condition that effects
ing to hold the joystick function. fluid viscosity. Extreme operating conditions, such as
Inspect the hydraulic system and fluid frequently, and be excessive operation, outside air temperature, and factors
vigilant for problems or conditions including the following: including aeration, cavitation, contamination and over-
• Aeration pressurization can cause fluid and component tempera-
tures to go beyond their specified limits. Excessive heat
Aeration is the presence of air bubbles in hydraulic fluid. causes oxidation in hydraulic fluid to occur more rapidly,
Sudden, violent inward collapse of the air (known as breaking down its viscosity. A chain reaction then results,
implosion) can occur when compressed air bubbles are and can lead to component damage or failure. The true
subjected to system pressure. Aeration can thus lead to cause of an excessive heat condition must be diagnosed
damage and overheating of components. and cured, or the problem will recur.
Pump aeration will produce a loud crackling sound, as • Implosion
though rocks or marbles were being forced through the
pump. Excessive aeration will give the hydraulic fluid a An implosion is a sudden, violent inward collapse, and
cloudy or milky appearance, and cause erratic operation can often cause a vacuum effect. Imploding air bubbles
of hydraulic system components. within a hydraulic system can cause component damage.

Aeration is caused by air being introduced into the sys- • Over-pressurization

tem, possibly through a leaky seal or joint in the pump or Over-pressurization is, simply, pressure greater than that
elsewhere in the system. Check for leaky hydraulic cylin- for which a component was engineered to withstand or
ders and threaded fittings; introduction of a special dye, operate under. Over-pressurization can cause equipment
visible under fluorescent light, may be helpful in deter- damage. DO NOT attempt to adjust or tamper with pres-
mining the source of the leak. sure cartridges, settings, etc., unless otherwise specified.
• Cavitation • Viscosity
Cavitation occurs when hydraulic fluid fails to entirely fill Viscosity is the property of a fluid or semi-fluid that
an existing space. Cavitation, like aeration, can produce enables it to develop and maintain shearing stress
a loud crackling sound, as though rocks or marbles were dependent upon flow rate (velocity), and to offer contin-
being forced through the system. Cavitation can be due ued resistance to flow. In other words, viscosity is a mea-
to a low hydraulic oil level in the reservoir, a restricted surement of a fluid's resistance to flow (internal friction).
intake line, or improperly high fluid viscosity.

9-8 Model 3606 • Origin 10/99

 Hydraulic System

9.5 HOSES, TUBE LINES, FITTINGS, ETC. 9.5.1 Hose, Tube, Line and Fitting Replacement
There are numerous hydraulic hoses, tube lines, fittings, Before removing a hydraulic hose or component, always
etc., used on this vehicle. Periodically inspect all of these mark or otherwise label the related parts and the exact
and carefully examine any signs of wear, abrasion and/or location the hose or component is being removed from to
deterioration. Determine whether any further use of the aid in proper re-installation. Hydraulic fluid is a good
component would constitute a hazard. If in doubt, replace cleaner and will, if only inadvertently, remove most liquid-
the component. Conditions including but not limited to the ink type markings, so make sure the mark or label will
following are sufficient for considering replacement: remain intact. Alternative methods to using so-called
“magic” markers, include color-coded tie wraps, number-
a. Any evidence of hydraulic fluid leakage at the surface
tag sets, alpha-numeric stampings or markings, and suit-
of a flexible hose or its junction with the metal and
ably-labeled pieces of tape. Select an appropriate mark-
couplings;
ing method for the conditions and proceed accordingly.
b. Any blistering or abnormal deformation to the outer
NEVER replace a hydraulic hose or other component
covering of a hydraulic hose;
with a part not specifically designed for this vehicle. For
c. Hydraulic oil leakage at any threaded or clamped example, replacing a hydraulic hose rated for use in a
joint that cannot be eliminated by normal tightening 3700 psi (255 bar) circuit with a common garden hose
or other recommended procedures; and/or can result in an exploded garden hose, hydraulic fluid
d. Evidence of excessive abrasion or scrubbing on the spray, and other damage or personal injury. Use only fac-
outer surface of a hose, rigid tube, or hydraulic fitting. tory-approved parts for best performance and safety.
Modification must be made to eliminate the Removal and replacement of hoses, tube lines, fittings,
interference of the elements in contact with one etc., usually involves straightforward procedures. When
another, or to otherwise protect the components from removing a hydraulic hose or other component, be aware
contact with one another. Slightly moving a hose or that O-rings are used throughout the hydraulic system.
adjusting a plastic tie wrap may often be all that is Always replace a used O-ring with a new one.
necessary to eliminate interference; evaluate each
Check all routing of hoses, wiring and tubing for sharp
situation and proceed as required by the individual
bends or interference with any rotating members. Install
circumstances.
appropriate protective devices such as tie wraps and
conduit to help shield hoses from damage. All tube and
hose clamps must be tight.

Model 3606 • Origin 10/99 9-9

 Section 9

9.6 HYDRAULIC RESERVOIR Hydraulic Reservoir Replacement

The hydraulic reservoir (Fig. 9–5) includes the engine In order to remove the hydraulic reservoir, the engine and
mounting crossmembers. The reservoir is secured to the transmission assemblies must first be removed, along
right side of the vehicle frame with 1-8 x 2-3/4" Grade 8 with all brackets, hoses, wiring, etc., Follow the proce-
hex-head capscrews, 1" hardened washers and 1-8 hex- dures for engine and transmission removal in the appro-
lock nuts. priate sections of this manual.

Occasionally, fluid may seep, leak or be more forcefully After the engine and transmission assemblies and all
expelled from the filter head (15, Fig. 9–5) or breather related brackets, hoses, wiring, etc. are removed, the
when system pressure exceeds the rating of the filter hydraulic reservoir must be supported with a suitable
head or breather. If the return filter becomes plugged, device and unbolted from the vehicle frame. Install the
return hydraulic oil will bypass the filter when pressure replacement reservoir and secure it to the vehicle with
reaches 25 psi (1,725 bar) and return to the reservoir 1-8 x 2-3/4" Grade 8 hex-head capscrews, 1" hardened
unfiltered. washers and 1-8 hex-lock nuts (Fig. 9–5). Torque the
nuts to 585 lb/ft (793 Nm).
Carefully examine fluid seepage or leaks from the
hydraulic reservoir to determine the exact cause. A
slightly different breather was installed on vehicles after
Serial Number 10017 to help eliminate potential seepage
problems. Clean the reservoir and note where seepage
occurs, if any does occur.

DANGER: Risk of death or severe personal

injury. NEVER weld in, on, near or around the
hydraulic reservoir. Hydraulic fluid and fumes
can cause the reservoir to explode.

Leaks from a cracked or damaged reservoir require that

the reservoir be removed from the vehicle, flushed
completely with water, and repaired by a certified welder
using approved techniques. If these conditions cannot be
met, the reservoir must be replaced in its entirety. Con-
tact Sky Trak or the nearest Sky Trak distributor should
reservoir welding or replacement be required.

9-10 Model 3606 • Origin 10/99

 Hydraulic System

Slightly different for

some models; consult
14 3606 Parts Manual
15

16 9
14 11 8
6

7
1

4 3

10
12
13 17

Torque to 4-5 lb/ft

(5,4 - 6,8 Nm)

3
2

Frame (ref.)

MS2010
Front of Vehicle

1. Hydraulic Reservoir 10. Sight Gage (includes seals and fasteners)

2. Hex-head Capscrew, Grade 8, 1-8 x 2-3/4" Torque to 4-5 lb/ft (5,4 - 6,8 Nm)
3. Hardened Washer, 1" 11. Inlet Tube Assembly
4. Hex-lock Nut, 1-8 12. Magnetic Drain Plug, 24 ORB
5. Strainer 13. Plug, 8 ORB
6. Gasket 14. Elastic Lock Nut, 5/16-18
7. Breather 15. Filter Head
8. Temperature Switch, 195° F (76° C) 16. Filter Element
9. Oil Pressure Switch, 20 psi (1,4 kPa) 17. Temperature Switch, 95° F (35° C)

Figure 9–5. Hydraulic reservoir/engine mount.

Model 3606 • Origin 10/99 9-11

 Section 9

9.7 HYDRAULIC SYSTEM PUMP 9.7.2 Pump Failure Analysis

The main gear pump (1, Fig. 9–6) is attached to the top The pump is the “heart” of the hydraulic system, and
of the transmission and driven via the pump main shaft whenever there is a problem in the system, the pump
via meshing with an internal transmission gear. almost always is blamed. Yet, pump failure is seldom due
to failure of pump components. Pump failure usually indi-
The pump draws fluid through a 1-1/2" inside diameter
cates another problem in the hydraulic system.
hose via negative displacement, commonly but incor-
rectly referred to as vacuum or suction. According to pump manufacturer statistics, ninety to
ninety-five percent of pump failures are due to one or
Fluid is forced from the pump through a 3/4" inside diam-
more of the following causes:
eter hose to the unloader valve. Hydraulic system pres-
sure begins at the main pump. Various factors are • Aeration
involved in creating the relatively high pressure used in • Cavitation
the hydraulic system. Main pump rpm, controlled via a
• Contamination
transmission idler gear (and dependent on engine rpm),
in addition to the internal pump gears and passageways, • Excessive heat
as well as the differential between pump inlet (1-1/2" I.D.) • Over-pressurization
and outlet (3/4" I.D.) openings, all contribute to pressure
• Improper fluid
supplied to the unloader valve. The unloader valve ulti-
mately regulates maximum system-operating pressure In the event of pump failure, investigate further to deter-
(3500 psi, or 241,5 bar) for various vehicle functions. mine the cause of the problem.

9.7.1 Pump, Unloader Valve and Cooling

Circuit
The pump, unloader valve and cooling circuit are shown
for reference purposes in Fig. 9–6.
Oil cooler replacement instructions are provided in the
appropriate engine section of this manual.

Legend for Pump, Unloader Valve and Cooling Circuit

1. Main Gear Pump 17. Plain Washer, 5/16" 31. Branch Tee, SAE 8 - Str. Thd. ORB x
2. Unloader Valve 18. Plain Washer, 1/2" O-Ring Face Seal
3. Main Gear Pump Gasket 19. Lockwasher, 5/16" 32. Hose, 1/2" I.D. x 28.3" Long
4. T-Bolt Band Clamp 20. Lockwasher, 3/8" 33. Connector, SAE 8 - Str. Thd. ORB x
O-Ring Face Seal
5. Hose, 1-1/2" I.D. x 19" 21. Lockwasher, 1/2"
34. Connector, SAE 6 - Str. Thd. ORB x
6. Hose, 3/4" I.D. x 39" 22. Hex-head Capscrew, 3/8-16 x 1-1/4" O-Ring Face Seal
7. Hose, 3/4" I.D. x 36" 23. Hex-head Capscrew, 1/2-13 x 1-1/2" 35. Hose, 3/4" I.D. x 28"
8. Hose, 3/4" I.D. x 81-1/2" 24. Hex-head Capscrew, 5/16-18 x 3-1/4" 36. 90°, SAE 12 - Str. Thd. ORB x O-Ring
9. Hose, 3/8" I.D. x 89-1/2" 25. Dust Plug Face Seal
10. Flange Half, 1-1/2" 26. Diagnostic Nipple 37. Male Flat-face Tube Connector, w/
11. Flange Half, 3/4" 27. Branch Tee, SAE 6 - Str. Thd. ORB x Inlet Check 8ORB-8FF
12. Flange Half, 1" O-Ring Face Seal 38. Hose
13. O-Ring, 3/4" SF 28. Relief Valve Assembly - Preset at 39. Washer, SAE 5/16"
3500 psi (241 bar) 40. Tie Wrap
14. O-Ring, 1" SF
29. Tee, Swivel Run, SAE 12 - o-ring face
15. O-Ring, 1-1/2" SF seal
16. Connector, SAE 12-16 - Str. Thd. 30. Diagnostic Nipple
ORB x O-Ring Face Seal

9-12 Model 3606 • Origin 10/99

 Hydraulic System

23
21
10 Oil
5 Cooler
15

10

5 Load
3
4 Sense
Port
35
18 34
1 9
21 36
35
23
16 VIEW FROM REAR
38 38
9
6 7 29 37
37

Inlet Tube 22 22 20
20
Assembly 40 11
7
13
9 14
27 12 Auxiliary
40 26
25 8 Function
22 Manifold
20
2 11
20 13
22 32
13
33
11
6
32
31
30 28 Torque to
17 Maximum
25
20 lb/ft.
Load (27 Nm)
Sense
Hydraulic Front Of Vehicle Bypass
Port
Reservoir Port
Primary
Port
2
Aux.
39 Supply
Port
19
Inlet
24 Port

PS0671

Figure 9–6. Pump, unloader valve and cooling circuit.

Model 3606 • Origin 10/99 9-13

 Section 9

9.7.3 Pump Replacement Fig. 9–8. Grind off the tip to fit the notch behind the
main pump shaft seal.
a. Pump Removal
1. Park the vehicle on a firm, level surface, fully retract
all hydraulic cylinders, ground the attachment (if any),
place the travel select lever in NEUTRAL (N), engage
the park brake switch and shut the engine OFF.
WARNING: Hot hydraulic fluid can cause
severe burns. Wait for hydraulic fluid to cool
before servicing any hydraulic component.

2. Unlatch, unlock and open the engine cover. Allow the

hydraulic fluid to cool.
WARNING: Escaping hydraulic fluid under
pressure can penetrate the skin, causing seri- 1/4 INCH
ous injury. Relieve hydraulic pressure before
servicing any hydraulic component. MA0801

Figure 9–8. Seal removal tool.

3. Remove the four 3/8-16 x 1-1/4" hex-head capscrews
(23, Fig. 9–6) and 1/2" lockwashers (21) securing the 3. A bushing installation tool made from A.I.S.I. 8620
1-1/2" flange halves (10) to the pump (1). Remove heat-treated, bearing-quality steel, as indicated in
the inlet hose (5) and SF O-ring (15). Fig. 9–9.
Note: It is not necessary to remove the T-bolt band
clamp (4) and inlet hose (5) from the inlet tube assembly. 3.00 "
4. Disconnect the outlet hose (6) from the connector 1.47 "
(16). Cap the outlet hose to prevent unnecessary
fluid spillage. 0.06 " 0.06 "
32
5. Remove both 1/2-13 x 1-1/2" hex-head capscrews
(23), 1/2" lockwashers (21) and 1/2" plain washers
(18) securing the pump (1) to the transmission. C D
Remove the pump and gasket (3) from the vehicle. 30
Wipe up hydraulic oil spillage.
30

b. Tools Required for Pump Repair

GRIND RELIEF ALLOWABLE
The following tools are required for servicing the pump:
1. A bushing puller made from Collet #33863 of Blind
C 1.054 PLUS 0.000, MINUS 0.002"
Hole Puller Set 981 by Owatonna® Tool Company or D 1.250" DIAMETER
an equivalent puller from another supplier. Modify the MA0811

collet as shown in Fig. 9–7. Figure 9–9. Bushing installation tool dimensions.
0.015" R. MAXIMUM 4. A special steel sleeve made from round steel bar
C
stock, 1-1/4" to 1-1/2" (31,75 to 38,1mm) in diameter
A B by 4-5/8" (117,5mm) as shown in Fig. 9–10. This
sleeve is used to insert the drive shaft through the lip
seal without causing damage.
A 0.980/0.970"
B 0.875/(REF)"
C 0.100/0.090" MA0791

Figure 9–7. Bushing puller.

2. A seal removal tool made by heating the tip of a
quality forged screwdriver and bending it as shown in

9-14 Model 3606 • Origin 10/99

 Hydraulic System

c. General Repair Precautions

1/4" DIAMETER DRILL
THROUGH HOLE 1. To facilitate repair of the pump and before any work is
done, first, read and understand all of the steps used
C RADIUS in the disassembly and assembly instructions.
2. The first requirement of good hydraulic equipment
maintenance is cleanliness. Perform procedures in a
clean area.
3. If it becomes necessary to pry sections apart, be
B extremely careful to avoid damaging the finely-
A machined surfaces. Excessive force used while
prying can result in misalignment and serious
damage to parts.
0.015" X 45° 4. Match-mark the exterior surfaces of any housings
CHAMFER
before separating the components. Use the marks to
return components to their original location during
E assembly.
5. Gears are closely-matched sets which wear in
D together. Keep gears together as sets when
MA0821
removing them from a unit. Handle gears with care to
A 3-3/8" avoid damaging the journals or teeth. Avoid touching
B 4-1/2" gear journals. Always replace matched parts as a
C 9/16" R set.
D 1.065 PLUS 0.000, MINUS 0.002"
E 1.002 PLUS 0.002, MINUS 0.000" 6. To help prevent damage, DO NOT grip machined
surfaces in a vise.
Figure 9– 10. Special steel sleeve dimensions.
7. If parts are difficult to fit together during assembly,
5. A lip seal installation bar, made from round steel bar tap gently with a soft hammer. NEVER use an iron or
stock 1-3/4" (44,45mm) in diameter by 2" (50,8mm) steel hammer to tap parts.
long. Grind the edges slightly to form the tool.
8. NEVER hammer bushings into bores. Use an arbor
6. The following tools will also be required: press and bushing drivers of appropriate sizes to
• arbor press install bushings.
• awl
d. Pump Disassembly (Fig. 9– 11)
• clean, lintless cloths
1. Secure the pump with the pump drive shaft pointing
• metal deburring tool down in a suitable holding device or bench vise if
• machinist's hammer possible. Scribe or otherwise make a mark across
• soft hammer the two pump housings (4 and 13, Fig. 9– 11) and the
gear housing (11) perpendicular to the parting lines
• non-hardening sealant for easy identification and proper alignment during
(Permatex® Aviation Form-A-Gasket No. 3) assembly later.
or equivalent
2. Remove the four capscrews (3) and washers (2) that
• medium-grit Carborundum stone secure the two pump housings (4 and 13) together.
• oil and grease 3. Carefully separate the pump housings (4 and 13)
• snap-ring pliers from the gear housing (11). If it becomes necessary
• scale, 1/32" (0,79mm) to pry the components apart, proceed carefully and
or 1/64" (0,40mm) graduations DO NOT damage the machined surfaces or internal
components. Dowel pins (5) will remain installed in
• small screwdriver most cases; however, DO NOT remove dowel pins
• torque wrench unless they are damaged.
• vise with 8" minimum open spread 4. Remove the square “R” seal (10), channel seals (8),
backup seals (7) and thrust plates (9).

Model 3606 • Origin 10/99 9-15

 Section 9

1 5
6

5 4
5
6
7
9

9 10
11
8
5
6
10

15 16
12

7
6

PF0760
PF0760
14 13
PS0020

Figure 9– 11. Hydraulic system pump.

Legend for Pump

5. Carefully remove the drive and driven gear set (12).
1. Main Pump To help avoid damaging the gears, DO NOT tap the
2. Washer gear teeth together or against other hardened
3. Capscrew surfaces. Keep the matched gears together as a set.
4. PEC Housing 6. Carefully clamp the SEC housing (13) in a vise with
5. Dowel Pin the mounting face down. Remove the lip seal (14)
6. Bushing with a suitable seal removal tool.
7. Back-up Seal
8. Channel Seal e. Pump Cleaning
9. Thrust Plate Clean all pump components with a suitable cleaner such
10. Square “R” Seal as trichlorethylene.
11. Gear Housing
12. Gear Set
13. SEC Housing
14. Lip Seal
15. Seal Kit (includes items 7, 8, 10 and 14)
16. Seal Kit w/Thrust Plates (includes items 7, 8, 9, 10 and 14)

9-16 Model 3606 • Origin 10/99

 Hydraulic System

f. Pump Inspection g. Pump Assembly

1. Inspect internal pump components for wear, damage, 1. Stone all surfaces with a medium grit carborundum
etc. If inner surfaces of the pump do not display an stone or equivalent.
ultra-smooth, polished finish, or are damaged in any
Note: Carborundum is boron nitride (c-BN) with cubic or
way, replace the damaged part. Most often, dirty
“diamond” molecular structure. c-BN is a hard, abrasive
hydraulic fluid causes failure of internal pump seals
composition.
and damage to the polished surfaces within the pump
and other hydraulic system components. 2. If bushings have been removed, deburr the bushing
2. If a dowel (5, Fig. 9– 11) or dowel-mounting hole is bores with fine grit emery cloth.
damaged, replace the dowel or housing as required. 3. Rinse all parts in an approved solvent. Blow dry and
3. Examine thrust plates for wear (9), scoring, erosion, wipe the parts with a clean, lintless cloth before
pitting, discoloration, abrasions or other damage and beginning assembly.
replace if necessary. The thrust plates seal the gear 4. Install new bushings (6) in bores as required. Support
set at the sides. Worn thrust plates allow internal the housings so that they are square and level. Press
slippage (oil bypasses the pump). A maximum 0.002" the bushings into the bores using the special
(0,05mm) of wear is allowable. Check the center of installation tool (Fig. 9– 9) and an arbor press. The
the thrust plates, where the gears mesh together. bushings must be flush with the casting surface after
Erosion at the center of the thrust plates indicates oil installation. Stone and rinse the components as
contamination. Pitted thrust plates indicate cavitation described in steps 1 and 3.
or oil aeration. Discolored thrust plates indicate 5. Coat the outer edge of the new lip seal (14) with a
overheating, probably due to low hydraulic oil level in non-hardening sealant (Permatex® Aviation Form-A-
the reservoir. Gasket No. 3 or equivalent). With the metal side of
4. Examine the gear set (12). Replace the gears as a the lip seal facing up, press the seal into the
matched set if there is any scoring (particularly mounting flange side of the shaft end cover with an
scoring on the gear hubs), grooves or burrs on the arbor press and a suitable lip seal driver. DO NOT
outside edges of teeth, or any nicks, grooves, frets or damage the lip seal. Press the seal into the housing
other damage to teeth surfaces. until the lip is flush with the housing recess. Wipe off
5. If the gear set is replaced (always replace the gears excess sealant.
as a set), the bushings (6) must be replaced. Inspect 6. Place the SEC housing (13), with the transmission-
all bushings for scoring or discoloration and replace if mounting surface down, in a suitable holding device
necessary. Use a bushing puller (Fig. 9– 7) to remove or bench vise if possible.
the bushings. 7. Install new dowels (5) as required. Verify that dowels
6. Examine the housings (4, 11 and 13) and replace if are clean and free of burrs. Gently tap the dowels in
necessary. Place a straight edge across each bore. with a soft hammer.
Attempt to slip a 007" (0,18mm) feeler gauge under 8. Lubricate both new square “R” seals with clean
the straight edge and into the bore. If bore expansion hydraulic oil. Insert the seals into their grooves in
is moderate, 007" (0,18mm) or less, the housing may each side of the gear housing (11).
be reused. If wear or distortion exceeds 0.007"
(0,18mm), replace the housing and examine the gear 9. Place new channel seals (8) into the grooves in both
set (12) and bushings (6) for wear. Replace as thrust plates (9) with the flat side of the seal facing
required. away from the thrust plate (Fig. 9– 11).
Operating pressure pushes the gears against the 10. Place a new backup seal (7) into the grooves in both
low-pressure side of the housing. As the hubs and thrust plates (9) above the channel seals (8).
bushings wear, the bore increases. Excessive bore 11. Install one thrust plate (with channel and backup
expansion in a short period of time indicates seals) into the SEC housing (13) so that the groove in
excessive pressure or oil contamination. If the relief the thrust plate will face away from the gear housing
valve settings are within prescribed limits, check for (11). The flat side of the seal should face down with
shock pressures or tampering. Check an oil sample the relief groove facing the outlet side of the housing.
and the reservoir for dirt.
7. Always use new seals, O-rings, gaskets, etc. to help
ensure proper pump sealing and operation. Replace
all flexible seals, including the square “R” seal (10),
lip seal (14), backup seals (7) and channel seals (8).

Model 3606 • Origin 10/99 9-17

 Section 9

12. Lubricate the gear set (12) with clean hydraulic oil 4. Thread the outlet hose (6) onto the connector (16).
from a filtered source. Slide the gear set into position 5. Prime the pump by filling the pump inlet opening with
within the SEC housing (13). Avoid damaging the lip fresh, filtered hydraulic oil before attaching the inlet
seal (14) when the driven gear passes through the hose (5).
housing. Apply additional oil to the gears after
installation. 6. Place a new 1-1/2" SF O-ring (15) into position over
the opening and secure the 1-1/2" I.D. x 19" long inlet
13. Install the other thrust plate (with channel and with hose (5) with two 1-1/2" flange halves (10), four 1/2"
backup seals) over the gears so that the groove in the lockwashers (21) and four 3/8-16 x 1-1/4" hex-head
thrust plate will face away from the gear housing (11). capscrews (23). Torque the capscrews to 31 lb/ft
The flat side of the seal should face up with the relief (42 Nm).
groove facing the outlet side of the housing.
7. Check all routing of hoses, wiring and tubing for
14. Place the gear housing (11) over the gear set. Align sharp bends or interference with any rotating
the pump housings according to the alignment mark members. All tube and hose clamps must be tight.
made during disassembly. Insert the dowel pins (5) in
the gear housing into the holes in the SEC housing WARNING: Avoid prolonged engine operation
(13). DO NOT pinch the square “R” seal (10). Gently in closed areas with inadequate ventilation.
tap the gear housing around the edges with a soft Failure to properly ventilate exhaust fumes can
hammer as needed to further engage the dowels and result in death or severe personal injury.
to bring the housings together for final seating.
8. Start the engine and run at approximately one-third
15. Place the PEC housing (4) over the gear set. Align to one-half throttle for about one minute without
the pump housings according to the alignment mark moving the vehicle or operating any hydraulic
made during disassembly. Insert the dowel pins (5) in functions.
the PEC housing with the holes in the gear housing
(11). DO NOT pinch the square “R” seal (10). Gently WARNING: Escaping hydraulic fluid under
tap the PEC housing in the center with a soft hammer pressure can penetrate the skin, causing seri-
as needed to further engage the dowels and to bring ous injury. Relieve hydraulic pressure before
the housings together for final seating. servicing any hydraulic component.
16. Install the four capscrews (4, Fig. 9– 11) and washers 9. Inspect for leaks and check all fluid levels. The
(2) that secure the pump housings (4, 11 and 13) hydraulic reservoir oil level must be visible in the sight
together. Tighten the capscrews in a criss-cross gage.
pattern to evenly draw the housing sections together.
Rotate the drive shaft to verify that there is no binding Note: Check for leaks and repair as required before con-
within the pump. After the capscrews are tight and tinuing.
there is no internal binding, torque the capscrews to
specification in a criss-cross pattern. Refer to the i. Pump Pressure Check Test
torque specification chart in Section 2 General Attach a 500 psi (34,5 bar) gauge to the unloader valve
Information, Specifications and Maintenance inlet port. Monitor the pump pressure at the unloader
Instructions. valve. It must exceed 200 psi (13,8 bar) within moments
after starting the engine. Failure to achieve this pressure
h. Pump Installation means that the pump is not properly functioning.
1. Place the pump (1), Fig. 9– 6 and a new gasket (3)
into position on the transmission. Align the pump Checking pump stand-by pressure
gear shaft with the internal transmission gear so that Connect a 1000 psi (69 bar) pressure gage to the pres-
the machined teeth mesh together. sure tap on the inlet of the main control valve center sec-
2. Align the gasket bolt holes with the pump mount tion.
holes. Secure the pump to the transmission with two Start the engine and run at idle. DO NOT operate any
plain 1/2" washers (3), 1/2" lockwashers (21) and functions for at least one minute. Record the system
1/2-13 x 1-1/2" hex-head capscrews (23). Torque the standby pressure while still at idle. It must be 250/350 psi
capscrews to 75 lb/ft (102 Nm). (17,25/24,15 bar).
3. If necessary, slide the T-bolt band clamp (4) onto the
pump inlet hose (5). Secure the hose to the inlet tube
assembly (item 8, P/C 6.11) with the T-bolt band
clamp.

9-18 Model 3606 • Origin 10/99

 Hydraulic System

9.8 HYDRAULIC CIRCUITS

This section describes each hydraulic circuit and The steer select valve is comprised of two electrical sole-
includes, on the following pages, a circuit schematic and noids that act on a spool valve to direct flow to the steer-
a discussion of the hydraulic function involved. ing cylinders, providing steering action.
The hydraulic system consists of several components The service brake valve is comprised of two identical
that operate with each other and in conjunction with the brake valves mounted next to each other in the same
electrical system to produce the desired function via casting. As force is applied to the brake pedal, the valve
input from operator controls or automated vehicle sys- sends oil to the service brakes at pressure that is propor-
tems (such as the patented Stabil-TRAK system). tional to the force that is applied to the pedal.
Components of the hydraulic system include the hydrau- In the manual mode of operation (ignition keyswitch OFF,
lic fluid, reservoir, filters, cooler, pump, unloader valve, engine OFF), the brake valve operates as a two-stage
the main control valve, auxiliary function valve, pilot pump. The first stage pumps a high volume of oil at a rel-
select manifold, joystick control valve, cylinders, steering atively low amount of pressure. The second stage then
select valve, brake valve, steering unit, hoses and fittings. pumps a low volume of oil for higher braking pressure,
The gear pump produces flow of the hydraulic fluid for the ultimately resulting in braking action.
system. When the gear pump is operating, the atmo- The power steering unit consists of a control valve and
spheric pressure condition on the inlet side of the pump metering sections. The control valve section contains
is lower and hydraulic fluid flows from the reservoir, mechanically actuated linear spool that is torsion bar
through a strainer (filter) and hose, to the pump. The centered and is of the open-center type. It directs fluid to
pump sends the fluid through a hose to the unloader and from the metering section and steering cylinders and
valve and from there to various places within the system. regulates the flow supplied to the steering cylinders. The
The unloader valve acts as a pressure regulator and as a metering section of the steering unit consists of a com-
pressure relief for the hydraulic system. mutator and a bi-directional gear-rotor element. It meters
the amount of fluid sent to the steering cylinders.
The main control valve directs flow of fluid to the appro-
priate circuit via spool valve movement. The main control valve contains four working sections,
plus an inlet section, and two end caps. Operating or
The auxiliary function valve contains pressure-reducing working sections for the hoist/lower, extend/retract, frame
valves and a pressure-relief valve to regulate circuit pres- tilt, and attachment tilt circuits are mounted between the
sure in the pilot pressure system, brake system, and end cap sections, forming a valve stack. The main control
steering system. valve directs fluid to and from the various hydraulic cir-
The pilot select manifold contains solenoids which, when cuits.
activated, open passages in the manifold to direct pilot
pressure flow to operate the spool valves in the main
control valve.
The joystick control valve contains four valves that are
activated by moving the joystick, plus a reservoir return
valve. Activated valves result in fluid flow being directed
to the pilot select manifold. The joystick contains switches
that, when pressed, activate solenoids in the pilot select
manifold, producing a combination of functions.

Model 3606 • Origin 10/99 9-19

 Section 9

9.8.1 Brake Circuit b. Service Brake Circuit

The brake system circuit (Fig. 9– 12) includes the park A hydraulic line from auxiliary function manifold port PS
brake and the service brake, along with the auxiliary (Fig. 9– 12) provides flow to the service brake valve when
function manifold, main control valve and various hoses, the engine is running. A reservoir line is installed on the
fittings and other components. service brake valve at port T. There are also lines for the
With the vehicle at rest (ignition keyswitch OFF, engine front wheel brakes, rear wheel brakes, and a shuttle in
OFF), the park brake is ON. line on the service brake valve. Pressure can be checked
at auxiliary function manifold port PSG and at the pres-
The vehicle is designed so that the service brake can be sure tap fitting installed in the rear brake line.
used to stop the vehicle with the engine OFF.
The service brake valve itself is a severe-duty type valve
The the park brake itself is part of the front axle ONLY. used in a variety of agricultural and industrial applica-
The service brakes are contained within both the front tions. The valve actually consists of two identical brake
and rear axles. Refer to Section 5 Axles, Wheels and valves mounted next to each other in the same casting.
Tires for further information. Each valve can operate independently of the other.

a. Park Brake Circuit The service brake valve operates much the same as a
pressure reducing valve in the power mode. As force is
The front axle (only) is equipped with a spring-applied, applied to the brake pedal, the valve sends oil to the vehi-
pressure-released park brake. The park brake operates cle brakes at pressure that is proportional to the force
via two solenoids at the auxiliary function manifold. With that is applied to the pedal.
the engine running and the park brake switch ON, one of
In the manual mode of operation (engine OFF), the brake
the solenoids is normally open and the other is normally
valve operates as a two-stage pump. The first stage
closed. This prevents flow in one direction but allows it in
pumps a high volume of oil up to a low amount of pres-
another. Spring pressure within the front axle engages
sure. The second stage then pumps a low volume of oil
the park brake. Oil is prevented from flowing to the front
for higher braking pressure.
axle and releasing the park brake.
At rest (or “standby”), system pressure exists at the ser-
With the engine running and the park brake switch OFF,
vice brake valve, ready for pedal application.
oil flows from the main hydraulic pump, to the auxiliary
function valve, through the park brake solenoid valve, out
Fluid Flow When Brake Pedal is NOT Pressed
the park brake port PB, to the front axle and to the park
brake section of the front axle. Oil pressure overcomes System pressure from the main pump flows to the
the spring pressure within the front axle, and the park unloader valve, then to the auxiliary function manifold.
brake is released. Oil is prevented from flowing back to From there, the oil is routed out to the brake valve,
the reservoir because of the closed solenoid valve at the located above the brake pedal and beneath the dash.
auxiliary function manifold. With the pedal NOT depressed, the spool valves are
With the engine OFF and the park brake switch OFF, closed and no oil is allowed to flow to the axles.
spring pressure at the front axle engages the park brake.

9-20 Model 3606 • Origin 10/99

 Hydraulic System

FROM
RESERVOIR (“ TANK” ) STEERING UNIT
RETURN LINE
LOAD SENSE OUT TO MAIN SHUTTLE
FROM MAIN CONTROL VALVE CONTROL VALVE VALVE

TO MAIN
CONTROL VALVE

65 T
PSI BYPASS TO TANK
UNLOADER VALVE
3500
PSI

SPOOL RELIEF
VALVE

250
PSI
INLET 2500 RPM
32.5 GPM
4
3.0 IN
25
PSI

0.5 PSI
BRAKE VALVE
5 PSI

TO JOYSTICK

PARK BRAKE
PSG PS PP PPG PB PBG

FRONT WHEEL BRAKE

.090
DIA
REAR WHEEL BRAKE 2500 550
PSI PSI

P
650
PSI
T

AUXILIARY FUNCTION MANIFOLD

MS0090

Figure 9– 12. Brake system circuit schematic.

Model 3606 • Origin 10/99 9-21

 Section 9

Legend for Brake Circuit

1. Service Brake Valve 8. Connector, SAE 6 - Str. Thd. 16. Hose, 3/8” I.D. x 111”
2. 90° Elbow, SAE 6 - Str. Thd. ORB x O-ring face seal 17. 90° Swivel Elbow, SAE 4,
ORB x O-ring face seal 9. Diagnostic Nipple, 9/16-18 O-ring face seal
3. Swivel Run Tee, SAE 6, 10. 90° Elbow, SAE 8 - Str. Thd. 18. Swivel Run Tee, SAE 4,
O-ring face seal ORB x O-ring face seal O-ring face seal
4. 90° Swivel, SAE 6, 11. Hose, 1/2” I.D. x 17” 19. Connector, SAE 8- Str. Thd.
O-ring face seal 12. Hose, 3/8” I.D. x 106” ORB x O-ring face seal
5. Diagnostic Nipple 13. Hose, 3/8” I.D. x 32” 20. Connector, M10-4, Metric Str. Thd.
6. Dust Plug ORB x O-ring face seal
14. Hose, 3/8” I.D. x 136-1/2”
7. Auxiliary Function Manifold 21. Cap, SAE 4 - O-ring face seal
15. Hose, 3/8” I.D. x 81”

9-22 Model 3606 • Origin 10/99

 Hydraulic System

Front of Vehicle

9
T

10 6
7

9
8 12
6 11

Hydraulic Reservoir/Engine Mount

Main Control Valve

2
Rear Axle
19 14
11

11
13
20
12
14 17 13
2 18
1

15
16
13

17 18
17 11 14
13 21
2
20 17 Shuttle Valve
18 (Ref.)
13 20 13
1
15
18 15

3
Front Axle
4
6
Front of Vehicle 5
MS1870

Figure 9– 13. Vehicle brake circuit.

Model 3606 • Origin 10/99 9-23

 Section 9

Rubber Boot

Piston

Plunger

Series Spring Relief Valve

Piston Ring Spool
Metering Notches One-way Orifice

Make-up Check with

Load Sense Spool
MS1880

Figure 9– 14. Cross section of service brake valve.

Fluid Flow When Brake Pedal is Pressed 4. Pressure in both the front and rear axle brake lines is
equal. A groove in each of the two spools opens to a
System pressure from the main pump flows to the
cross-hole between the two spool bores, preventing
unloader valve, to the auxiliary function manifold, to the
uneven brake pressure. This feature is called the
brake valve. With the pedal depressed, spool valves open
equalizer function.
and oil is allowed to flow through the brake valve and out
to the axles. 5. Power-mode braking begins when the metering
notches in the spool meter oil from the inlet port to
Service Brake Valve Operation the spool chamber. Oil flows from the spool chamber,
through the one-way orifice, and into the brake lines.
Valve operation occurs in two modes, Power Mode and Brake pressure is controlled by a force balance
Manual Mode. The steps below describe service brake between the force applied at the pedal and the
valve function in both of those modes. resulting force from pressure in the spool area.
Power Mode 6. The load sense bleed orifice helps provide stability
1. Displacement of the brake pedal is transmitted to the and aids in purging air from the system.
valve at the plunger (Fig. 9– 14).
2. The series spring transmits plunger displacement to Manual Mode
the piston. The series spring also absorbs slight
pedal pressure variations, and helps to provide In the event that hydraulic pressure at the inlet port is too
smoother braking. low to provide the braking force required, the service
brake valve automatically transitions to the manual mode
3. At rest (or “standby”), system pressure exists at the to provide braking power.
service brake valve, and the lines are vented to the
reservoir. The reservoir venting is restricted as pedal Flow paths out of the valve that would rob efficiency are
pressure is applied, causing the piston to contact the automatically blocked in the manual mode. The inlet port
piston sealing ring. The piston is blocked when the check valve seals off the inlet port, and the load sense
fluid return metering notches on the spool are shutoff valve closes. The service brake valve then acts as
covered by the spool bore. a two-stage pump.

9-24 Model 3606 • Origin 10/99

 Hydraulic System

1. Brake pedal displacement is transmitted to the valve 7. Further displacement of the service brake pedal
at the plunger (Fig. 9– 14). causes higher pressure in the spool chamber. The
2. The series spring transmits plunger displacement to load sense pin in the make-up check device is
the piston. sensitive to the increased pressure and transmits a
force to the relief ball. The increasing force on the
3. The piston and spool, functioning as pumps, send oil relief ball effectively lowers the relief setting within the
to the brake lines. Initially, the brake lines are vented piston chamber. Eventually, piston chamber pressure
to the reservoir by an annular gap between a reaches zero, and the valve has moved completely
stepped-down piston diameter and the piston bore. from the first stage to the second stage. The smaller
Flow to the reservoir is restricted when the piston area of the second stage permits the brake valve to
contacts the piston sealing ring. develop higher braking pressure.
4. Volume generated by piston displacement causes the 8. Controlling the force applied to the service brake
spool make-up check device to unseat. Oil flows into pedal controls the amount of braking power.
the spool chamber and out to the brake lines.
9. If the first application of force applied to the service
5. Pressure in both the front and rear axle brake lines is brake pedal was not enough to deliver the braking
equal. A groove in each of the two spools opens to a required, the one way orifices at the work ports help
cross-hole between the two spool bores, preventing give the brake valve “pump up” ability. The one-way
uneven brake pressure. This feature is called the orifices allow unrestricted flow to the brake lines but
equalizer function. also restrict the rate of decompression.
6. At a set piston chamber pressure, a relief valve
begins to meter oil and limits the pressure within the
piston chamber. The pressure in the piston chamber
becomes isolated from the pressure in the spool
chamber when the make-up check device reseats
itself.

Model 3606 • Origin 10/99 9-25

 Section 9

9.8.2 Boom Hoist/Lower Circuit b. Lower Circuit

When the joystick is in the boom lowering position, pilot
a. Hoist Circuit
pressure shifts the hoist/lower spool valve (Fig. 9– 15) in
With the joystick in the boom lift position, pilot pressure the directional control valve to direct system pressure
shifts the hoist/lower spool valve (Fig. 9– 15) in the direc- through ports A-D, through the flow compensator. Oil is
tional control valve to direct system pressure to ports A-D then directed through ports F-B to the rod end of the
through E-B and through the check valve to the base end hoist cylinder. System pressure also pilots open the
of the hoist cylinder. counterbalance valve in the hoist cylinder.
Return oil from the rod end of the cylinder flows through The open counterbalance valve allows return oil from the
ports C-F of the spool valve to the return filter and then to base of the cylinder to flow to ports C-E of the directional
the hydraulic fluid reservoir (Fig. 9– 16). control valve, to the return filter and then to the hydraulic
• If system pressure exceeds 3500 psi (241,5 bar), fluid reservoir (Fig. 9– 16).
the main relief will open, allowing oil to return to the • If system pressure exceeds 3500 psi (241,5 bar),
reservoir. the main relief will open allowing oil to return to the
• If the return filter becomes plugged, return hydraulic reservoir.
oil will bypass the filter when pressure reaches 25 • If the return filter becomes plugged, return hydraulic
psi (1,725 bar) and return to the reservoir unfiltered. oil will bypass the filter when pressure reaches 25
psi (1,725 bar) and return to the reservoir unfiltered.
The counterbalance valve in the boom hoist cylinder
serves another main function for safety purposes. This
CBACBACBA
function can be described as follows:
HOIST/LOWER CYLINDER Should any of the hydraulic lines routed to the hoist cylin-
der fail, there will be a loss of hydraulic system pressure
FED FEDFED
4000
PSI
BASE END
to the cylinder. For example, if a hydraulic line failure
X X INLET
occurred in the pressurized lowering line during lowering,
the counterbalance valve would lose pilot pressure, clos-
ROD END HOIST/LOWER SPOOL VALVE
(Part of Main Control Valve)
ing off flow returning to the reservoir. The oil in the base
end of the cylinder would then be trapped, which would
RESERVOIR
PILOT SELECT MANIFOLD
immediately stop boom lowering and prevent an elevated
load from falling to the ground uncontrolled.
LOAD SENSE OUT
MS1890
The load can be lowered safely to the ground by following
Figure 9– 15. Hoist/lower spool valve schematic. the Emergency Boom Lowering procedures in Section 3
Boom of this manual.
IMPORTANT: DO NOT attempt to reset the counterbal-
ance valve cartridges. In the event that the counterbal-
ance valve cartridges were disabled for emergency boom
lowering, or if any unauthorized adjustments are ever
made to these cartridges, remove and replace both car-
tridges with new parts. Failure to replace these cartridges
with new parts may alter the holding characteristics of the
counterbalance valves, creating an unsafe condition for
vehicle operation.

9-26 Model 3606 • Origin 10/99

 Hydraulic System

HOIST/LOWER CYLINDER

4000 HOIST/LOWER
PSI SOLENOID VALVE
(Part of Pilot Select Manifold)
X X
a b B A

1 3
FWD. BACK
TANK JOYSTICK

LOAD SENSE
OUT
T

HOIST/LOWER
SECTION
(Part of Main Control Valve Assy)

INLET

PSG PS PP PPG PB PBG

BYPASS TO TANK
65 UNLOADER VALVE
PSI
3500
PSI
.090
DIA
RELIEF 2500 550
SPOOL VALVE PSI PSI

250
PSI
P
INLET 2500 RPM 650
32.5 GPM PSI
4
25 3.0 IN T
PSI
AUXILIARY FUNCTION MANIFOLD
0.5 PSI

5 PSI
MS0020

Figure 9– 16. Boom hoist/lower hydraulic circuit schematic.

Model 3606 • Origin 10/99 9-27

 Section 9

9.8.3 Boom Extend/Retract Circuit

Hydraulic flow is applied in the boom extend/retract cir- c. Retract Position
cuit (Fig. 9– 17 and Fig. 9– 18) by the hydraulic gear
When the joystick is in the boom RETRACT position, the
pump. System pressure is directed to either side of the
extend/retract spool valve (Fig. 9– 17) is shifted by pilot
extend/retract cylinder by the shifting of the spool valve in
pressure so that system pressure is directed through
the directional control valve of the main control valve. The
ports A-D, then F-B of the spool valve, to the rod end of
spool valve is shifted by pilot pressure, regulated by the
the extend/retract cylinder. The counterbalance valve is
position of the joystick.
piloted open by high pressure, allowing return oil from the
base end of the cylinder to flow through ports C-E of the
a. Center Position
spool valve to the return filter and the reservoir. If system
When the joystick is in the center or NEUTRAL (N) posi- pressure reaches 3500 ± 50 psi (241,5 ± 3,5 bar), the
tion, the extend/retract spool valve (Fig. 9– 17) in the main main relief valve opens, allowing hydraulic oil to return to
control valve is centered so system pressure cannot flow the reservoir.
through the ports to the cylinder. No boom movement PILOT SELECT
occurs with the joystick in the center position. MANIFOLD
RETRACT PORT 12
b. Extend Position EXTEND/RETRACT
RESERVOIR CYLINDER ROD END
When the joystick is in the boom EXTEND position, the SHUTTLE IN EXTEND/RETRACT
spool valve (Fig. 9– 17) is shifted by pilot pressure so flow CYLINDER BASE END
is directed through extend/retract spool valve ports A-D, INLET
LOAD SENSE
then E-B, through the check valve to the base end of the OUT
EXTEND PILOT SELECT
extend/retract cylinder. If system pressure exceeds 3200 MANIFOLD PORT 11
± 50 psi (220,8 ± 3,5 bar), the extend port relief will open
and allow hydraulic oil to return to the reservoir.
Return oil from the rod end of the cylinder attempts to exit
through the counterbalance valve. The counterbalance
valve is piloted open by high oil pressure and oil will pass F C
from the cylinder to ports C-F of the spool valve to the
return filter and the reservoir. E B
D A
If the return filter is plugged, the oil returning to the reser-
voir bypasses the filter when the filter's internal pressure F C
reaches 25 psi (1,725 bar).
E B
D A
F C
E B
D A

MS1910

Figure 9– 17. Extend/retract spool valve schematic.

9-28 Model 3606 • Origin 10/99

 Hydraulic System

EXTEND/RETRACT CYLINDER
1 PILOT SELECT MANIFOLD

2
4000
PSI
RETRACT EXTEND
4000
PSI
12 11

3750 3200
PSI PSI
2 4
LEFT RIGHT
TO RESERVOIR
JOYSTICK

LOAD SENSE OUT

P T
SHUTTLE IN
RETRACT

EXTEND

INLET

PSG PS PP PPG PB PBG

BYPASS TO TANK
65 UNLOADER VALVE
PSI .090
3500 DIA
PSI 2500 550
PSI PSI

RELIEF
SPOOL VALVE
P
250 650
PSI PSI
T
INLET 2500 RPM
32.5 GPM
4
AUXILIARY FUNCTION MANIFOLD
3.0 IN
25
PSI

0.5 PSI

5 PSI
MS0040

Figure 9– 18. Extend/retract hydraulic circuit schematic.

Model 3606 • Origin 10/99 9-29

 Section 9

4
Port “ R” 8
(retract)
4
8

Port “ E”
(extend)

Extend/Retract
Cylinder

1 5

2
Bulkhead
4
(ref.)
4
7
6 2
3 7
8
6
5
3
3

Main Control
5 Valve
3

Hoist/Lower
Cylinder Front of Vehicle

Legend
Lower
Hoist
1. Hose, 3/4” I.D. x 21-1/2”
2. Hose, 3/4” I.D. x 27”
3. Hose, 3/4” I.D. x 45”
4. Hose, 3/4” I.D. x 36”
Extend Retract
5. 90° Elbow, SAE 12 - Str. Thd.
ORB x O-Ring Face Seal
6. Bulkhead Nut, SAE 12
O-Ring Face Seal
7. Bulkhead Connector, SAE 12
O-Ring Face Seal
8. Connector, SAE 12 - Str. Thd.
ORB x O-Ring Face Seal

Directional Control Valve Ports

PS0690
Figure 9– 19. Hoist/lower and extend/retract components.

9-30 Model 3606 • Origin 10/99

 Hydraulic System

d. Extend/Retract Cylinder Counterbalance Valve

The extend/retract cylinder (Fig. 9– 19) includes two Example: If there was a hydraulic line failure in the
counterbalance valves (Fig. 9– 20). The valves serve two pressurized retract line during retracting, the
main functions. One of the functions is to help prevent counterbalance valve would lose pilot pressure,
component damage. closing off flow returning to the reservoir. The oil in
The other counterbalance valve function can be the base end of the cylinder would then be trapped,
described as follows: which would immediately stop boom retraction,
preventing an elevated load from uncontrolled
• If the vehicle is travelling and the boom runs into a retraction. The load can be lowered safely to the
solid object, pressure will build up on the base end ground by following the Emergency Boom Lowering
of the cylinder. Without a counterbalance valve, the procedures in Section 3 Boom of this manual.
cylinder rod would bend, damaging the cylinder.
With the counterbalance valve installed, the
pressure will build up until it reaches 4000 psi (276 IMPORTANT: DO NOT attempt to reset a counterbal-
bar) and then the counterbalance valve will be ance valve cartridge. In the event that a counterbalance
internally piloted open, allowing the pressure to valve cartridge was disabled for emergency boom lower-
return to the reservoir. This condition will only exist ing or any unauthorized adjustments are ever made to
if the cylinder has been extended. If the cylinder is this cartridge, remove and replace the cartridge with a
already fully retracted, the counterbalance valve will new part. Failure to replace this cartridge with a new part
have no effect and damage can result. may alter the holding characteristics of the counterbal-
ance valve, creating an unsafe condition for vehicle oper-
• Should any of the hydraulic lines going to the ation.
extend/retract cylinder (Fig. 9– 19) fail, there will be
a loss of hydraulic system pressure to the cylinder.

Counterbalance
Valves
(set at 4000 psi,
or 276 bar)
Extend/Retract
Cylinder

Front of Vehicle
MS2230

Figure 9– 20. The extend/retract cylinder counterbalance valves serve two main functions.

Model 3606 • Origin 10/99 9-31

 Section 9

9.8.4 Frame Tilt Circuit

PILOT SELECT
a. Frame Tilt LEFT MANIFOLD
PORT 9
With the two frame tilt select buttons on the joystick FRAME TILT CYLINDER
depressed and held, and the joystick moved to the left, RESERVOIR PORT “FTB”
the spool valve in the frame tilt directional control valve SHUTTLE IN STABIL-TRAK
(Fig. 9– 21) of the main control valve assembly (see 2 GPM MANIFOLD PORT “V”
Fig. 9– 22) is shifted by pilot pressure. System pressure is MAX INLET
LOAD SENSE
directed to ports A-D (Fig. 9– 21), then B-F of the spool OUT PILOT SELECT
valve (in the main control valve), and from there to the MANIFOLD PORT 10
base end of the frame tilt cylinder. Oil from the rod end of
the frame tilt cylinder flows through a check valve,
unseated by system pressure, to the stabilizer cylinder,
through the solenoid valve, back to the spool valve
through ports E-C to the return filter and the reservoir.
F C
b. Frame Tilt RIGHT E B
D A
With the two frame tilt select buttons on the joystick
depressed and held, and the joystick moved to the right, F C
the spool valve in the frame tilt directional control valve of
E B
the main control valve assembly is shifted by pilot pres-
sure. D A

System pressure is directed to ports D-A then B-E of the F C

spool valve (Fig. 9– 21), then to the stabilizer cylinder, E B
through the solenoid valve, back to the frame tilt cylinder, D A
where it flows to the rod end of the cylinder. Oil from the
base end of the cylinder flows through the check valve,
which was unseated by system pressure, then to ports
MS1920
F-C of the spool valve, to the return filter and the
hydraulic fluid reservoir. Figure 9– 21. Frame tilt spool valve circuit schematic.

9-32 Model 3606 • Origin 10/99

 Hydraulic System

V FTR G2 G3 FRAME TILT CYLINDER

5 .030” TOP FTB
CYL2
PILOT SELECT MANIFOLD

FTR
STABILI ER
1 3 4 2 CYLINDER

T 100
PSI .060”
10 9

P G1 STABIL-TRAK
MANIFOLD

b a B A

JOYSTICK

RETURN LINE TO RESERVOIR 2 4

LEFT RIGHT
LOAD SENSE
OUT
SHUTTLE
IN

P T

2
GPM
MAX

FRAME TILT

INLET MAIN CONTROL VALVE

65 BYPASS TO TANK PSG PS PP PPG PB PBG

PSI UNLOADER VALVE
3500
PSI
SPOOL

250 RELIEF
PSI VALVE .090
2500 DIA
550
2500 RPM PSI PSI
INLET
32.5 GPM
4
3.0 IN
25
PSI
P
650
FILTER 0.5 PSI PSI
T
5 PSI
RESERVOIR AUXILIARY FUNCTION MANIFOLD
MS0080
Figure 9– 22. Frame tilt and stabilizer hydraulic schematic.

Model 3606 • Origin 10/99 9-33

 Section 9

9.8.5 Stabil-TRAK Hydraulic Circuit Frame Tilt/Stabilizer Legend

a. Stabil-TRAK System 1. Stabil-TRAK Manifold
The patented rear axle lock or Stabil-TRAK system works 2. Dual Pilot Operated Check Manifold
to stabilize the vehicle under various conditions. The SKY 3. Tie Wrap
TRAK Owners/Operators Manual Model 3606 contains 4. Hose, 3/8” I.D. x 158”
basic Stabil-TRAK information; a copy of the owners/ 5. Hose, 3/8” I.D. x 104”
operators manual should always be available in the stor- 6. Hose, 3/8” I.D. x 160”
age compartment beneath the operators seat. 7. Hose, 3/8” I.D. x 93”
The stabilizing system operates via an interface between 8. Hose, 3/8” I.D. x 117”
the boom proximity switch, the park brake, service brake 9. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
and travel select lever hydraulic and electrical circuits, 10. Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
and five solenoid-operated valves on the Stabil-TRAK 11. Swivel Elbow, SAE 6, O-Ring Face Seal
manifold (Fig. 9– 23) mounted on the left side of the rear
12. Lockwasher, SAE 3/8”
axle.
13. Lockwasher, 3/8”
The frame tilt cylinder is also involved in the Stabil-TRAK 14. Grade 8 Hex-head Capscrew, 3/8-16 x 3-3/4”
system, but only passively as hydraulic fluid is cycled to 15. Grade 8 Hex-head Capscrew, 3/8-16 x 4-3/4”
accommodate Stabil-TRAK system operation.
16. Branch Tee, SAE 8 - Str. Thd. ORB x O-Ring Face Seal
The rear axle lock system can only be activated when the 17. 90° Swivel Elbow, SAE 8, O-Ring Face Seal
boom angle is greater than 40 degrees. Any one, any two (w/o Aux. Hyd. option)
or all three of the following selections will activate the Swivel Run Tee, SAE 8, O-Ring Face Seal
system: (w/ Aux. Hyd. option)
• Engaging the Parking Brake Switch 18. Long Connector, SAE 8 - Str. Thd. ORB x O-Ring Face Seal
19. Connector, SAE 6-8 - Str. Thd. ORB x O-Ring Face Seal
• Placing the Travel Select Lever in (N) NEUTRAL
20. Swivel Branch Tee, SAE 16, ORB x O-Ring Face Seal
• Depressing and holding the Service Brake
21. Reducer, SAE 16,
With the boom lowered to an angle of less than 40 O-Ring Face Seal x SAE 8 O-Ring Face Seal
degrees, the rear axle lock system is not active and none 22. Tube Nut, SAE 16, O-Ring Face Seal
of these functions will affect the rear axle lock system. 23. Connector, SAE 16-12 - Str. Thd. ORB x O-Ring Face Seal
24. Hex-head Plug, SAE 4, Male Str. Thd. O-Ring
25. Manifold
FT
R
26. O-Ring
27. Socket-head Capscrew, 3/8-16 x 1-1/2”
Solenoid/circuit
28. Hex-head Plug, SAE 6, Male Str. Thd. O-Ring
numbers
29. Connector, SAE 8-6 - Str. Thd. ORB x O-Ring Face Seal
5 30. 90° Swivel Elbow, SAE 8, O-Ring Face Seal
31. Reducer, SAE 8,
O-Ring Face Seal x SAE 6 O-Ring Face Seal
32. Hex-head Capscrew, 5/16-18 x 1-1/4”
2
33. Lockwasher, 5/16”
1 4 34. Twin Clamp Cover
3 35. Twin Hose Clamp Set, 0.68” I.D.
36. Stacking Bolt, 5/8” Long
37. Stacking Bolt, 1-1/8” Long
38. Locking Plate
39. Twin Hose Clamp Set, 0.78” I.D.
100 psi (7 bar) 40. Grade 8 Hex-head Capscrew, 5/16-18 x 1-1/2”
Pressure-reducing
Valve 41. Tie Wrap
MS1930 42. Loctite® , 0.5 ounce
Figure 9– 23. Stabil-TRAK manifold.

9-34 Model 3606 • Origin 10/99

 Hydraulic System

23 Main Control Valve

(ref.)

8 16
17
20
17
22 18
21

NOTE: With optional Aux.

Hydraulics, a tee replaces the
90° elbow (see item 17).
8
REAR VIEW

11 7
19 4
5 5
7 4
39
41 37
38
35 35
34 36
33 38
32
3 35
4 34
33
40

Front of Vehicle
7
8
6
42 5
6 5
31
6 30
PH0940
Torque to
31 37 lb/ft (50 Nm)
29

4 15
13 14
9 13
27 12
12 25
Apply Loctite
to items 15
FT Apply Loctite to
B

and 24
2 item 14 and
FT
R
torque to
26 24
37 lb/ft (50 Nm) 28 10
7
6
9 8

Frame Tilt Cylinder Stabilizer Cylinder

MS0460
Figure 9– 24. Frame tilt and stabilizer components.

Model 3606 • Origin 10/99 9-35

 Section 9

b. Stabil-TRAK Modes
The function of the Stabil-TRAK system varies under dif- Free Pivot Mode
ferent operating conditions. The basic modes include the (Fig. 9– 25)
free pivot mode (Fig. 9– 25), final positioning mode
• Base Oil OUT
(Fig. 9– 26), and locked mode (Fig. 9– 27). A hydraulic cir-
cuit diagram of each of the modes is included on the fol- Conditions: Boom angle is below 40° . Rear axle pivots
lowing pages. freely, solenoids 1 and 2 energized, the travel select lever
is in FORWARD (F) or REVERSE (R), park brake OFF
Free Pivot Mode and service brake OFF.
(Fig. 9– 25) With solenoids 1 and 2 energized, hydraulic fluid from the
• Rod Oil OUT base end of the stabilizer cylinder flows through the stabi-
lizer block and solenoid-operated valves, to the rod side
Conditions: Boom angle is below 40° . Rear axle pivots of the stabilizer cylinder. Because the volume of oil
freely, solenoids 1 and 2 energized, the travel select lever needed on the rod side is less than that needed on the
is in FORWARD (F) or REVERSE (R), park brake OFF base side, excess oil is returned to the tank through a
and service brake OFF. 100 psi (7 bar) reducing cartridge in the stabilizer block.
With solenoids 1 and 2 energized, hydraulic fluid from the
rod end of the stabilizer cylinder flows through the stabi-
lizer block and solenoid-operated valves, to the base side
of the stabilizer cylinder. Because the volume of oil
needed on the base side is larger than that needed on
the rod side, the extra oil needed is supplied from the
main hydraulic system through a 100 psi (7 bar) reducing
cartridge in the stabilizer block.

9-36 Model 3606 • Origin 10/99

 Hydraulic System

3606 Stabil-TRAK HYDRAULIC CIRCUIT

Free Pivot Mode
STABILIER FRAME TILT
CYLINDER SOLENOID #s:
CYLINDER
V FTR G2 G3 5
FT
0.30 ORIFICE v
R

5
2
4

1 3 4 2
1
100 3
PSI 0.60 ORIFICE
T 100 PSI
P G1 CARTRIDGE
FTR FTB

( TO / FROM PILOT
SELECT MANIFOLD )
b a B A
TO RESERVOIR FRAME TILT SECTION OF
MAIN CONTROL VALVE

LOAD SENSE OUT

SHUTTLE IN

FRAME TILT
SECTION OF
3500 MAIN CONTROL
PSI VALVE

2
GPM
MAX

INLET

25 PSI 4 VARIABLE
BYPASS 3.0 IN DISPLACEMENT
PUMP • 32 GPM

MAIN CONTROL VALVE

HYDRAULIC HYDRAULIC (located on valve plate under rear cover)
FILTER RESERVOIR

CONDITIONS: MS1940

• Boom angle is below 40° .

• Rear axle pivots freely.
• Solenoids 1 and 2 energized.
• Park Brake and Service Brake OFF.
• Travel Select Lever in (F) FORWARD or (R) REVERSE.
Figure 9– 25. Free pivot mode hydraulic circuit.

Model 3606 • Origin 10/99 9-37

 Section 9

Final Positioning Mode Final Positioning Mode

(Fig. 9– 26) (Fig. 9– 26)
• Rod Oil OUT • Base Oil OUT
Conditions: Boom angle is above 40° , park brake OFF, Conditions: Boom angle is above 40° , park brake OFF
and service brake released, and travel select lever in and service brake released, and travel select lever in
FORWARD (F) or REVERSE (R) position; solenoids 3 FORWARD (F) or REVERSE (R) position; solenoids 3
and 4 are energized. and 4 are energized.
From the rod end of the stabilizer cylinder, oil flows From the base end of the stabilizer cylinder, oil flows
through solenoid-operated valve 4, through a 0.060" ori- through solenoid-operated valve 3, through a 0.060" ori-
fice, through another 0.060" orifice, then through sole- fice, through another 0.060" orifice, through solenoid
noid/valve 3, then to the base end. Because of the larger valve 4, to the rod end. Because of the larger volume of
volume of oil in the base end, extra oil will be supplied oil in the base end, extra oil is returned to the tank
from the main system through the 100 psi (7 bar) reduc- through the 100 psi (7 bar) reducing cartridge in the sta-
ing cartridge in the stabilizer block. The restrictions pro- bilizer block. The restrictions produce the slow move-
duce the slow movement, or “final positioning” mode. ment, or “final positioning” mode.

9-38 Model 3606 • Origin 10/99

 Hydraulic System

3606 Stabil-TRAK HYDRAULIC CIRCUIT

Final Positioning Mode
STABILIER FRAME TILT
CYLINDER SOLENOID #s:
CYLINDER
V FTR G2 G3 5
FT
0.30 ORIFICE v
R

5
2
4

1 3 4 2
1
100 0.60 ORIFICE 3
PSI
T 100 PSI
P G1 CARTRIDGE
FTR FTB

( TO / FROM PILOT
SELECT MANIFOLD )
b a B A
TO RESERVOIR FRAME TILT SECTION OF
MAIN CONTROL VALVE

LOAD SENSE OUT

SHUTTLE IN

FRAME TILT
SECTION OF
3500 MAIN CONTROL
PSI VALVE

2
GPM
MAX

INLET

25 PSI 4 VARIABLE
BYPASS 3.0 IN DISPLACEMENT
PUMP • 32 GPM

MAIN CONTROL VALVE

HYDRAULIC HYDRAULIC (located on valve plate under rear cover)
FILTER RESERVOIR
MS1950

CONDITIONS:
• Boom angle is above 40° . • Boom angle is above 40° .
• Park Brake is OFF. • Solenoids 3 and 4 energized.
• Service Brake released. • Rear axle pivots slowly.
• Travel Select Lever in F or R.
Figure 9– 26. Final positioning mode hydraulic circuit.

Model 3606 • Origin 10/99 9-39

 Section 9

Locked Mode
(Fig. 9– 27)
• Rod Oil OUT • Frame TILT LEFT
Conditions: Boom angle is above 40° , park brake ON, or Oil flows to the base end of the frame-tilt cylinder. Oil
service brake applied, or travel select lever in neutral. from the rod-end of the frame-tilt cylinder flows through a
In the locked mode, oil is prevented from flowing through check valve (which was unseated by pilot pressure), then
the stabilizer valve block because of check valves that flows to port FTR on the stabilizer valve block. From
stop the flow of oil. there, oil flows through solenoid valve #5, through a pas-
sage in the stabilizer valve block, then unseats another
• Base Oil OUT check valve, and goes to the rod end of the stabilizer cyl-
Conditions: Boom angle is above 40° , park brake ON, or inder. Oil from the base end of the stabilizer cylinder
service brake applied, or travel select lever in flows through a check valve (which was unseated by pilot
NEUTRAL (N). pressure), through a 0.030" orifice, through solenoid
In the locked mode, oil is prevented from flowing through valve #5, to the frame tilt section of the main control
the stabilizer valve block because of check valves that valve.
stop the flow of oil.
• Frame TILT RIGHT
Oil flows from the spool and is shifted by pilot pressure in
the frame tilt section of the main control valve to Stabil-
TRAK manifold port V, through solenoid cartridge #5,
through a 0.030" orifice, to the base end of the stabilizer
cylinder. Rod end oil from the stabilizer cylinder flows
through a check valve opened by pilot pressure in the
stabilizer manifold. Solenoid #5 is energized, allowing oil
to flow through its cartridge valve and to the rod end of
the frame tilt cylinder. Oil from the base end of the frame
tilt cylinder flows through a piloted-open check valve and
back through the frame tilt section of the main control
valve, dumping to the reservoir.

9-40 Model 3606 • Origin 10/99

 Hydraulic System

3606 Stabil-TRAK HYDRAULIC CIRCUIT

Locked Mode
STABILIZER FRAME TILT
CYLINDER SOLENOID #’s:
CYLINDER
V FTR G2 G3
5
FT
5 0.30 ORIFICE v
R

E
2
4

1 3 4 2
1
100 3
PSI 0.60 ORIFICE
T 100 PSI
P G1 CARTRIDGE
FTR FTB

( TO / FROM PILOT
SELECT MANIFOLD )
b a B A
TO RESERVOIR FRAME TILT SECTION OF
MAIN CONTROL VALVE

LOAD SENSE OUT

SHUTTLE IN

FRAME TILT
SECTION OF
3500 MAIN CONTROL
PSI VALVE

2
GPM
MAX

INLET

25 PSI 4 VARIABLE
BYPASS 3.0 IN DISPLACEMENT
PUMP • 32 GPM

MAIN CONTROL VALVE

HYDRAULIC HYDRAULIC (located on valve plate under rear cover)
FILTER RESERVOIR
CONDITIONS: MS1960
• Boom angle is above 40° . • Boom angle is above 40° .
• Park Brake is ON, or • Solenoid 5 is energized.
Service Brake applied, or • Rear axle does not pivot.
Travel Select Lever in N.

Figure 9– 27. Stabil-TRAK locked mode hydraulic circuit.

Model 3606 • Origin 10/99 9-41

 Section 9

9.8.6 Steering Circuit

Vehicle steering modes are two-wheel steer, four wheel b. Two-wheel Steer
steer and crab steer. Fig. 9– 35 shows an exploded view
• Right Turn
of the steering circuit components.
(Fig. 9– 29)
a. Two-wheel Steer With the steer select switch in the two-wheel steer posi-
tion, when a right turn is made, the steering control valve
• Left Turn spool is shifted so that system pressure is applied
(Fig. 9– 28) through ports E-B of the intake side of the steering unit
With the steer select switch in the two-wheel steer posi- metering section. A specific amount of hydraulic oil is
tion, when a left turn is made, system pressure from the exhausted from the metering section and routed to the
auxiliary function manifold is applied through ports E-C of control section, where it is channeled through ports C-D.
the intake side of the steering unit metering section. A System oil is routed from port T-P in the steer select
specific amount of hydraulic oil is exhausted from the valve. Both solenoids in the steer select valve are de-
metering section and routed to the control section, where energized. Oil flows to the right side rod end of the front
it is channeled through ports B-A to the left rod end of the steering cylinder. Oil from the left side rod end of the
front steering cylinder. Return oil from the right side rod same cylinder flows to ports A-F in the steering control
end of the front steering cylinder flows through ports P-T valve section and then to the reservoir (Fig. 9– 30).
of the steer select valve and through ports D-F of the
steering control valve, to the reservoir (Fig. 9– 30).

bT Pa 2-WHEEL
A B CD STEER
A B RIGHT
Pa 2
bT WHEEL EF EF
A B CD A B STEER
LEFT
EF EF RESERVOIR

RESERVOIR SHUTTLE

PSG PS PP PPG PB PBG

SHUTTLE
SERVICE
PSG PS PP PPG PB PBG BRAKE
SERVICE
BRAKE 2500
PSI 0.090”
550
2500 PSI
PSI 0.090” P
INLET
550 650
PSI PSI
INLET P
650 T
PSI AUXILIARY FUNCTION MANIFOLD
MS0130
T
AUXILIARY FUNCTION MANIFOLD Figure 9– 29. Two-wheel steer mode, right turn.
MS0140

Figure 9– 28. Two-wheel steer mode, left turn.

9-42 Model 3606 • Origin 10/99

 Hydraulic System

TO/FROM
JOYSTICK
FRONT
STEERING CYLINDER

T P
STEERING UNIT b a
RESERVOIR RETURN A B

LOAD SENSE OUT REAR

SHUTTLE IN STEERING CYLINDER

65
PSI TO BRAKE VALVE
BYPASS TO TANK
UNLOADER VALVE
3500
PSI

RELIEF
SPOOL VALVE

250
PSI
INLET
2500 RPM
32.5 GPM
4
3.0 IN
25
PSI

0.5 PSI

5 PSI

PSG PS PP PPG PB PBG

.090
DIA
FRONT WHEEL BRAKE 2500 550
PSI PSI

P
TO BRAKE VALVE REAR WHEEL BRAKE
650
PSI
T

AUXILIARY FUNCTION MANIFOLD

MS0120

Figure 9– 30. Steering hydraulic circuit schematic.

Model 3606 • Origin 10/99 9-43

 Section 9

c. Four-wheel Steer
• Left Turn • Right Turn
(Fig. 9– 31) (Fig. 9– 32)
With the steer select switch in the four-wheel steer posi- With the steer select switch in the four-wheel steer posi-
tion, the steering unit control valve spool is shifted so that tion, the steering unit control valve spool is shifted so that
the system pressure is applied through ports E-C to the the system pressure is applied through ports E-B to the
intake side of the power steering unit metering section. A intake side of the power steering unit metering section. A
specific amount of hydraulic oil is exhausted from the specific amount of hydraulic oil is exhausted from the
metering section and routed back to the control valve metering section and routed back to the control section
section where it is channeled through ports B-A to the left where it is channeled through ports T-B in the steer select
rod end of the front steering cylinder. Return oil from the valve; oil flows to the right side rod end of the rear steer-
right side rod end of the front steering cylinder flows ing cylinder. Oil from the left side rod end of the same cyl-
through ports P-A of the steer select valve to the left side inder flows through ports A-P in the steer select valve, to
rod end of the rear steer cylinder. Oil from the right side the right side rod end of the front steer cylinder. Return
rod end of the rear steer cylinder flows through ports B-T oil from the left side rod end of the front steer cylinder
in the steer select valve to ports D-F in the steering con- flows through ports A-F in the steering control and to the
trol valve, then to the reservoir. reservoir.

P 4-WHEEL
bT Pa 4-WHEEL bT a
STEER STEER
A B CD A B RIGHT
A B CD A B LEFT
EF EF
EF EF
RESERVOIR
RESERVOIR

SHUTTLE
SHUTTLE
PSG PS PP PPG PB PBG
PSG PS PP PPG PB PBG
SERVICE
SERVICE BRAKE
BRAKE

2500
2500 PSI 0.090”
PSI 0.090”
550
550 PSI
PSI INLET P
INLET P
650
650 PSI
PSI
T
T
AUXILIARY FUNCTION MANIFOLD
AUXILIARY FUNCTION MANIFOLD
MS0150
MS0160

Figure 9– 31. Four-wheel steer mode, left turn. Figure 9– 32. Four-wheel steer mode, right turn.

9-44 Model 3606 • Origin 10/99

 Hydraulic System

d. Crab Steer
• Left Turn • Right Turn
(Fig. 9– 33) (Fig. 9– 34)
With the steer select switch in the crab steer position, the With the steer select switch in the crab steer position, the
steering control valve spool is shifted so that system steering control valve spool is shifted so that system
pressure is applied through ports E-C to the intake side pressure is applied through ports E-B to the intake side
of the steering unit metering section. A specific amount of the steering unit metering section. A specific amount
of hydraulic oil is exhausted from the metering section of hydraulic oil is exhausted from the metering section
and routed back to the control valve section where it is and routed back to the control section where it is chan-
channeled through ports B-A to the left rod end side of neled through ports C-D. The steer select valve solenoid
the front steer cylinder. The steer select valve solenoid is is energized and shifts the valve spool. Oil is channeled
energized and shifts the valve spool. Oil from the right through ports T-A in the steer select valve then flows to
side rod end of the front steer cylinder is channeled the left side rod end of the rear steer cylinder. Oil from the
through ports P-B of the steer select valve to the right right side rod end of the same cylinder flows through
side rod end of the rear steer cylinder. Oil from the left ports B-P in the steer select valve to the right side rod
side rod end of the rear steer cylinder flows through ports end of the front steer cylinder. Return oil from the left side
A-T of the steer select valve to ports D-F in the steering rod end of the front steer cylinder flows to ports A-F in the
control valve, then to the reservoir. steering control valve and to the reservoir.

CRAB Pa 4-WHEEL
bT
P
a STEER bT STEER
A B CD LEFT A B CD A B LEFT
A B
EF EF EF EF

RESERVOIR RESERVOIR

SHUTTLE SHUTTLE

PSG PS PP PPG PB PBG PSG PS PP PPG PB PBG

SERVICE SERVICE
BRAKE BRAKE

2500 2500
PSI 0.090” 0.090”
PSI
550 550
PSI
INLET P PSI
INLET P
650
PSI 650
PSI
T
T
AUXILIARY FUNCTION MANIFOLD
AUXILIARY FUNCTION MANIFOLD
MS0180 MS0170

Figure 9– 33. Crab steer mode, left turn. Figure 9– 34. Crab steer mode, right turn.

Model 3606 • Origin 10/99 9-45

 Section 9

24 33 Auxiliary 42
33 Function
Valve 43
25
12 17
12
27 P

PS T

41 PS
G

14
19 PP

PP

9 G

PB

28 18
13
19 18
Unloader 15
Valve 16

30 VIEW FROM REAR OF VEHICLE

40
33
12
34 Rear
29 Axle
UNDERSIDE VIEW 21
11
32
10
9 35
37
20 21 36 35
39 22
31
29 46 31 37 32
24 38 48
15 15 30
25 48 47 52
52
27 53
29
28 15 45

44 55
30 51 46
46 49 28
49 25
51 22 27
46 Transfer 3
49 46 Case
51 32
50 35 52
47 37 15 2
15 36 37 46 47 26
27 L
53 35 49 51 R
T

32 51 P
46
46 5
54 49 23 4
46
48
1
15
24
52
Brake Valve

Front Axle
8
7
26
6
Front Of Vehicle
PS0410

Figure 9– 35. Steering circuit.

9-46 Model 3606 • Origin 10/99

 Hydraulic System

Steering Circuit Legend

1. Steering Unit 29. Hose, 1/2" I.D. x 42"
2. 90° Elbow, SAE 6-4 - str. thd. ORB x o-ring face seal 30. Hose, 1/2" I.D. x 112"
3. Long Connector, SAE 8 - str. thd. ORB x o-ring face seal 31. Hose, 1/2" I.D. x 30"
4. Check Valve 8-8 32. Nut, SAE 8
5. Swivel Run Tee, SAE 6 - o-ring face seal 33. 90° Elbow, SAE 8 - str. thd. ORB x o-ring face seal
6. 90° Elbow, SAE 6 - str. thd. ORB x o-ring face seal 34. 90° Swivel Elbow, SAE 8 - o-ring face seal
7. Shuttle Valve 35. Bleed Adapter Cap, 8 - o-ring face seal
8. 90° Elbow, SAE 6 - str. thd. ORB x o-ring face seal swivel 36. 90° Elbow, M18-8 - metric str. thd. ORB x o-ring face seal
9. Dust Plug 37. Swivel Run Tee, SAE 8 - o-ring face seal
10. Diagnostic Nipple 38. 90° Bulkhead Elbow, SAE 8 - o-ring face seal
11. Branch Tee, SAE 8 - str. thd. ORB x o-ring face seal 39. Bulkhead Nut, SAE 8 - o-ring face seal
12. Connector, SAE 8 - str. thd. ORB x o-ring face seal 40. Socket-head Capscrew, 5/16-18 x 1-1/8"
13. Diagnostic Nipple, 9/16-18 41. Socket-head Capscrew, #10-24 x 1-1/8"
14. Hex-head Capscrew, 5/16-18 x 2-1/2" 42. Hex-head Capscrew, M14-2,0 x 20mm
15. Lockwasher, 5/16" 43. Lockwasher, M14
16. Hex Nut, 5/16-18 44. Clamp Base
17. Auxiliary Valve Mounting Bracket 45. Twin Hose Clamp Set, 0.62" I.D.
18. Steer Select Valve 46. Twin Hose Clamp Set, 0.78" I.D.
19. Steer Select Manifold 47. Twin Weld Cover
20. Bulkhead Fittings Bracket 48. Twin Weld Cover
21. Hose, 1/2" I.D. x 28.3" 49. Stacking Bolt, 1-1/8"
22. Hose, 1/2" I.D. x 84" 50. Twin Hose Clamp Set, 0.68" I.D.
23. Hose, 1/2" I.D. x 14" 51. Locking Plate
24. Hose, 1/2" I.D. x 98" 52. Hex-head Capscrew, 5/16-18 x 2"
25. Hose, 1/2" I.D. x 87" 53. Hex-head Capscrew, 5/16-18 x 1-1/2" Gr. 8
26. Hose, 3/8" I.D. x 13" 54. Hose, 1/2" I.D. x 74"
27. Hose, 1/2" I.D. x 76-1/2" 55. Tie Wrap
28. Hose, 1/2" I.D. x 78"

Model 3606 • Origin 10/99 9-47

 Section 9

9.8.7 Attachment Tilt and Slave Cylinder

Circuit Attachment
Tilt Mode
The attachment tilt functions are dependent on the posi- MODE 2A Switch In
MODE 2A
tion of the attachment tilt mode switch (Fig. 9– 36 and Fig.
9– 37) and can be achieved by pressing and holding the Attachment Tilt Up/Down display panel symbol
button on the top right of the joystick. Moving the joystick & Boom Extend/Retract
(Right button depressed) Attachment Tilt with
backward controls attachment tilt UP. Moving the joystick Extend & Retract
forward controls attachment tilt DOWN.
logic panel symbol
Flow is directed to either side of the attachment tilt and
move handle
slave cylinder pistons by shifting of the spool valve (Fig. Attachment Tilt Up ........ backward
9– 39) in the attachment tilt section of the main control
move handle
valve assembly. The spool valve is shifted by pilot pres- Attachment Tilt Down.... forward
sure, actuated by joystick control and electrical solenoids.
move handle
System pressure is applied in the attachment tilt and Boom Extend ................ to the right
slave cylinder circuit (Fig. 9– 38 and Fig. 9– 40) from the OS2060
move handle
attachment tilt section of the main control valve. Boom Retract ................ to the left
Depress
Right Button OS2060

Figure 9– 36. Control positions for attachment tilt up/down

and boom extend/retract.

Boom Lift/Lower &

Attachment Tilt Up/Down
(Right button depressed)

Attachment
Tilt Mode
Switch In
MODE 2B

display panel symbol

Attachment Tilt
with Lift & Lower

logic panel symbol

move handle
Boom Lift ...................... backward

move handle
Boom Lower.................. forward

move handle
Attachment Tilt Down .... to the right

move handle
OS2070
Attachment Tilt Up ........ to the left
Depress
Right Button OS2070

Figure 9– 37. Control positions for boom lift/lower

and attachment tilt up/down.

9-48 Model 3606 • Origin 10/99

 Hydraulic System

SLAVE CYLINDERS
PILOT SELECT MANIFOLD
1 3

2 4

ATTACHMENT AUX 1
4000 TILT
ATTACHMENT TILT PSI
CYLINDER 8 7 15 16
4000
PSI

a B A b

3700 3700
RETURN TO RESERVOIR PSI PSI
LOAD
SENSE OUT

SHUTTLE IN

15
GPM
MAX

INLET ATTACHMENT TILT

MAIN CONTROL VALVE ASSEMBLY

1 3
FWD BACK
JOYSTICK

P T
BYPASS TO RESERVOIR
65 UNLOADER VALVE
PSI PSG PS PP PPG PB PBG
3500
PSI

RELIEF
SPOOL VALVE

250 .090
PSI DIA
2500 550
INLET 2500 RPM PSI PSI
32.5 GPM
4
3.0 IN
25
PSI
P

0.5 PSI 650

PSI
5 PSI T

AUXILIARY FUNCTION MANIFOLD

MS0060
Figure 9– 38. Attachment tilt/slave cylinder schematic.

Model 3606 • Origin 10/99 9-49

 Section 9

a. Center Position
PILOT SELECT
MANIFOLD When the joystick is in the center or neutral position, the
PORT 7 attachment tilt spool valve (Fig. 9– 39) in the directional
BASE OF control valve is positioned to prevent flow to any of the
RESERVOIR CYLINDERS working ports.
SHUTTLE IN ROD END OF
CYLINDERS
15 GPM b. UP Position
MAX INLET
LOAD SENSE With the right button depressed and held on the joystick,
OUT PILOT SELECT
MANIFOLD PORT 8
and the joystick moved to the left, the attachment tilt
spool valve (Fig. 9– 39) in the directional control valve is
shifted so system pressure is directed to ports A-D,
through ports B-F to the base end of the attachment tilt
cylinder and slave cylinders. The extension of the slave
cylinders is fixed by the position of the boom so that only
F C the attachment tilt cylinder is extended to tilt the attach-
E ment upward.
B
D A If system pressure reaches 3500 ± 50 psi (241,5 ± 3,5
bar) the main relief will open, allowing hydraulic oil to flow
F C to the return filter and to the reservoir. If the return filter
E B becomes restricted, hydraulic oil will bypass the filter
D A when the pressure reaches 25 psi (1,7 bar).
F C Return oil from the rod side of the attachment tilt cylinder
is directed back to the attachment tilt section of the main
E B control valve through ports E-C of the spool valve, to the
D A return filter and to the reservoir. If the return filter
becomes restricted, hydraulic oil will bypass the filter
when the pressure reaches 25 psi (1,7 bar).

MS1970
Figure 9– 39. Attachment tilt spool valve circuit.

9-50 Model 3606 • Origin 10/99

 Hydraulic System

c. DOWN Position
With the right button depressed and held on the joystick,
and the joystick moved to the right, the attachment tilt
spool valve (Fig. 9– 39) in the directional control valve is
shifted so system pressure is directed to ports A-D,
through ports E-B to the rod end of the attachment tilt cyl-
inder and the slave cylinders. The extension of the slave
cylinders is fixed by the position of the boom so that only
the attachment tilt cylinder is retracted to tilt the attach-
ment downward. This system pressure also pilots open
the counterbalance valve. The open counterbalance
valve allows return oil from the base of the attachment tilt
cylinder to flow to ports C-F of the attachment tilt section
of the main control valve, to the return filter and ultimately
to the reservoir. If system pressure reaches 3500 ± 50
psi (241,5 ± 3,5 bar) the main relief will open and allow
hydraulic oil to return to the return filter and to the reser-
voir. In any case, if the return filter becomes restricted,
hydraulic oil will bypass the filter when the pressure
reaches 25 psi (1,7 bar).

Model 3606 • Origin 10/99 9-51

 Section 9

13
15
20
6 Inner Boom
23
16 3
11 24 10
7 3
26

5 Inner tube
at bulkhead
25
15
19

23 Inner tube 16
under boom Outer tube
11 16 at bulkhead
24
14
7

17

22
Front of Vehicle 15
14 Outer tube
22 under boom
21
29 18

22 Main Control Valve

21
Assembly (ref.)
29

Attachment 3
Tilt Cylinder 3

1
27
22 28 1
1

20 1
27 29
22
28
20 17
4
2
8 18 RH
9
2
12
LH
PS0390

Figure 9– 40. Attachment tilt/slave cylinder circuit.

9-52 Model 3606 • Origin 10/99

 Hydraulic System

Attachment Tilt/Slave Cylinder Legend

1. Hose, 1/2” I.D. x 33-1/2” 16. Attachment Tilt Extend Tube Assembly
2. Hose, 1/2” I.D. x 16” 17. Tube Assembly
3. Hose, 1/2” I.D. x 39” 18. Tube Assembly
4. Bulkhead Fitting Support 19. Grade 5 Fully-threaded Tap Bolt, 5/16-18 x 2-1/2”
5. Twin Hose Clamp Set, 0.78” I.D. 20. Bulkhead Nut, SAE 10 - O-Ring Face Seal
6. Twin Welding Plate 21. 90° Swivel Elbow, SAE 8 - O-Ring Face Seal
7. Hex-head Capscrew, 5/16-18 x 1-1/2” 22. Hose, 1/2” I.D. x 321”
8. Plain Washer, 1/4” 23. Twin Hose Clamp Set, 0.62” I.D.
9. Hex-lock Nut, 1/4-20 24. Lockwasher, 5/16”
10. Hex-lock Nut, 5/16-18 25. Cover Plate
11. Cover Plate 26. Twin Welding Plate
12. 90° Bulkhead Elbow, SAE 10 - O-Ring Face Seal 27. Male Run Tee, SAE 8 - ORFS Tube End x Str. Thd. O-Ring
13. 45° Bulkhead Elbow, SAE 10 - O-Ring Face Seal 28. Cap, SAE 8 - O-Ring Face Seal
14. Union Connector, SAE 10 - O-Ring Face Seal 29. 90° Elbow, SAE 8 - Str. Thd. ORB x O-Ring Face Seal
15. Attachment Tilt Retract Tube Assembly

Model 3606 • Origin 10/99 9-53

 Section 9

9.8.8 Joystick Circuit Joystick Circuit Legend

Joystick hydraulic circuit (Fig. 9– 43) commands are
achieved through electric and hydraulic signals via a set 1. Joystick Valve
of cartridge-type, solenoid-operated control valves 2. Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
mounted in an array at the pilot select manifold 3. Long Connector, SAE 6
(Fig. 9– 42). 4. Hose, 3/8” I.D. x 67”
The cartridge valves shift to allow hydraulic oil to flow to 5. Hose, 3/8” I.D. x 120-1/2”
the proper circuit as commanded by joystick position. 6. Hose, 3/8” I.D. x 116”
Hydraulic oil flows from the joystick valve to the pilot 7. Swivel Run Tee, SAE 6 - O-Ring Face Seal
select manifold (Fig. 9– 41), then to the appropriate 8. Cap, SAE 6 - O-Ring Face Seal
working section of the main control valve. 9. Branch Tee, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
The valve plate assembly is provided in either standard 10. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
(Fig. 9– 44) or optional auxiliary hydraulics (Fig. 9– 45) 11. 90° Elbow, SAE 6-8 - Str. Thd. ORB x O-Ring Face Seal
configurations. The valve plate assembly includes the
pilot select manifold and the main control valve.

TO PILOT SELECT MANIFOLD

1 3 2 4

FWD. BACK LEFT RIGHT

JOYSTICK

P T
INPUT RESERVOIR
MS1980

Figure 9– 41. Joystick hydraulic circuit schematic.

Optional Aux.
Hydraulics ONLY

Solenoid Coil

Cartridge Valve
Pilot Select
Manifold
MS1990

Figure 9– 42. Pilot select manifold.

9-54 Model 3606 • Origin 10/99

 Hydraulic System

5
Front of Vehicle

UNDERSIDE 9

8 8
2 3
2

6 5 4

10

Auxiliary
Function
Valve
7
9
8
8

Port
“ PP”
11
4
Valve Plate
Assembly

Front of Vehicle

PS0760

Figure 9– 43. Joystick circuit.

Model 3606 • Origin 10/99 9-55

 Section 9

27 21 15
27 13
41 10 1
40 19
26 34
20 29
23 21
19
24
25 16 22

43

38 35
39 31
30 12
11

37 5

17 36
7 See
18 2 “ Main Control
7
6 16 Valve”
15
4
28
17 28
15
8 30
FRAME 32 Front Of Vehicle
9 33

7
6 12 3 17

See Front Of Vehicle

“ Directional 12 15
6
Control Valves” 42
19 15
12
3 14
8
12 6
16
6
14 7
42 15
6 16 6
16 12 19
13 14
15
7 6 17 17

17
15 19
REAR VIEW OF 6 7 15 7
VALVE PLATE 1
PS0380

Figure 9– 44. Valve plate assembly (without auxiliary hydraulics).

9-56 Model 3606 • Origin 10/99

 Hydraulic System

Valve Plate Assembly Legend

(without auxiliary hydraulics)
1. Pilot Select Manifold 24. 90° Elbow, SAE 12 - Str. Thd. ORB x O-Ring Face Seal
2. Main Control Valve 25. Connector, SAE 16-12 - Str. Thd. ORB x O-Ring Face Seal
3. Shuttle Valve 26. Swivel Branch Tee, SAE 16 - O-Ring Face Seal
4. Spacer 27. 90° Swivel Elbow, SAE 8 - O-Ring Face Seal
5. Main Valve Bracket 28. Washer, Plain 1/2"
6. Hose, 3/8" I.D. x 18" 29. Lockwasher, 1/4"
7. Hose, 3/8" I.D. x 19.3" 30. Lockwasher, 1/2"
8. Hose, 3/8" I.D. x 20" 31. Hex-head Capscrew, 1/4-20 x 2-1/2" Gr. 5
9. Carriage Bolt, 3/8-16 x 2-1/4" 32. Hex-head Capscrew, 1/2-13 x 3-1/2" Gr. 5
10. Long Connector, SAE 8 - Str. Thd. ORB x O-Ring Face Seal 33. Hex-head Capscrew, 1/2-13 x 1" Gr. 5
11. Branch Tee, SAE 8 - Str. Thd. ORB x O-Ring Face Seal 34. Hex Nut, 1/4-20
12. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 35. Hex Nut, 1/2-13
13. Branch Tee, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 36. Lockwasher, 3/8"
14. Swivel Run Tee, SAE 6 - O-Ring Face Seal 37. Hex Nut, 3/8-16
15. Cap, SAE 6 - O-Ring Face Seal 38. Dust Plug
16. Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 39. Diagnostic Nipple
17. Male Run Tee, SAE 6 - ORFS Tube End x Str. Thd. O-Ring 40. Tube Nut, SAE 16 - O-Ring Face Seal
18. Long Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 41. Reducer, SAE 16 - O-Ring Face Seal x SAE 8 - O-Ring
19. 90° Swivel Elbow, SAE 6 - O-Ring Face Seal Face Seal
20. Connector, SAE 6-8 - Str. Thd. ORB x O-Ring Face Seal 42. 90° Swivel Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face
Seal
21. Swivel Run Tee, SAE 8 - O-Ring Face Seal
43. Hex-head Plug, SAE 6 - Male Str. Thd. O-Ring
22. Connector, SAE 8 - Str. Thd. ORB x O-Ring Face Seal
44. Shut-off Plug
23. Connector, SAE 12 - Str. Thd. ORB x O-Ring Face Seal

Model 3606 • Origin 10/99 9-57

 Section 9

18
NOTE: 17
The Auxiliary Hydraulic System is an 15
option that consists of the parts
shown on this page PLUS the parts
shown on the “ Valve plate assembly 12
Front Of Vehicle
without auxiliary hydraulics”
6
See
13 “ Main
10 Control
11 Valve”

To Stabilizer
Cylinder Port “T”
14

26 7
27
28 17
25 16
2
9 17

1 9
15
17 8
13
REAR VIEW OF VALVE PLATE
11 15
17 20 10
18 19 6
14 18
15
3
13
23
24
4 19
16 29
5 Remove
Plug
14 7
3
8
PF0760

21

Front Of Vehicle 22
PS0550

Figure 9– 45. Valve plate assembly (with auxiliary hydraulics)

9-58 Model 3606 • Origin 10/99

 Hydraulic System

Valve Plate Assembly Legend

(with auxiliary hydraulics)
1. Auxiliary Control Valve 16. Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
2. Auxiliary Control Valve Mounting Bracket 17. 90° Swivel Elbow, SAE 6 - O-Ring Face Seal
3. Lockwasher, 3/8" 18. Cap, SAE 6 - O-Ring Face Seal
4. Hex-head Capscrew, 3/8-16 x 1-1/4" 19. Connector, SAE 8-10 - Str. Thd. ORB x O-Ring Face Seal
5. Hex-head Capscrew, 3/8-16 x 3/4" Gr. 5 20. Union Connector, SAE 6-4,
6. Hose, 1/2" ID x 21" O-Ring Face Seal x O-Ring Face Seal
7. Hose, 1/2" ID x 26" 21. Solenoid Valve (service with Kit, Item 29)
8. Hose, 3/8" ID x 21-1/2" 22. Coil w/Female Pins
9. Hose, 3/8" ID x 10-1/2" 23. Diagnostic Nipple
10. Hose, 3/8" ID x 26" 24. Dust Plug
11. Hose, 3/8" ID x 41" 25. Manually Operated Relief Valve
12. Modified 90° Elbow, SAE 6, 26. Plain Washer, 1/4"
Str. Thd. ORB x O-Ring Face Seal 27. Lockwasher, 1/4"
13. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 28. Hex-head Capscrew, 1/4-20 x 2"
14. Swivel Run Tee, SAE 8 - O-Ring Face Seal 29. Kit, Valve Seal
15. Swivel Run Tee, SAE 6 - O-Ring Face Seal

Model 3606 • Origin 10/99 9-59

 Section 9

9.8.9 Auxiliary Hydraulics Circuit (optional) Manually Operated Pressure Relief Valve
The optional auxiliary hydraulic circuit (Fig. 9– 47 and The optional auxiliary hydraulic circuit contains a manu-
Fig. 9– 48) functions can be achieved by pressing and ally operated pressure relief valve (Fig. 9– 46) to facilitate
holding the center button on the joystick. Moving the joy- attaching or detaching the couplers. The purpose of this
stick to the left controls auxiliary function in one direction, pressure relief is to relieve residual pressure trapped in
usually forward, if the auxiliary device is so designed. the auxiliary hydraulic system. Pulling the knob releases
Moving the joystick to the right controls auxiliary func- pressure in the auxiliary hydraulic circuit. The valve is
tions in reverse, or the opposite direction. spring-loaded, and the knob will return to its original posi-
With the center button on the joystick pressed and held, tion after being pulled.
and the joystick moved to the left, pilot pressure will shift
the auxiliary spool valve, allowing oil to flow from the aux-
iliary spool valve to the male connection of the auxiliary
hydraulic coupler. From the coupler, oil flows to the
attachment, back to the female auxiliary coupler, and to
the auxiliary spool valve, then to the return oil filter and
reservoir. Manually-operated
Release Valve
With the center button depressed and held on the joy- (for OPTIONAL
stick, and the joystick moved to the right, pilot pressure Auxiliary Hydraulics)
will shift the auxiliary spool valve, allowing system pres-
sure to flow from the auxiliary spool valve to the female
connection of the auxiliary hydraulic coupler. From the
coupler, oil flows to the attachment, back to the male aux-
iliary coupler, and to the auxiliary spool valve, then to the
return oil filter and reservoir.
OS0360

Figure 9– 46. The manually-operated release valve,

located at the rear of the frame, is part of the
optional auxiliary hydraulic system.

9-60 Model 3606 • Origin 10/99

 Hydraulic System

RESERVOIR

MALE FEMALE B

P T
MANUAL PRESSURE
RELIEF VALVE

PILOT SELECT MANIFOLD

1
a B A b 2
3700 3700
PSI PSI AUX 2 (OPTIONAL)
6 5

15
GPM 2 4
MAX
P LEFT RIGHT

AUXILIARY CONTROL VALVE

(Option)

LOAD SENSE OUT

SHUTTLE IN P T
(MAIN CONTROL VALVE) JOYSTICK

INLET

TO AUXILIARY
FUNCTION MANIFOLD LOAD SENSE
OUT
BYPASS TO TANK
65 UNLOADER VALVE
PSI
3500
PSI

RELIEF
SPOOL VALVE

250
PSI

INLET 2500 RPM

32.5 GPM
3
3.0 IN
25
PSI

0.5 PSI
5 PSI

MS2000

Figure 9– 47. Optional auxiliary hydraulic schematic.

Model 3606 • Origin 10/99 9-61

 Section 9

15
31
12
11
13
11
12
19 31
15
22 3
10
20

21 7
Front Of Vehicle
18

4
10
6
Auxiliary Hydraulics
8 Bulkhead
3 14
4 5
33
23 39
29 36
30 37
14 7 40
See
2
“ Valve Plate 34
17 Assembly
6 35
16 With 1 40
9 Auxiliary
Hydraulics” 39

42 41
23 43
38 23
38
32
26 44 36
43
25
27
24
41
28 44 32 37

PS0520

Figure 9– 48. Optional auxiliary hydraulic circuit.

9-62 Model 3606 • Origin 10/99

 Hydraulic System

Auxiliary Hydraulics Legend

1. Shuttle Valve 25. Bulkhead Connector, SAE 8 - Str. Thd. ORB x O-Ring Face
2. Bulkhead Fitting Support Bracket Seal
3. Tube Assembly, Outer-Aux. Hydraulics (Rear) 26. Dust Plug
4. Tube Assembly, Inner-Aux. Hydraulics (Rear) 27. Dust Cap
5. Swivel Run Tee, #10 28. Male Quick Disconnect, SAE 8-8 ORB - Female Internal
6. Tube Assembly, Inside-Aux. Hydraulics (Front) 29. Reducer, SAE 10 - O-Ring Face Seal x SAE 6 - O-Ring
Face Seal
7. Tube Assembly, Outside-Aux. Hydraulics (Front)
30. Tube Nut, SAE 10 - O-Ring Face Seal
8. 45° Bulkhead Elbow, SAE 10 - O-Ring Face Seal
31. Spring Lockwasher, 5/16"
9. 90° Bulkhead Elbow, SAE 10 - O-Ring Face Seal
32. Connector, SAE 8 - Str. Thd. ORB x O-Ring Face Seal
10. Connector, Union, SAE 10 - O-Ring Face Seal
33. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
11. Twin Hose Clamp Set, 0.62"
34. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
12. Cover Plate swivel
13. Twin Weld Plate 35. 45° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
14. Bulkhead Nut, SAE 10 - O-Ring Face Seal 36. Hose, 1/2" ID x 35-1/2"
15. Hex-head Capscrew, 5/16-18 x 1-1/2" 37. Hose, 1/2" ID x 39"
16. Hex-lock Elastic Nut, 1/4-20 38. Bulkhead Nut, SAE 8 - O-Ring Face Seal
17. Plain Washer, 1/4" 39. Hose, 3/8" I.D. x 31-1/2"
18. Hex-head Tap Bolt, 5/16 x 2-1/2" Gr. 5 40. Hose, 3/8" I.D. x 18"
19. Hex-lock Elastic Nut, 5/16-18 41. Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
20. Twin Hose Clamp Set, 0.78" 42. Male Run Tee, SAE 6 - ORFS tube end x Str. Thd. O-Ring
21. Cover Plate 43. Hose, 3/8" I.D. x 18"
22. Twin Welding Plate 44. Hose, 3/8" I.D. x 22"
23. Hose, 1/2" ID x 340"
24. Female Quick Disconnect, SAE 8-8 ORB - Female Internal

Model 3606 • Origin 10/99 9-63

 Section 9

9.9 VALVES AND MANIFOLDS a. Unloader Valve Removal

Valves are devices that open or close passageways. 1. Park the vehicle on a firm, level surface, fully retract
Manifolds (derived from the words, “many folds”) contain all hydraulic cylinders, ground the attachment (if any),
circuit passageways involved in the distribution of hydrau- place the travel select lever in NEUTRAL (N), engage
lic fluid flowing under pressure. There are various valves the park brake switch and shut the engine OFF.
and manifolds in use on this vehicle. As valves open and
WARNING: Hot hydraulic fluid can cause
close, hydraulic fluid is directed to flow through various
severe burns. Wait for hydraulic fluid to cool
passageways to the prescribed circuit, causing vehicle
before servicing any hydraulic component.
functions occur.
2. Unlatch, unlock and open the engine cover. Allow the
9.9.1 Unloader Valve hydraulic fluid to cool.
The unloader valve (Fig. 9–49 ) creates system pressure WARNING: Escaping hydraulic fluid under
and distributes the hydraulic fluid for various vehicle func- pressure can penetrate the skin, causing seri-
tions via its load sense, bypass, primary, and auxiliary ous injury. Relieve hydraulic pressure before
supply ports.The unloader valve distributes fluid to the servicing any hydraulic component.
hydraulic system oil cooler (Fig. 9–6) and is secured to
the underside of the frame near the transmission. 3. Label, disconnect and cap the hydraulic lines at the
unloader valve.
4. Remove the two 5/16-18 x 3-1/4" hex-head
capscrews, two 5/16" lockwashers and two 5/16"
SAE washers securing the unloader valve (Fig. 9–49)
to the vehicle frame. Remove the valve from the
vehicle. Wipe up any spilled hydraulic fluid.

b. Unloader Valve Disassembly

Safely secure the unloader valve (1, Fig. 9–50) in a
bench vise or by other suitable means. Remove the cap
(2), O-ring (3), spool spring (4), tube spacer (5), spool
(6), and relief valve assembly (8) from the unloader valve
housing (7). Discard the O-ring (3). Always replace O-
rings with new O-rings lubricated with clean hydraulic oil.

MS2020 c. Cleaning and Drying

Figure 9–49. The unloader valve is secured to Clean metal parts in an approved solvent such as triclor-
the underside of the frame, located near the transmission. ethylene and blow dry.

d. Inspection
DO NOT loosen, disassemble or attempt to adjust any of
the cartridges unless specifically instructed by Sky Trak Inspect all sealing surfaces. They must be clean, smooth,
to do so! Tampering with the cartridges will irrevocably and free of damage, and have no indication of wear.
alter pressure in the affected circuits. A new cartridge will Replace parts if damaged or worn.
be required to rectify the situation.
e. Reassembly
Safely secure the unloader valve (1, Fig. 9–50) in a
bench vise or by other suitable means. Install the relief
valve assembly (8) and torque to 20 lb/ft (27 Nm). Install
the spool (6), tube spacer (5), spool spring (4), and new
O-ring (3). Always replace O-rings with new O-rings lubri-
cated with clean hydraulic oil. Thread the cap (2) tightly
into the unloader valve housing (7).

9-64 Model 3606 • Origin 10/99

 Hydraulic System

2 Torque to Maximum 20 lb/ft.

(27 Nm)
3

4
8
5

1
7
PS0510

Figure 9– 50. Unloader valve detail.

Unloader Valve Legend

1. Unloader Valve (includes items 2 through 8) 4. Start the engine and run at approximately one-third
2. Cap to one-half throttle for approximately one minute
3. O-Ring without moving the vehicle or operating any hydraulic
4. Spool Spring functions.
5. Tube Spacer 5. Inspect for leaks and check all fluid levels. The
6. Spool hydraulic reservoir oil level must be visible in the sight
7. Valve Housing gage.
8. Relief Valve Assembly Note: Check for leaks and tighten fittings or repair as
Preset at 3500 psi ± 100 psi (241 bar ± 7 bar)
required before continuing. Wipe up any spilled hydraulic
fluid.
f. Unloader Valve Installation
1. Secure the unloader valve to the vehicle frame near g. Unloader Valve Pressure Check Test
the transmission (Fig. 9– 49) with two 5/16" SAE
Attach a 4000 psi (276 bar) gauge to the unloader valve
washers, two 5/16" lockwashers and two 5/16-18 x 3-
inlet port. Monitor the outlet pressure at the unloader
1/4" hex-head capscrews. Torque the capscrews to
valve. It must provide 250 to 350 psi (17,25 to 24,15 bar)
18 lb/ft (24 Nm).
within moments after starting the engine. Failure to
2. Connect the hydraulic lines to their appropriate ports achieve this pressure means that the unloader valve is
on the unloader valve. not properly functioning.
3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members. All tube and hose clamps must be tight.
WARNING: Avoid prolonged engine operation
in closed areas with inadequate ventilation.
Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.

Model 3606 • Origin 10/99 9-65

 Section 9

9.9.2 Main Control Valve a. Main Control Valve Replacement

The main control valve assembly (2, Fig. 9– 51) is located The main control valve assembly (2, Fig. 9– 51), pilot
at the rear of the vehicle, beneath the rear cover, secured select manifold (1), plus the auxiliary hydraulics control
to the valve plate assembly. The main control valve valve and mounting bracket (Fig. 9– 52), IF EQUIPPED,
assembly consists of various working sections with their are fastened to the main valve bracket (5, Fig. 9– 51).
own valve assemblies, each with a particular purpose in These instructions cover the removal of the main control
providing vehicle functions. valve plate assembly and bracket in its entirety with the
If service to the main control valve assembly is required, main control valve, pilot select manifold and auxiliary
label, disconnect and cap the hoses leading to the main hydraulics control valve and mounting bracket, IF
control valve assembly and remove the assembly from EQUIPPED, in place on the bracket.
the vehicle. Secure the control valve assembly to a work
bench, vise, or stabilize by other suitable means.
Always replace O-rings with new O-rings lubricated with
clean hydraulic oil.

9-66 Model 3606 • Origin 10/99

 Hydraulic System

b. Main Control Valve Removal 4. Label or otherwise mark the hydraulic hoses at the
main control valve, pilot select manifold, and, IF
1. Park the vehicle on a firm, level surface, fully retract
EQUIPPED, the auxiliary hydraulic control valve.
all hydraulic cylinders, ground the attachment (if any),
Place a suitable container to catch hydraulic fluid
place the travel select lever in NEUTRAL (N), engage
drainage beneath the rear ballast weight. Disconnect
the park brake switch and shut the engine OFF.
and cap all hoses and fittings, etc. Label and
WARNING: Hot hydraulic fluid can cause disconnect all wire terminal leads.
severe burns. Wait for hydraulic fluid to cool 5. Remove the four hex nuts (37, Fig. 9– 51) and lock
before servicing any hydraulic component. washers (36) securing the main control valve (2) to
the main valve bracket (5). Remove the four carriage
2. Unlatch, unlock and open the engine cover. Allow the
bolts (9) from beneath the vehicle frame, and remove
hydraulic fluid to cool.
the four plain washers (28) and spacers (4) from
WARNING: Escaping hydraulic fluid under beneath the main valve bracket.
pressure can penetrate the skin, causing seri- 6. Remove the entire valve plate assembly, including
ous injury. Relieve hydraulic pressure before the pilot select manifold, main control valve and, IF
servicing any hydraulic component. EQUIPPED, the optional auxiliary hydraulic control
valve from the vehicle.
3. Thoroughly clean the pilot select manifold, main
control valve, optional auxiliary hydraulic control 7. Wipe up any hydraulic fluid spillage in, on, near and
valve (IF EQUIPPED) and surrounding area, around the vehicle and the work area.
including all hoses and fittings, before proceeding.

Model 3606 • Origin 10/99 9-67

 Section 9

21 13 15
27 27
41 10
40 1
19
26 34
20 29
23 21
19 24
25 16 22

43

38 35
39 31
30 12
11

37 5

17 36
7 See
18 2 “ Main Control
7
6 16 Valve”
15
4
28
17 28
15
8 30
FRAME 32 Front Of Vehicle
9 33

7
12 3 17
6
See Front Of Vehicle
“ Directional
6 Control 12 15
42
Valves”
19 12 15
3 14
8
12 6
16
6
14 7
42 15
6 16 6
16 12 19
13 14
15
7 6 17 17

17
15 19
REAR VIEW OF 6 7 15 7
VALVE PLATE
44 PS0380

Figure 9– 51. Main control valve plate assembly (without auxiliary hydraulics).

9-68 Model 3606 • Origin 10/99

 Hydraulic System

Main Control Valve Plate Assembly Legend

(without auxiliary hydraulics)
1. Pilot Select Manifold 24. 90° Elbow, SAE 12 - Str. Thd. ORB x O-Ring Face Seal
2. Main Control Valve 25. Connector, SAE 16-12 - Str. Thd. ORB x O-Ring Face Seal
3. Shuttle Valve 26. Swivel Branch Tee, SAE 16 - O-Ring Face Seal
4. Spacer 27. 90° Swivel Elbow, SAE 8 - O-Ring Face Seal
5. Main Valve Bracket 28. Washer, Plain 1/2"
6. Hose, 3/8" I.D. x 18" 29. Lockwasher, 1/4"
7. Hose, 3/8" I.D. x 19.3" 30. Lockwasher, 1/2"
8. Hose, 3/8" I.D. x 20" 31. Hex-head Capscrew, 1/4-20 x 2-1/2" Gr. 5
9. Carriage Bolt, 3/8-16 x 2-1/4" 32. Hex-head Capscrew, 1/2-13 x 3-1/2" Gr. 5
10. Long Connector, SAE 8 - Str. Thd. ORB x O-Ring Face Seal 33. Hex-head Capscrew, 1/2-13 x 1" Gr. 5
11. Branch Tee, SAE 8 - Str. Thd. ORB x O-Ring Face Seal 34. Hex Nut, 1/4-20
12. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 35. Hex Nut, 1/2-13
13. Branch Tee, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 36. Lockwasher, 3/8"
14. Swivel Run Tee, SAE 6 - O-Ring Face Seal 37. Hex Nut, 3/8-16
15. Cap, SAE 6 - O-Ring Face Seal 38. Dust Plug
16. Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 39. Diagnostic Nipple
17. Male Run Tee, SAE 6 - ORFS Tube End x Str. Thd. O-Ring 40. Tube Nut, SAE 16 - O-Ring Face Seal
18. Long Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 41. Reducer, SAE 16 - O-Ring Face Seal x SAE 8 - O-Ring
19. 90° Swivel Elbow, SAE 6 - O-Ring Face Seal Face Seal
20. Connector, SAE 6-8 - Str. Thd. ORB x O-Ring Face Seal 42. 90° Swivel Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face
Seal
21. Swivel Run Tee, SAE 8 - O-Ring Face Seal
43. Hex-head Plug, SAE 6 - Male Str. Thd. O-Ring
22. Connector, SAE 8 - Str. Thd. ORB x O-Ring Face Seal
44. Shut-off Plug
23. Connector, SAE 12 - Str. Thd. ORB x O-Ring Face Seal

Model 3606 • Origin 10/99 9-69

 Section 9

18
NOTE: 17
The Auxiliary Hydraulic System 15
is an option that consists of
the parts shown on this page 12
PLUS the parts shown at Front Of Vehicle
“ Valve plate assembly
(without auxiliary hydraulics)” 6
13
See
10 “ Main Control
11 Valve”

To Stabilizer
Cylinder Port “T”
14

26 7
27
28 17
15 16
9 17
2

1 9
15
17 8
13
REAR VIEW OF VALVE PLATE
11
15
17
20 10
18 19 6
14 18
15
3
13
23
24
4 19
16 29
5 Remove
Plug 14 7
3
8
PF0760

21

Front Of Vehicle 22

PS0550

Figure 9– 52. Main control valve plate assembly (with auxiliary hydraulics)

9-70 Model 3606 • Origin 10/99

 Hydraulic System

Main Control Valve Assembly Legend

(with auxiliary hydraulics)
1. Auxiliary Control Valve 16. Connector, SAE 6 - Str. Thd. ORB x O-Ring Face Seal
2. Auxiliary Control Valve Mounting Bracket 17. 90° Swivel Elbow, SAE 6 - O-Ring Face Seal
3. Lockwasher, 3/8" 18. Cap, SAE 6 - O-Ring Face Seal
4. Hex-head Capscrew, 3/8-16 x 1-1/4" 19. Connector, SAE 8-10 - Str. Thd. ORB x O-Ring Face Seal
5. Hex-head Capscrew, 3/8-16 x 3/4" Gr. 5 20. Union Connector, SAE 6-4,
6. Hose, 1/2" ID x 21" O-Ring Face Seal x O-Ring Face Seal
7. Hose, 1/2" ID x 26" 21. Solenoid Valve (service with Kit, Item 29)
8. Hose, 3/8" ID x 21-1/2" 22. Coil w/Female Pins
9. Hose, 3/8" ID x 10-1/2" 23. Diagnostic Nipple
10. Hose, 3/8" ID x 26" 24. Dust Plug
11. Hose, 3/8" ID x 41" 25. Manually Operated Relief Valve
12. Modified 90° Elbow, SAE 6, 26. Plain Washer, 1/4"
Str. Thd. ORB x O-Ring Face Seal 27. Lockwasher, 1/4"
13. 90° Elbow, SAE 6 - Str. Thd. ORB x O-Ring Face Seal 28. Hex-head Capscrew, 1/4-20 x 2"
14. Swivel Run Tee, SAE 8 - O-Ring Face Seal 29. Kit, Valve Seal
15. Swivel Run Tee, SAE 6 - O-Ring Face Seal

c. Main Control Valve Disassembly To disassemble the main control valve:

The main control valve (Fig. 9– 53 and Fig. 9– 54) consists 1. Place the valve plate assembly on a suitable work
of various section assemblies held together by three tie surface.
rods (items 4 and 5, Fig. 9– 54), secured with special hex
nuts (2 and 3). From left to right, the section assemblies 2. Working from beneath the main valve bracket (5,
are the attachment and frame tilt outlet section assembly, Fig. 9– 51), remove the hex-head capscrews (32 and
attachment tilt section assembly, frame tilt section 33), lockwashers (30) and plain washers (28)
assembly, mid inlet section assembly, boom extend/ securing the main control valve (2) to the bracket (5).
retract section assembly, boom hoist/lower section Remove the main control valve from the bracket.
assembly, and the extend/retract and hoist/lower outlet 3. Disassemble the main control valve by removing the
section assembly. Each section assembly includes a pre- special nuts (2 and 3, Fig. 9– 54) from one end of the
adjusted relief valve assembly that regulates pressure in tie rods (4 and 5). Pull the tie rods out through the
a specific circuit. section assemblies.
IMPORTANT: DO NOT adjust any of the relief valve 4. Disassemble each section assembly as required.
assemblies! Tampering with a relief valve assembly will
irrevocably alter pressure in the affected circuit, requiring
re-calibration or a new relief valve assembly.

Model 3606 • Origin 10/99 9-71

 Section 9

Outlet Section Relief Valve

Remove the SAE plug (7, Fig. 9– 53) and O-ring (8) from The relief valve assembly (27, Fig. 9– 53) is part of the
the outlet section assembly (6) to facilitate cleaning and attachment and frame tilt section assemblies. The valve
removal of any debris from within the outlet section. is preset at 3700± 50 psi (255 ± 3,5 bar).
1. Remove the relief valve assembly (27, Fig. 9– 53)
Attachment Tilt Section from the applicable section assembly.
1. Carefully separate the outlet section assembly (6, 2. Grip the housing (40) with a suitable tool and use
Fig. 9– 53) from the attachment tilt section assembly another tool to remove the acorn nut (48), revealing
(9). Avoid dislodging or loosing the shuttle (12), an O-ring (35) and the adjustment screw (47).
spring (13) and control valve (C.V.) compensator Discard the O-ring.
(14).
3. Remove the O-ring, then loosen the jam nut (46) and
2. Remove the O-ring (11) from between the two remove the adjustment screw, jam nut, and another
sections. O-ring (35). Discard the O-ring.
3. Remove the shuttle (12), spring (13) and control 4. Carefully remove the plug (45), O-ring (36), spring
valve (C.V.) compensator (14) from the attachment tilt (34), pilot poppet (44), wave spring (32), back-up ring
section casting (9). (31), O-ring (30), spring (33), O-ring (28), back-up
4. Remove both socket-head capscrews (15) securing ring (29), and relief valve poppet (43). Discard the O-
the seal plate (16) to the section assembly (9). rings, back-up rings and wave rings.
5. Remove the seal plate (16), spool end (17), spool Remove the check valve poppet (42), piston (41) and O-
cap (18), spring seat (19), spring (20), and another ring (37). Discard the O-ring.
spring seat (19).
Mid Inlet Section
6. Remove and discard the O-rings (21 and 22).
7. Remove the spool cap retainer (23). 1. Carefully separate the frame tilt section assembly
(10, Fig. 9– 53) from the mid inlet section assembly
8. Remove and discard the O-ring (24). (37, Fig. 9– 54). Remove and discard the O-ring (38).
9. Remove both socket-head capscrews (26) securing 2. Carefully separate the boom extend/retract section
the seal plate (16) to the section assembly (9). assembly (8, Fig. 9– 54) with the boom hoist/lower
10. Remove the spool cap (25) and O-ring (24). Discard assembly (9) and outlet section assembly (7) from
the O-ring. the mid inlet section assembly (37). Remove and
discard the O-ring (39).
Frame Tilt Section 3. Remove the shuttle (40), SAE plug assembly (41)
1. Carefully separate the attachment tilt section and O-ring (42). Discard the O-ring (42).
assembly (9, Fig. 9– 53) from the frame tilt section
assembly (10), being careful not to dislodge or loose Boom Extend/Retract Section
the small internal parts. Remove the O-ring (11) from 1. Carefully separate the boom extend/retract section
between the two sections. Remove the shuttle (12), assembly (8, Fig. 9– 54) from the boom hoist/lower
spring (13) and control valve (C.V.) compensator (14) section assembly (9) and outlet section assembly (7).
from the frame tilt section casting (10). Remove and discard the O-ring (20).
2. Remove both socket-head capscrews (15) securing 2. Remove the shuttle (21), spring (25) and poppet (24).
the seal plate (16) to the section assembly (10).
3. Remove the seal plate (16), spool end (17), spool Relief Valve
cap (18), spring seat (19), spring (20), and another
The relief valve assembly (27, Fig. 9– 54) is oriented
spring seat (19).
toward the rear of the vehicle and is preset at 3750± 50
4. Remove and discard the O-rings (21 and 22). psi (258 ± 3,5 bar). Relief valve assembly (28, Fig. 9– 54)
5. Remove the spool cap retainer (23). is oriented toward the front of the vehicle and is preset at
3200± 50 psi (220 ± 3,5 bar).
6. Remove and discard the O-ring (24).
1. Use a wrench on the housing (51, Fig. 9– 54) to
7. Remove both socket-head capscrews (26) securing
remove the relief valve assembly (27 and/or 28) from
the seal plate (16) to the section assembly (10).
the section assembly.
8. Remove the spool cap (25) and O-ring (24). Discard
the O-ring.

9-72 Model 3606 • Origin 10/99

 Hydraulic System

2. Remove the plug (45), poppet (46), back-up rings d. Main Control Valve Parts Cleaning
(47), and jam nut (48). Keep the back-up rings (47)
Clean all components with a suitable cleaner, such as tri-
for re-use later during assembly.
clorethylene, before continuing. Blow dry.
3. Carefully remove the plug (49) with O-ring (29) from
the housing (51), exposing the spring (36) and pilot e. Main Control Valve Parts Inspection
poppet (50). Discard the O-ring (29).
Inspect all parts and internal passageways for wear,
4. Remove the check valve poppet (54) from the damage, etc. If inner surfaces of any component do not
housing (51). display an ultra-smooth, polished finish, or are damaged
5. Remove the relief valve poppet (53), O-ring (30), and in any way, replace the damaged part. Most often, dirty
back-up ring (35). Discard the O-ring (30) and back- hydraulic fluid causes failure of internal seals, damage to
up ring (35). the polished surfaces within the component, and wear of
6. Remove the piston (52), spring (33), back-up ring and/or harm to other parts.
(32), O-ring (31), and another back-up ring (32).
Discard the O-ring (31) and back-up rings (32).
7. Remove the spring (34) and O-ring (29) from the
housing (51). Discard the O-ring (29).

Boom Hoist/Lower Section

1. Carefully separate the boom hoist/lower section
assembly (9, Fig. 9– 54) from the outlet section
assembly (7). Remove and discard the O-ring (20).
2. Remove the shuttle (21), spring (25) and poppet (24).
3. Remove the anti-void assembly (26).

Extend/Retract and Hoist/Lower Outlet Section

Remove the shut-off plug assembly orifice (6, Fig. 9– 54)
from the outlet section assembly (7).

Model 3606 • Origin 10/99 9-73

 Section 9

38

39

PF0760

1 7
8 4
13 2
14
13 27
17 14
12 3
15
20
16 21
23 12 5
18 11 6
19 22 25 11
24 9

10
24
26
16

Boom Raise/Lower & Extend/Retract

Sections for Reference Only

40
42
29
30
37 41 31
44
43 36 45 27
28 35
33
32
34 47

46
48
PS0780

Figure 9– 53. Attachment tilt and frame tilt sections.

9-74 Model 3606 • Origin 10/99

 Hydraulic System

Main Control Valve Legend

Attachment Tilt and Frame Tilt Sections
1. Main Control Valve Assembly 26. Socket-head Capscrew
(includes items 2 through 37) 27. Relief Valve Assembly, preset at 3700 ± 50 psi
2. Special Upper Nut (255 ± 3,5 bar),
3. Special Lower Nut (includes items 28 through 37)
4. Upper Tie Rod 28. O-Ring
5. Lower Tie Rod 29. Back-up Ring
6. Outlet Section Assembly 30. O-Ring
7. SAE Plug 31. Back-up Ring
8. O-Ring 32. Wave Spring
9. Attachment Tilt Section Assembly 33. Spring
(includes items 11 through 26) 34. Spring
10. Frame Tilt Section Assembly 35. O-Ring
(includes items 11 through 26) 36. O-Ring
11. O-Ring 37. O-Ring
12. Shuttle 38. Seal and Spring Kit, relief valve
13. Spring (includes items 28 through 37)
14. C.V. Compensator Piston 39. Seal Kit, entire valve
15. Socket-head Capscrew (includes items 8, 11, 21, 22 and 24 and additional items on
Boom Hoist/Lower and Extend/Retract Sections)
16. Seal Plate
40. Housing
17. End Spool
41. Piston
18. Spool Cap
42. Check Valve Poppet
19. Spring Seat
43. Relief Valve Poppet
20. Spring
44. Pilot Poppet
21. O-Ring
45. Plug
22. O-Ring
46. Jam Nut
23. Spool Cap Retainer
47. Adjustment Screw
24. O-Ring
48. Acorn Nut
25. Spool Cap

Model 3606 • Origin 10/99 9-75

 Section 9

f. Main Control Valve Reassembly 5. Secure the seal plate (16) to the section assembly
(10) with two socket-head capscrews (15).
Note: Always replace O-rings with new O-rings to help
ensure a leak-proof seal and proper vehicle performance. 6. Install the control valve (C.V.) compensator (14),
spring (13) and shuttle (12) into the frame tilt section
Attachment and Frame Tilt Outlet Section Assembly casting (10).

Install a new O-ring (8, Fig. 9– 53), and the SAE plug (7), 7. Place a new O-ring (11) between the attachment tilt
into the outlet section assembly (6). section assembly (10) and frame tilt section
assembly (10) being careful not to dislodge or loose
Attachment Tilt Section the control valve (C.V.) compensator (14), spring (13)
or shuttle (12).
The section can be identified by manufacturing markings
made for the inlet (triangle) and outlet (“B”) ports. The Assembling the Relief Valve
inlet side faces the front of the vehicle when installed; the
outlet faces the rear of the vehicle. Install a new O-ring The relief valve assembly is part of both the attachment
(24, Fig. 9– 53) and spool cap (25) in the inlet side lower and frame tilt section assemblies and is preset at 3700±
port. 50 psi (255 ± 3,5 bar).

1. Secure the seal plate (16, Fig. 9– 53) to the section 1. Install the check valve poppet (42, Fig. 9– 53) and
assembly (9) with two socket-head capscrews (26). piston (41) into the housing (40).

2. On the outlet (“B”) port side, install a new O-ring (24) 2. Carefully install the relief valve poppet (43), back-up
and the spool cap retainer (23) into the lower port. ring (29), new O-ring (28), spring (33), new O-ring
(30), back-up ring (31), wave spring (32), pilot poppet
3. Install new O-rings (21 and 22). (44), spring (34), new O-ring (36), and plug (45) into
4. Install the spring seat (19), spring (20), another the housing (40).
spring seat (19), spool cap (18), spool end (17), and 3. Install a new O-ring (35) into the housing (40) on top
seal plate (16). of the plug (45).
5. Secure the seal plate (16) to the section assembly (9) 4. Thread the jam nut (46) onto the adjustment screw
with two socket-head capscrews (15). (47), then thread the adjustment screw and jam nut
6. Install the control valve (C.V.) compensator (14), into the plug (45) within the housing (40).
spring (13) and shuttle (12) into the attachment tilt 5. Install another new O-ring (35) over the jam nut (46)
section casting (9). and adjustment screw (47), then thread the acorn nut
7. Place a new O-ring (11) between the attachment tilt (48) onto the adjustment screw.
section assembly and outlet section assembly (6). 6. Place a new O-ring (37) onto the housing and install
8. Avoid dislodging or loosing the shuttle (12), spring the relief valve assembly (27) into the section
(13) and control valve (C.V.) compensator (14). assembly (27). Tighten securely.
Carefully join the outlet section assembly (6) to the
attachment tilt section assembly (9). Assembling the Mid Inlet Section
1. Install a new O-ring (42, Fig. 9– 53), and the SAE
Frame Tilt Section
plug assembly (41) and shuttle (40) into the mid inlet
The section can be identified by markings made for the section assembly (37).
inlet (triangle) and outlet (“B”) ports. The inlet side faces 2. Install a new O-ring (39, Fig. 9– 53) into the mid inlet
the front of the vehicle when installed; the outlet faces the section assembly (37). Carefully attach the boom
rear of the vehicle. Install a new O-ring (24, Fig. 9– 53) extend/retract section assembly (8) with the boom
and spool cap (25) in the inlet side lower port. hoist/lower assembly (9) and outlet section assembly
1. Secure the seal plate (16, Fig. 9– 53) to the section (7) to the mid inlet section assembly (37).
assembly (10) with two socket-head capscrews (26). 3. Install a new O-ring (38, Fig. 9– 53). Carefully attach
2. On the outlet (“B”) port side, install a new O-ring (24) the frame tilt section assembly (10, Fig. 9– 54) to the
and the spool cap retainer (23) into the lower port. mid inlet section assembly (37, Fig. 9– 53).
3. Install new O-rings (21 and 22).
4. Install the spring seat (19), spring (20), another
spring seat (19), spool cap (18), spool end (17), and
seal plate (16).

9-76 Model 3606 • Origin 10/99

 Hydraulic System

Boom Extend/Retract Section g. Main Control Valve Installation

1. Install the poppet (24, Fig. 9– 54), spring (25) and 1. Place the main control valve into position on the valve
shuttle (21) into the boom extend/retract section plate assembly.
assembly (8). 2. Align gaskets, bolt holes, etc. with component mount
2. Install a new O-ring (20) into the boom extend/retract holes. Secure the main control valve with the
section assembly (8). necessary fasteners. Torque fasteners to
3. Carefully attach the boom extend/retract section specification. Refer to the torque specification chart
assembly (8) to the boom hoist/lower section in Section 2 General Information, Specifications and
assembly (9) and outlet section assembly (7). Maintenance Instructions.
3. Prime the main control valve by filling the inlet
Assembling the Relief Valve Assemblies openings with fresh, filtered hydraulic oil before
attaching the hoses.
Relief valve assembly (27, Fig. 9– 54) is oriented toward
the rear of the vehicle and is preset at 3750± 50 psi (258 4. Use new O-rings as required. Reattach and secure
± 3,5 bar). Relief valve assembly (28) is oriented toward all hoses, clamps, etc.
the front of the vehicle and is preset at 3200± 50 psi (220 5. Check the routing of all hoses, wiring and tubing for
± 3,5 bar). sharp bends or interference with any rotating
For each relief valve assembly (27 and 28, Fig. 9– 54): members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
1. Install a new O-ring (29, Fig. 9– 54) and the spring
clamps.
(34) into the housing (51).
2. Install a new back-up ring (32), new O-ring (31), WARNING: Avoid prolonged engine operation
another new back-up ring (32), spring (33), and the in closed areas with inadequate ventilation.
piston (52) into the housing (51). Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.
3. Install the relief valve poppet (53), new O-ring (30),
and new back-up ring (35). 6. Start the engine and run at approximately one-third
4. Install a new back-up ring (35), new O-ring (30), and to one-half throttle for about one minute without
the relief valve poppet (53) into the housing (51), then moving the vehicle or operating any hydraulic
install the check valve poppet (54) into the housing functions.
(51). 7. Inspect for leaks and check the level of the hydraulic
5. Place the pilot poppet (50) and spring (36) into the fluid in the reservoir. Shut the engine OFF.
housing (51), then add a new O-ring (29) and secure Note: Check for leaks and repair as required before con-
with the plug (49). tinuing. Add hydraulic fluid to the reservoir as needed.
6. Install jam nut (48), back-up rings (47), poppet (46),
8. Conduct a pressure check of the hydraulic system in
and plug (45).
its entirety. Adjust pressure(s) as required.
7. Use a wrench on the housing (51) to install the relief
9. Wipe up any hydraulic fluid spillage in, on, near and
valve assembly (27 and/or 28) into the section
around the vehicle, work area and tools.
assembly.

Boom Hoist/Lower Section

1. Install the anti-void assembly (26, Fig. 9– 54) into the
boom hoist/lower section assembly (9).
2. Install the poppet (24), spring (25) and shuttle (21).
3. Install a new O-ring (20), then carefully attach the
boom hoist/lower section assembly (9) to the outlet
section assembly (7).

Extend/retract and hoist/lower outlet section assembly

Install the shut-off plug assembly orifice (6, Fig. 9– 54)
into the outlet section assembly (7).

Model 3606 • Origin 10/99 9-77

 Section 9

Attachment Tilt and

Frame Tilt Sections for
1 Reference Only

24
24 25 37
14
10 25
16 26 39
27
11 14
12
13
15 20 38
17
6 18 42
19
28 41
4 21 8 40
27
2
19 23
43
11
20 9 22 44
7 21 23
3 5
PF0760

45
46
48

30 36
47
51 29
49
31 27
29 50 33 28
52 30
34
32 54

35
53
PS0770

Figure 9– 54. Hoist/lower and extend/retract sections.

9-78 Model 3606 • Origin 10/99

 Hydraulic System

Main Control Valve Legend

Hoist/Lower and Extend/Retract Sections
1. Main Control Valve Assembly 28. Relief Valve Assembly, preset at 3200 ± 50 psi
(includes items 2 through 42) (220,8 ± 3,5 bar),
2. Special Upper Nut (includes items 29 through 36)
3. Special Lower Nut 29. O-Ring
4. Upper Tie Rod 30. O-Ring
5. Lower Tie Rod 31. O-Ring
6. Orifice Shut-off Plug Assembly 32. Back-up Ring
7. Outlet Section Assembly 33. Spring
8. Boom Extend/Retract Section Assembly 34. Spring
(includes items 10 through 25) 35. Back-up Ring
9. Boom Hoist/Lower Section Assembly 36. Spring
(includes items 10 through 26) 37. Mid Inlet Section Assembly
10. Socket-head Capscrew (includes items 38 through 40)
11. Retainer 38. O-Ring
12. Spool Cap 39. O-Ring
13. Shoulder Socket-head Screw 40. Shuttle
14. Flat Washer 41. SAE Plug Assembly
15. Spring 42. O-Ring
16. Spacer 43. Seal Kit, entire valve (includes items 17, 19, 20 and 42 and
17. O-Ring additional items on Attachment Tilt and Frame Tilt Sections)
18. Spool Cap Retainer 44. Seal and Spring Kit, relief valve
19. O-Ring 45. Plug
20. O-Ring (see KITS) 46. Poppet
21. Shuttle 47. Back-up Ring
22. Spool Cap 48. Jam Nut
23. Socket-head Capscrew 49. Plug
24. Poppet 50. Pilot Poppet
25. Spring 51. Housing
26. Anti-void Assembly 52. Piston
27. Relief Valve Assembly, preset at 3750 ± 50 psi 53. Relief Valve Poppet
(258,75 ± 3,5 bar) 54. Check Valve Poppet
(includes items 29 through 36)

Model 3606 • Origin 10/99 9-79

 Section 9

9.9.3 Auxiliary Function Manifold a. Auxiliary Function Manifold Replacement

The auxiliary function manifold (Fig. 9–55) is located 1. Park the vehicle on a firm, level surface, fully retract
near the battery, secured to a bracket at the hydraulic all hydraulic cylinders, ground the attachment (if any),
fluid place the travel select lever in NEUTRAL (N), engage
reservoir/engine mount with two capscrews and lock- the park brake switch and shut the engine OFF.
washers.
WARNING: Hot hydraulic fluid can cause
Auxiliary Function severe burns. Wait for hydraulic fluid to cool
Manifold before servicing any hydraulic component.

Pressure Reducing
Valve “PS”

Pressure Reducing
Valve “PB”

Pressure Relief
Valve

Battery

P
MS2100

Figure 9–55. The auxiliary function manifold PS T

is located near the battery.

G
PS
The auxiliary function manifold (Fig. 9–56) is a machined
block with ports for three pressure reducing valves, two
solenoid valves, and related hose fittings. The auxiliary
function manifold also contains a check valve that can be PP

replaced if defective. PP
G PB
G Solenoid
PB
Pressure reducing valve “PS” is set at 2500 psi (172 bar);
valve “PB” is set at 550 psi (38 bar), and the pressure
relief valve is set at 650 psi (45 bar). Check
Valve
Verify the correct operation of the solenoids before con-
sidering replacement of the auxiliary function manifold. Solenoid
The manifold itself is not serviceable and must be
replaced in its entirety if replacement of parts does not MS2030

solve the problem. Figure 9–56. Auxiliary function manifold components.

DO NOT loosen, disassemble or attempt to adjust any of
1. Unlatch, unlock and open the engine cover. Allow the
the pressure valves unless specifically instructed by Sky
hydraulic fluid to cool.
Trak to do so! Tampering with a pressure valve will irre-
vocably alter pressure in the affected circuits. A new WARNING: Escaping hydraulic fluid under
pressure reducing valve will be required to rectify the sit- pressure can penetrate the skin, causing seri-
uation. ous injury. Relieve hydraulic pressure before
servicing any hydraulic component.

2. Label or otherwise mark the hydraulic hoses in

relation to the auxiliary function manifold (Fig. 9–55).
Disconnect and cap all hoses, fittings, solenoid wire
terminal leads, etc.
3. Remove the auxiliary function manifold from the
vehicle. Wipe up any hydraulic fluid spillage in, on,
near and around the vehicle.

9-80 Model 3606 • Origin 10/99

 Hydraulic System

b. Auxiliary Function Manifold Disassembly,

Cleaning, Inspection and Reassembly
WARNING: Avoid prolonged engine operation
1. Secure the auxiliary function manifold (Fig. 9– 56) in a in closed areas with inadequate ventilation.
suitable bench vise if possible. Failure to properly ventilate exhaust fumes can
2. Remove the pressure-reducing valve “PS” (Fig. 9– result in death or severe personal injury.
56) set at 2500 psi (172 bar).
6. Start the engine and run at approximately one-third
3. Remove the pressure-reducing valve “PB” set at 550 to one-half throttle for about one minute without
psi (38 bar). moving the vehicle or operating any hydraulic
4. Remove the pressure-relief valve set at 650 psi (45 functions.
bar). 7. Inspect the auxiliary function manifold for leaks and
5. Remove the check valve. check the level of the hydraulic fluid in the reservoir.
Shut the engine OFF.
6. Remove the diagnostic nipples at “PPG” and PBG”.
7. Clean all components with a suitable cleaner before Note: Check for leaks and repair as required before con-
inspection. tinuing. Add hydraulic fluid to the reservoir as needed.

8. Inspect internal passageways of the auxiliary function 8. Conduct a pressure check of the service brake and
manifold and it component parts for wear, damage, steering hydraulic circuits.
etc. If inner surfaces of the auxiliary function manifold 9. Wipe up any hydraulic fluid spillage in, on, near and
do not display an ultra-smooth, polished finish, or around the vehicle, work area and tools.
components are damaged in any way, replace the
auxiliary function manifold or appropriate part. Most 9.9.4 Joystick Valve
often, dirty hydraulic fluid causes failure of internal
seals and damage to the polished surfaces within the The joystick valve (1, Fig. 9– 43) is part of the joystick
auxiliary function manifold. assembly. Refer to Section 4 Cab, Covers and Mirrors for
further information regarding replacement of the joystick
Note: Always replace seals, O-rings, gaskets, etc. with assembly.
new parts to help ensure proper sealing and operation.
Joystick commands are actuated both electrically and
hydraulically via a set of solenoid-operated control valves
c. Auxiliary Function Manifold Installation
mounted in an array at the pilot select manifold.
1. Align the auxiliary function manifold with its mount Verify the correct operation of the joystick switches and
holes on the hydraulic reservoir/engine mount near circuit solenoids before considering replacement of the
the battery (Fig. 9– 55). joystick valve. The valve itself is not serviceable and must
2. Align gaskets, bolt holes, etc. with component mount be replaced in its entirety if replacement of electrical
holes. Secure the auxiliary function manifold with the parts does not solve the problem.
necessary fasteners. Torque fasteners to
specification.
3. Before attaching the hoses, prime the auxiliary
function manifold by filling the hydraulic hose ports
with fresh, filtered hydraulic oil.
4. Use new O-rings as required. Reattach and secure
all valves, diagnostic nipples, hoses, clamps,
solenoids and wiring, etc.
5. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.

Model 3606 • Origin 10/99 9-81

 Section 9

9.9.5 Pilot Select Manifold 4. Remove the four 1/4-20 x 2-1/2 Grade 5 hex-head
capscrews (31, Fig. 9– 51), 1/4-20 hex nuts (34) and
The pilot select manifold (Fig. 9– 57) is a precisely-
1/4” lockwashers (29) securing the manifold (1) to the
machined block located inside the rear cover, secured at
main control valve plate bracket (5).
its four corners by capscrews and lockwashers to the
main control valve plate assembly (Fig. 9– 51) near the 5. Remove the pilot select manifold (1) from the vehicle.
left inside frame rail. The pilot select manifold contains Wipe up any hydraulic fluid spillage in, on, near and
ports for cartridge valves and hose fittings. around the vehicle.
DO NOT loosen, disassemble or attempt to adjust any of
b. Pilot Select Manifold Disassembly, Cleaning,
the cartridges unless specifically instructed by Sky Trak
Inspection and Reassembly
to do so!
1. Secure the pilot select manifold in a suitable bench
vise if possible. Remove the solenoid coils (Fig. 9–
57) and cartridge valves from the manifold.
2. Clean all components with a suitable cleaner before
inspection.
3. Inspect internal passageways and parts for wear,
damage, etc. If inner surfaces of the pilot select
manifold do not display an ultra-smooth, polished
finish, or are damaged in any way, replace the
manifold in its entirety. Most often, dirty hydraulic fluid
causes failure of internal seals and damage to the
polished surfaces within the component.
Note: Always replace seals, O-rings, gaskets, etc. with
Solenoid Coil new parts to help ensure proper sealing and operation.

Pilot Select Cartridge Valve c. Pilot Select Manifold Installation

Manifold
1. Place the pilot select manifold (1, Fig. 9– 51) into
MS1990 position on the main valve plate bracket (5) at the left
rear inner frame wall of the vehicle.
Figure 9– 57. Pilot select manifold.
2. Install the four 1/4-20 x 2-1/2 Grade 5 hex-head
a. Pilot Select Manifold Replacement capscrews (31), 1/4-20 hex nuts (34) and 1/4”
lockwashers (29) to secure the pilot select manifold
1. Park the vehicle on a firm, level surface, fully retract to the main valve plate bracket (5). Torque fasteners
all hydraulic cylinders, ground the attachment (if any), to 9 lb/ft (12 Nm).
place the travel select lever in neutral (N), engage the
park brake switch and shut the engine OFF. 3. Prime the pilot select manifold by adding a small
quantity of fresh, filtered hydraulic oil through the port
WARNING: Hot hydraulic fluid can cause holes before attaching the hoses.
severe burns. Wait for hydraulic fluid to cool 4. Use new O-rings as required. Reattach and secure
before servicing any hydraulic component. all hoses, clamps, wire terminals, etc.
2. Unlatch, unlock and open the engine cover. Allow the 5. Check the routing of all hoses, wiring and tubing for
hydraulic fluid to cool. sharp bends or interference with any rotating
members, and install tie wraps and/or protective
WARNING: Escaping hydraulic fluid under conduit as required. Tighten all tube and hose
pressure can penetrate the skin, causing seri- clamps.
ous injury. Relieve hydraulic pressure before
servicing any hydraulic component. WARNING: Avoid prolonged engine operation
in closed areas with inadequate ventilation.
3. Label or otherwise mark all of the hydraulic hoses Failure to properly ventilate exhaust fumes can
and solenoid wire terminal leads in relation to the result in death or severe personal injury.
pilot select manifold. Disconnect the wiring, and cap
all hoses, fittings, etc.

9-82 Model 3606 • Origin 10/99

 Hydraulic System

6. Start the engine and run at approximately 1/3 to 1/2 9.9.7 Steer Select Valve
throttle for about one minute without moving the
The steer select valve and manifold (Fig. 9–59 and
vehicle or operating any hydraulic functions.
Fig. 9–60) are secured with four capscrews and O-rings
7. Inspect for leaks and check the level of the hydraulic to the hydraulic fluid reservoir/engine mount.
fluid in the reservoir. Shut the engine OFF.
The steer select valve contains two solenoids that direct
Note: Check for leaks and repair as required before con- the flow of hydraulic fluid according to steering input. The
tinuing. Add hydraulic fluid to the reservoir as needed. valve is a direct dual-solenoid operated, spool-type direc-
tional control valve.
8. Conduct a pressure check of all boom function
hydraulic circuits. Steer Select
9. Wipe up any hydraulic fluid spillage in, on, near and Manifold
around the vehicle, work area and tools.
Steer Select
Solenoid Valve
Capscrew
9.9.6 Steering Valve
The steering valve (Fig. 9–58) is located at the base of
the steering wheel shaft, concealed by the lower dash Capscrew
cover. The valve is not serviceable and must be replaced
in its entirety if defective. Hydraulic Hose
Steering Valve Replacement
Refer to Section 4 Cab, Covers and Mirrors for steering
valve replacement information. DO NOT attempt to dis-
assemble the steering valve.

Steering Valve

MS2070

Figure 9–59. Steer select valve location and mounting.

The steer select valve controls the start, stop and direc-
tion of hydraulic fluid flow to the steering cylinders
Brake Valve
mounted on each axle.
MS2050 The valve consists of a housing (2, Fig. 9–60), two sole-
Figure 9–58. Steering valve. noids (3), a control spool (4), and two return springs (5).
In the de-energized state, the spool (4) is held by the
return springs (5) in the center position.
The spool is shifted via the action of the two wet-pin type
solenoids (3). The force of an acting solenoid pushes
against the push pin (6) on the end of the spool (4).
The spool is shifted from its normal position to the end
position for selected flow. The selected flow pattern will
be one of two possible patterns: either P to A and B to T,
or P to B and A to T.

Model 3606 • Origin 10/99 9-83

 Section 9

When the solenoid is de-energized, the control spool (4)

is returned to its normal condition by the centering
springs (5). P2

P3
8
P1

MS2080
4 3 Figure 9– 61. Shuttle valve.
3 2
7 5 6 7
6 5

WARNING: Hot hydraulic fluid can cause

severe burns. Wait for hydraulic fluid to cool
before servicing any hydraulic component.

2. Unlatch, unlock and open the engine cover. Allow the

MS2060
hydraulic fluid to cool.
1. O-rings 5. Return Springs
2. Housing 6. Push Pin WARNING: Escaping hydraulic fluid under
3. Solenoids (2) 7. Manual Override
pressure can penetrate the skin, causing seri-
ous injury. Relieve hydraulic pressure before
4. Control Spool 8. Solenoid-operated Valve
servicing any hydraulic component.
Figure 9– 60. Steer select valve location.
3. Label or otherwise mark the hydraulic hoses (Fig. 9–
62) at the service brake valve in relation to the shuttle
When troubleshooting a steering problem, also check the valve. Disconnect and cap all hoses and fittings, etc.
steer select valve solenoids for proper operation, and 4. Remove the shuttle valve from the vehicle. Wipe up
check the wiring for continuity or shorts. any hydraulic fluid spillage in, on, near and around
Refer to Section 10 Electrical System for further informa- the vehicle.
tion on electrical components. Replace a defective or
faulty steer select valve with a new unit. b. Shuttle Valve Cleaning, Inspection
and Reassembly
1. Clean the shuttle valve with a suitable cleaner before
9.9.8 Shuttle Valve inspection.
The shuttle valve (Fig. 9– 61 and Fig. 9– 62) is attached to 2. Inspect internal passageways and the shuttle valve
the brake valve (Fig. 9– 58) with a 90° elbow fitting. The overall for wear, damage, etc. If inner surfaces of the
shuttle valve joins the steering valve shuttle fluid input component do not display an ultra-smooth, polished
line, shuttle-in line from the main control valve, and the finish, or are damaged in any way, replace the shuttle
brake valve load-sense line. The shuttle valve contains a valve. Most often, dirty hydraulic fluid causes failure
pressure-dependent two-way check and is a non-service- of internal seals and damage to the polished
able item. It must be replaced in its entirety if defective. surfaces within the shuttle valve.
3. Replace a defective shuttle valve with a new one.
a. Shuttle Valve Removal
Note: Always replace seals, O-rings, gaskets, etc. with
1. Park the vehicle on a firm, level surface, fully retract new parts to help ensure proper sealing and operation.
all hydraulic cylinders, ground the attachment (if any),
place the travel select lever in neutral (N), engage the
park brake switch and shut the engine OFF.

9-84 Model 3606 • Origin 10/99

 Hydraulic System

c. Shuttle Valve Installation 9.9.9 Service Brake Valve

1. Attach the shuttle valve (Fig. 9– 61) to the brake valve The service brake valve (Fig. 9– 58 and Fig. 9– 63) is
(Fig. 9– 62) with a 90° elbow fitting. The shuttle valve secured with four capscrews and lockwashers at the
(Fig. 9– 61) joins the steering valve shuttle fluid input base of the steering column support, concealed by the
line (port P1, Fig. 9– 61), shuttle-in line from the main lower dash cover.
control valve (port P2), and the brake valve load- The service brakes themselves are part of the axles (the
sense line (port P3). Use new O-rings as required. park brake is part of the front axle only). Refer to Section
Reattach and secure all hoses, clamps, etc. 5 Axles, Wheels and Tires for further information.
2. Check the routing of all hoses, wiring and tubing for Service Brake Valve Replacement
sharp bends or interference with any rotating
members, and install tie wraps and/or protective Refer to Section 4 Cab, Covers and Mirrors for informa-
conduit as required. Tighten all tube and hose tion on replacing the service brake valve.
clamps. DO NOT disassemble the service brake valve. The ser-
vice brake valve is not serviceable and must be replaced
WARNING: Avoid prolonged engine operation
in its entirety if defective as no replacement parts are
in closed areas with inadequate ventilation.
available for internal components.
Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.

3. Start the engine and run at approximately 1/3 to 1/2

throttle for about one minute without moving the
vehicle or operating any hydraulic functions.
4. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before con-
tinuing. Add hydraulic fluid to the reservoir as needed.
5. Conduct a pressure check of the service brake and
steering hydraulic circuits.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle, work area and tools. MS2090

Figure 9– 63. Service brake valve.

From Main
Control Valve Shuttle
Valve

To Front
Brakes

To Rear
Brakes

Diagnostic
Nipple

MS2510

Figure 9– 62. Service brake valve and shuttle valve detail.

Model 3606 • Origin 10/99 9-85

 Section 9

9.10 CYLINDERS Note: An additional O-ring may be included at the base

of the cylinder rod. This additional O-ring may be
There are many factors involved with the proper disas- discarded, as it served only in a temporarily protective
sembly, cleaning, inspection, repair and reassembly of role to keep paint off the rod while the cylinder was
hydraulic cylinders; therefore, only qualified professionals painted at the factory.
with proper training, supervision, tools and equipment
should rebuild the cylinders used on this vehicle. b. General Cylinder Cleaning Instructions
For example, special pin spanner wrenches of the correct
Clean all reusable metal parts thoroughly after disassem-
size are needed to disassemble the cylinders. Also, the
bly and prior to inspection. Use an approved solvent such
hoist/lower cylinder rod locknut must be torqued to 1550-
as trichlorethylene.
1750 lb/ft (2034-2305 Nm); this requires a special torque
wrench and/or torque multiplier. If the proper knowledge
c. General Cylinder Assembly Instructions
and equipment are not available, the cylinders must be
sent out for rebuilding by a competent professional at a 1. Before reassembly, assure that parts are clean and
company that specializes in rebuilding agricultural and free from foreign matter. Use an approved solvent for
industrial heavy-equipment hydraulic cylinders. cleaning, such as trichlorethylene.
Rebuild cylinders only in a clean, well-lighted area where 2. Use the proper tools for specific installation tasks.
all components can be carefully and thoroughly Clean tools are required for installation.
inspected. If leaving a cylinder dismantled for any length 3. Protect the finish on the rod at all times. Damage to
of time longer than the immediate rebuilding period, and the rod can cause premature seal failure.
especially in high-humidity environments, coat the metal
parts with a suitable preservative and place them in pro- 4. Always use new O-rings, seals, gaskets, etc. DO
tective storage. NOT over-stretch seals, wipers and O-rings. After
installing such parts, verify that they are not twisted in
Refer to the specific instructions for removal, rebuilding their grooves.
and installation of each cylinder.
5. To aid in installation, lubricate piston seals and the
a. General Cylinder Disassembly Instructions seal installation path with clean, filtered hydraulic oil.
6. Lubricate the outer surfaces of the seals and O-rings
WARNING: To help prevent severe burns, pro- and the inside of the tube, piston and head gland with
ceed with caution when applying heat to parts. clean hydraulic oil from a filtered source. Use a
Avoid the use of excessive heat, which will suitable installation or compression tool when
damage parts and make them unusable. installing the piston and head gland into the cylinder
to help prevent twisting or damaging the seals and O-
Some cylinder parts are sealed with a “special organic”
rings. When sliding the rod and piston assembly in
sealant and locking compound. Before attempting to dis-
the tube, DO NOT damage the piston by scraping it
assemble these parts, remove any accessible seals from
against the threads in the tube. Keep the rod in line
the area of the bonded parts. Wipe off any hydraulic oil,
with the tube to prevent binding.
then heat the part(s) uniformly to break the bond. A tem-
perature of 300° F to 400° F (149° C to 204° C) will 7. Follow the manufacturer's instructions when applying
destroy the bond. Avoid overheating, or the parts may primer, locking or retaining compounds that are
become distorted or damaged. Apply sufficient torque for specified in the cylinder assembly procedures. The
removal while the parts are still hot. The sealant often use of primer is recommended in some cases to
leaves a white, powdery residue on threads and other decrease cure time. Allow sealant to cure fully before
parts, which must be removed by brushing with a soft proceeding with the assembly procedure. The curing
brass wire brush prior to reassembly. process may be hastened by the use of a heat gun to
blow warm, dry air on the parts.
Note: Significant pressure may be trapped inside the
cylinder. Exercise caution when removing counter-bal- 8. After assembling a cylinder, test the cylinder at low
ance valves from a cylinder and when disassembling a operating pressures. Verify that the piston and rod
cylinder with a pilot-to-open check valve. move freely in both directions.
9. Increase the operating pressure to the maximum
DO NOT attempt to salvage cylinder seals, sealing rings
pressure recommended for the cylinder. Check for
or O-rings. Always use a new, complete seal kit when
external leakage and for free movement in both
rebuilding hydraulic components. Consult the parts cata-
directions.
log for ordering information.
10. Retracting the piston fully. Cap the hydraulic fittings.

9-86 Model 3606 • Origin 10/99

 Hydraulic System

9.10.1 Attachment Tilt Cylinder role to keep paint off the rod while the cylinder was
painted at the factory.
The attachment tilt cylinder (Fig. 9– 64) is attached at the
front of the inner boom inside the gooseneck. 1. Clean the attachment tilt cylinder (Fig. 9– 64) with a
suitable cleaner before inspection.
a. Attachment Tilt Cylinder Removal 2. Place the attachment tilt cylinder in a soft-jawed vise
1. Park the vehicle on a firm, level surface, fully retract or other acceptable holding equipment if possible.
all hydraulic cylinders, ground and remove the DO NOT damage the tube. If necessary, remove the
attachment. Allow sufficient work space at the front of grease fitting from the end of the rod weldment (18).
the boom. Raise the boom enough to allow the quick Note: Significant pressure may be trapped inside the
attach or the bottom of the gooseneck to clear the cylinder. Exercise caution when removing the counter-
ground. Place the travel select lever in NEUTRAL balance valves (2) from the cylinder.
(N), engage the park brake switch and shut the
engine OFF. 3. Remove the two 4000 psi (276 bar) counterbalance
valves (2) from the attachment tilt cylinder.
WARNING: Hot hydraulic fluid can cause
4. Extend the rod weldment (18) to allow access to the
severe burns. Wait for hydraulic fluid to cool
base of the cylinder.
before servicing any hydraulic component.
5. Using a pin spanner wrench, unscrew the head gland
2. Unlatch, unlock and open the engine cover. Allow the (14) from the tube (3). The gland was originally
hydraulic fluid to cool. torqued to 300-400 lb/ft (407-542 Nm), so a
WARNING: Escaping hydraulic fluid under considerable amount of force is required to remove it.
pressure can penetrate the skin, causing seri- Slide the gland down along the rod toward the eyelet
ous injury. Relieve hydraulic pressure before end, away from the cylinder tube (3).
servicing any hydraulic component. IMPORTANT: Protect the finish on the rod at all times.
Damage to the surface of the rod can cause seal failure.
3. Label or otherwise mark the hydraulic hoses in
6. Carefully pull the rod (18) along with the head gland
relation to the attachment tilt cylinder. Disconnect
and all attachments straight out of the tube (3).
and cap both hoses and attachment tilt cylinder
fittings. Refer to Section 3 Boom as required. IMPORTANT: When sliding the rod and piston assembly
in the tube, prevent the threaded end of the tube from
4. Unbolt the lower pivot pin.
damaging the piston (6). Keep the rod centered within the
5. Screw an eyelet, hook, or other suitable fastener into tube to help prevent binding.
the tapped hole on top of the attachment tilt cylinder.
7. Fasten the eye of the rod in a soft-jawed vise and put
Make sure the device used can actually support the
a padded support below and near the threaded end
cylinder. Attach a suitable sling to an overhead crane
of the rod to help prevent damage to the rod.
or other appropriate lifting device and to the
attachment tilt cylinder at the eyelet or hook. 8. Remove the 1.50-12 NF lock nut (4) from the rod
(18). The lock nut is a deformed-thread type nut
6. Remove the two 2" external retaining rings securing
torqued at 1100-1250 lb/ft (1492-1695 Nm).
the attachment tilt cylinder base pin to the boom.
7. Remove the attachment tilt cylinder base pin by Note: It may be necessary to apply heat to break the
tapping it out through the top of the gooseneck. bond of the sealant between the 1.50-12 NF lock nut (4)
and the rod (18) before the piston (6) can be removed.
8. Remove the lower attachment tilt cylinder pin by Some parts of cylinders are sealed with a special organic
tapping it out through the bottom of the quick attach sealant and locking compound. Before attempting to dis-
(if installed). assemble these parts, remove any accessible seals from
9. Remove the attachment tilt cylinder from the vehicle. the area of the bonded joint. Wipe off any hydraulic oil
Wipe up any hydraulic fluid spillage in, on, near or and heat the joint uniformly to break the bond. A temper-
around the vehicle. ature of 300° to 400° F (149° to 204° C) will destroy the
bond. Avoid overheating or the parts may become dis-
b. Attachment Tilt Cylinder Disassembly torted or damaged. Apply sufficient torque or pressure for
removal while the parts are still hot. Breakdown of seal-
Note: An additional O-ring may be included at the base
ant will leave a white, powdery residue on threads and
of the cylinder rod. This additional O-ring may be
parts. Clean the residue away with a soft brass wire
discarded, as it served only in a temporarily protective
brush prior to reassembly, and wipe with Loctite “T”
cleaner before reinstallation.

Model 3606 • Origin 10/99 9-87

 Section 9

17
1
Torque to 300-400 lb/ft. 16
(407-542 Nm) 14
17
18

8
Apply Loctite #271 and 15
13
Torque to 1100-1250 lb/ft.
12
(1492-1695 Nm)
11
10
3 9
5
7
6 19
2 5
4 PF0760

20
Torque to 30-35 lb/ft.
(41-47 Nm) - 2 Places
2 PF0760
PS0580

Figure 9– 64. Attachment tilt cylinder.

Attachment Tilt Cylinder Legend

1. Attachment Tilt Cylinder w/Bushings 9. Remove the piston (6) and the head gland (14) from
(includes items 2 through 18) the rod (18).
2. Counterbalance Valve - Set at 4000 psi (276 bar)
10. Remove the O-ring (9), back-up ring (10), O-ring
3. Tube
(11), precision wearband (12) and deep Z-seal with
4. Lock Nut, 1.50-12 NF rod backup (13) from the head gland (14).
5. Precision Wearband
11. Remove the locking insert (15) from its hole in the
6. Piston
head gland threads. Pry or drill out the insert as
7. Capped T-Seal, Type 730
required. DO NOT damage the head gland threads. A
8. O-Ring new locking insert will be required for reassembly.
9. O-Ring
12. Remove both precision wearbands (5) and the Type
10. Backup Ring
730 capped T-seal (7) from the piston (6).
11. O-Ring
12. Precision Wearband Note: The T-seal actually consists of four components; a
13. Deep Z-Seal with Rod Backup wide, flexible inner band, the flexible T-seal band itself,
14. Head Gland and two supportive split caps that mount on either side of
the “T” itself.
15. Locking Insert
16. HD Rod Wiper, Sealed OD 13. Remove the sealed outside diameter heavy-duty rod
17. Bushing wiper (16) from the head gland (14).
18. Rod Weldment 14. Remove the small O-ring (8) from within the piston
(6).
KITS
19. Seal Kit (includes items 5, 7-13 & 15-16) 15. If the bushings (17) need replacement, support the
20. Seal Kit (for item 2) rod (18) in a soft-jawed vise or other suitable holding
device. Carefully press the bushings from the rod.

9-88 Model 3606 • Origin 10/99

 Hydraulic System

c. Attachment Tilt Cylinder Cleaning and two supportive split caps that mount on either side of
the “T” itself.
1. Thoroughly clean the inner surface of the attachment
tilt cylinder (Fig. 9– 64) with trichlorethylene or 4. Install the O-ring (9), back-up ring (10), O-ring (11),
another approved cleaner. precision wearband (12) and deep Z-seal with rod
2. Discard all seals, backup rings and O-rings. Replace backup (13) onto the head gland (14).
with new items from a complete seal kit to help 5. Install the head gland (14) and piston (6) onto the rod
ensure proper cylinder function. weldment (18).
3. Clean all metal parts with an approved cleaning IMPORTANT: When sliding the rod and piston assembly
solvent such as trichlorethylene. Carefully clean in the tube, prevent the threaded end of the tube from
cavities, grooves, threads, etc. damaging the piston (6). Keep the rod centered within the
tube to help prevent binding.
Note: If a white, powdery residue is present on threads
and parts, it can be removed. Clean the residue away 6. Place the attachment tilt cylinder in a soft-jawed vise
with a soft brass wire brush prior to reassembly, and wipe or other acceptable holding equipment if possible.
with Loctite “T” cleaner before reinstallation. DO NOT damage the tube. Carefully insert the rod
(18) with all attachments straight into the tube (3).
d. Attachment Tilt Cylinder Inspection IMPORTANT: Protect the finish on the rod at all times.
1. Inspect internal surfaces and all parts for wear, Damage to the surface of the rod can cause seal failure.
damage, etc. If inner surface of the tube (3, Fig. 9– 7. Fasten the eye of the rod in a soft-jawed vise and put
64) does not display a smooth finish, or is scored or a padded support below and near the threaded end
damaged in any way, replace the tube. Most often, of the rod to help prevent damage to the rod.Apply
dirty hydraulic fluid causes failure of internal seals Loctite #271 (red) and install the 1.50-12 NF lock nut
and damage to the smooth surface within the tube. (4) onto the rod (18). Torque the nut to 1100-1250 lb/
Remove slight scratches on the piston, rod, or inner ft (1492-1695 Nm). The threads will deform upon
surface of the tube with very fine grit emery cloth. tightening, locking the nut in place.
Use the emery cloth in a rotary motion to polish out 8. Using a pin spanner wrench, thread the head gland
and blend the scratch(es) into the surrounding (14) almost completely into the tube (3), leaving just
surface. enough room to install a new locking insert (15) into
2. Inspect all other components for wear, damage, etc. its hole in the head gland threads.
Clean parts with trichlorethylene. 9. Install a new locking insert (15). Thread the head
3. Check that the rod (18) is straight. If it is bent, a new gland tightly into the tube and torque to 300-400 lb/ft
rod must be installed. (407-542 Nm).
10. Thread the two 4000 psi (276 bar) counterbalance
e. Attachment Tilt Cylinder Assembly valves (2) into the attachment tilt cylinder. Torque to
Note: Follow Section 9.10 c. General Cylinder Assembly 30-35 lb/ft (41-47 Nm).
Instructions. 11. If necessary, install a grease fitting into the tapped
1. If the bushings (17, Fig. 9– 64) need replacement, hole in the end of the rod weldment (18). Lubricate
support the rod (18) in a soft-jawed vise or other the bearings in the rod end through the grease fitting
suitable holding device. Carefully press the bushings with multi-purpose grease before the vehicle is
into the rod eyelet. Install the grease fittings and operated.
lubricate with multi-purpose grease after installing
the attachment tilt cylinder onto the inner boom. f. Attachment Tilt Cylinder Installation

2. Install the small O-ring (8) into the rod-end of the 1. Screw an eyelet, hook, or other suitable fastener into
piston (6). the tapped hole on top of the attachment tilt cylinder
(Fig. 9– 64). Make sure the device used can actually
IMPORTANT: Install the sealed outside diameter heavy-
support the cylinder. Attach a suitable sling to an
duty rod wiper (16) into the outside end of the head gland
overhead crane or other suitable device and to the
(14).
attachment tilt cylinder at the eyelet or hook. Place
3. Install both precision wearbands (5) and the Type the attachment tilt cylinder in position within the
730 capped T-seal (7) onto the piston (6). gooseneck. Refer to Section 3 Boom as required.
Note: The T-seal actually consists of four components; a
wide, flexible inner band, the flexible T-seal band itself,

Model 3606 • Origin 10/99 9-89

 Section 9

2. Install the lower attachment tilt cylinder pin by tapping 9.10.2 Slave Cylinders
it out through the bottom of the quick attach (if
Each slave cylinder (Fig. 9– 65) is secured to the vehicle
installed).
frame and outer boom with cylinder mount pins, hex-
3. Coat the attachment tilt cylinder base pin with anti- head capscrews and nuts.
seize compound and install the pin by tapping it in
through the top of the gooseneck. a. Slave Cylinder Removal
4. Secure the attachment tilt cylinder base pin to the Note: An additional O-ring may be included at the base
boom with two 2" external retaining rings. of the cylinder rod. This additional O-ring may be
5. Install the lower pivot pin and quick attach as discarded, as it served only in a temporarily protective
required. role to keep paint off the rod while the cylinder was
6. Connect the attachment tilt cylinder hydraulic hoses painted at the factory.
in relation to the labels or markings made during 1. Park the vehicle on a firm, level surface, fully retract
removal. all hydraulic cylinders, then raise the boom to
WARNING: Avoid prolonged engine operation approximately a 30-degree angle. Place the travel
in closed areas with inadequate ventilation. select lever in NEUTRAL (N), engage the park brake
Failure to properly ventilate exhaust fumes can switch and shut the engine OFF.
result in death or severe personal injury. WARNING: Hot hydraulic fluid can cause
severe burns. Wait for hydraulic fluid to cool
7. Start the engine and run at approximately one-third
before servicing any hydraulic component.
to one-half throttle for about one minute without
moving the vehicle or operating any hydraulic 2. Unlatch, unlock and open the engine cover. Allow the
functions. hydraulic fluid to cool.
8. Inspect for leaks and check the level of the hydraulic WARNING: Escaping hydraulic fluid under
fluid in the reservoir. Add hydraulic fluid to the pressure can penetrate the skin, causing seri-
reservoir as needed. Shut the engine OFF. ous injury. Relieve hydraulic pressure before
9. Wipe up any hydraulic fluid spillage in, on, near and servicing any hydraulic component.
around the vehicle, work area and tools.
3. Label or otherwise mark the hydraulic hoses in
10. Conduct a pressure check of the attachment tilt
relation to the slave cylinder being removed.
cylinder hydraulic circuit and bleed the circuit as
Disconnect and cap the hydraulic hoses and slave
outlined below.
cylinder fittings.
g. Attachment Tilt Cylinder Pressure Checking 4. Securely support the slave cylinder. Remove the
and Circuit Bleeding nuts, hex-head capscrews and cylinder pins securing
the slave cylinder to the vehicle frame and outer
1. Attach a 4000 psi (276 bar) gauge to the main control boom. Refer to Section 3.2.3 A. Outer Boom
valve at the extend base port relief to test the Removal as required.
attachment tilt cylinder hydraulic system circuit
pressure. The unit is equipped with test fittings from 5. With the help of at least one assistant, remove the
the factory. Pressure readings should be 3200 psi ± slave cylinder from the vehicle. Wipe up any hydraulic
100 psi (220,6 ± 7 bar). fluid spillage in, on, near and around the vehicle.

2. With no accessory installed on the quick attach, start b. Slave Cylinder Disassembly
with the hoist and fork tilt cylinders fully retracted.
1. Clean the slave cylinder (Fig. 9– 65) with a suitable
3. Fully extend the fork tilt cylinder. Hold the fork tilt
cleaner before inspection.
joystick at full extend while fully raising the hoist
cylinder. 2. Place the slave cylinder in a soft-jawed vise or other
acceptable holding equipment if possible. DO NOT
4. Fully retract the fork tilt cylinder. Hold the fork tilt
damage the tube. If necessary, remove the grease
joystick at full retract while fully retracting the hoist
fitting from the end of the rod weldment (15).
cylinder.
3. Extend the rod weldment (15) to allow access to the
5. Repeat steps 3 and 4 five times.
base of the cylinder.

9-90 Model 3606 • Origin 10/99

 Hydraulic System

Torque to 250-300 lb/ft.

(339-407 Nm) 14

11 15
10
13
7
12
Apply Loctite #271 and
Torque to 445-515 lb/ft.
(603-698 Nm) 9
8
6
5
4
3
PF0760

16
2
PS0560

Figure 9– 65. Slave cylinder exploded view drawing.

Slave Cylinder Legend

1. Slave Cylinder 4. Using a pin spanner wrench, unscrew the head gland
(includes items 2 through 15) (10) from the tube (2). The gland was originally
2. Tube torqued at 250-300 lb/ft (339-407 Nm). Slide the
3. Lock Nut, 1.125 - 12 NF gland down along the rod toward the eyelet end,
4. Capped T-Seal away from the cylinder tube (2).
5. Piston IMPORTANT: Protect the finish on the rod at all times.
6. O-Ring Damage to the surface of the rod can cause seal failure.
7. Precision Wearband
5. Carefully pull the rod (15) with all attachments
8. Deep Z-Seal with Rod Backup straight out of the tube (2).
9. Locking Insert
IMPORTANT: When sliding the rod and piston assembly
10. Head Gland
in the tube, prevent the threaded end of the tube from
11. Heavy-duty Rod Wiper, Sealed OD
damaging the piston (5). Keep the rod centered within the
12. O-Ring tube to help prevent binding.
13. Backup Ring
6. Fasten the eye of the rod in a soft-jawed vise and put
14. O-Ring
a padded support below and near the threaded end
15. Weldment Rod
of the rod to help prevent damage to the rod.
KITS 7. Remove the O-ring (12), back-up ring (13), O-ring
16. Seal Kit (includes items 4, 6-9 & 11-14) (14), precision wearband (12) and deep Z-seal with
rod backup (13) from the head gland (10).
8. Remove the locking insert (15) from its hole in the
head gland threads. Pry or drill out the insert as
required. DO NOT damage the head gland threads. A
new locking insert will be required for reassembly.

Model 3606 • Origin 10/99 9-91

 Section 9

9. Remove the capped T-seal (4) from the piston (5). d. Slave Cylinder Inspection
Note: The T-seal actually consists of four components; a 1. Inspect internal surfaces and all parts for wear,
wide, flexible inner band, the flexible T-seal band itself, damage, etc. If inner surface of the tube (2, Fig. 9–
and two supportive split caps that mount on either side of 65) does not display a smooth finish, or is scored or
the “T” itself. damaged in any way, replace the tube. Most often,
dirty hydraulic fluid causes failure of internal seals
c. Slave Cylinder Cleaning and damage to the smooth surface within the tube.
Remove slight scratches on the piston, rod, or inner
1. Remove all hydraulic fluid, dirt and debris from the
surface of the tube with very fine grit emery cloth.
inner surface of the cylinder.
Use the emery cloth in a rotary motion to polish out
2. Discard all seals, backup rings and O-rings. Replace and blend the scratch(es) into the surrounding
with new items from a complete seal kit to help surface.
ensure proper cylinder function.
2. Clean parts with trichlorethylene.
3. Clean all metal parts with an approved cleaning
3. Check that the rod (15) is straight. If it is bent, install
solvent such as trichlorethylene. Carefully clean
a new rod.
cavities, grooves, threads, etc.
Note: If a white, powdery residue is present on threads e. Slave Cylinder Assembly
and parts, it can be removed. Clean the residue away
Note: Follow Section 9.10 c. General Cylinder Assembly
with a soft brass wire brush prior to reassembly, and wipe
Instructions.
with Loctite “T” cleaner before reinstallation.
IMPORTANT: Use a suitable installation tool or com-
4. Remove the 1.125-12 NF lock nut (3, Fig. 9– 65) from
pression sleeve to help prevent twisting or damaging the
the rod (15). The deforming-thread type nut was
seals and O-rings when installing the piston and head
coated with Loctite #271 (red) and torqued to 445-
gland into the cylinder. When sliding the rod and piston
515 lb/ft (603-698 Nm). Discard the nut.
assembly in the tube, DO NOT damage the piston by
Note: It may be necessary to apply heat to break the scraping it against the threads in the tube. Keep the rod
bond of the sealant between the 1.125-12 NF lock nut (3) in line with the tube to prevent binding.
and the rod (15) before the piston (5) can be removed. 1. Fasten the eye of the rod in a soft-jawed vise and put
Some parts of cylinders are sealed with a special organic a padded support below and near the threaded end
sealant and locking compound. Before attempting to dis- of the rod to help prevent damage to the rod.
assemble these parts, remove any accessible seals from
the area of the bonded joint. Wipe off any hydraulic oil 2. Within the piston (5), install the small O-ring (6, Fig.
and heat the joint uniformly to break the bond. A temper- 9– 65) and the precision wearband (7).
ature of 300° to 400° F (149° to 204° C) will destroy the 3. From within the head gland (10), install the sealed
bond. Avoid overheating or the parts may become dis- outside diameter heavy-duty rod wiper (11), the deep
torted or damaged. Apply sufficient torque or pressure for Z-seal with backup (8), and the precision wearband
removal while the parts are still hot. Breakdown of seal- (7).
ant will leave a white, powdery residue on threads and 4. Carefully install the piston (5) and head gland (10)
parts. Clean the residue away with a soft brass wire onto the rod (15).
brush prior to reassembly, and wipe with Loctite “T”
cleaner before reinstallation. IMPORTANT: When sliding the rod and piston assembly
in the tube, prevent the threaded end of the tube from
5. Remove the piston (5) and head gland (10) from the damaging the piston (5). Keep the rod centered within the
rod (15). tube to help prevent binding.
6. From within the head gland (10), remove the Note: If a white, powdery residue remains on the
precision wearband (7), the deep Z-seal with backup threads and parts, clean the residue away with a soft
(8), and the sealed outside diameter heavy-duty rod brass wire brush prior to reassembly, and wipe with
wiper (11). Loctite “T” cleaner before proceeding.
7. From within the piston (5), remove the precision
5. Apply Loctite Threadlocker #271 (red) to the 1.125-
wearband (7) and the small O-ring (8).
12 NF lock nut (3). Thread the lock nut onto the rod
(15) and torque to 445-515 lb/ft (603-698 Nm). The
threads will deform upon tightening, locking the nut in
place.

9-92 Model 3606 • Origin 10/99

 Hydraulic System

6. Install the capped T-seal (4) onto the piston (5). 5. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: The T-seal actually consists of four components; a
wide, flexible inner band, the flexible T-seal band itself, Note: Check for leaks and repair as required before con-
and two supportive split caps that mount on either side of tinuing. Add hydraulic fluid to the reservoir as needed.
the “T” itself.
6. Conduct a pressure check of the attachment tilt/slave
7. Install the deep Z-seal with rod backup (13), cylinder hydraulic circuit.
precision wearband (7), O-ring (14), back-up ring 7. Wipe up any hydraulic fluid spillage in, on, near and
(13), and O-ring (12) onto the head gland (10). around the vehicle, work area and tools.
8. Carefully insert the rod (15) with all attachments 8. Conduct a pressure check of the attachment tilt
straight into the tube (2). cylinder hydraulic circuit and bleed the circuit as
IMPORTANT: When sliding the rod and piston assembly outlined below.
in the tube, prevent the threaded end of the tube from
damaging the piston (5). Keep the rod centered within the g. Slave Cylinder Pressure Checking
tube to help prevent binding. Protect the finish on the rod and Circuit Bleeding
at all times. Damage to the surface of the rod can cause
1. Attach a 4000 psi (276 bar) gauge to the main control
seal failure.
valve at the fork tilt port to test the fork tilt and slave
9. Install the locking insert (9) into its hole in the head cylinder hydraulic system circuit pressure. The unit is
gland threads. equipped with test fittings from the factory. Pressure
10. Using a pin spanner wrench, thread the head gland readings should be 3700 psi ± 100 psi (255 ± 7 bar).
(10) into the tube (2). Torque to 250-300 lb/ft 2. With no accessory installed on the quick attach, start
(339-407 Nm). with the hoist and fork tilt cylinders fully retracted.
3. Fully extend the fork tilt cylinder. Monitor pressure
f. Slave Cylinder Installation
while fully raising the hoist cylinder.
1. Align the slave cylinder with its mounting bosses 4. Fully retract the fork tilt cylinder. Monitor pressure
within the rear frame uprights. while fully retracting the hoist cylinder.
2. Align the mount pin bolt holes with the slave cylinder 5. Repeat steps 3 and 4 five times.
mount holes. Align the self-aligning bearing. Secure
the slave cylinder with the cylinder pins, hex-head
capscrews and nuts. Torque the hex-head capscrews
and nuts to specification. Refer to the fastener torque
chart in Section 2 General Information, Specifications
and Maintenance Instructions.
3. Use new O-rings and reattach and secure the
hydraulic hoses to the slave cylinder fittings.
WARNING: Avoid prolonged engine operation
in closed areas with inadequate ventilation.
Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.

4. Start and run the engine at approximately one-third

to one-half throttle for about one minute without
moving the vehicle or operating any hydraulic
functions.

Model 3606 • Origin 10/99 9-93

 Section 9

9.10.3 Extend/Retract Cylinder 8. Remove the locking insert (15) from its hole in the
head gland threads. Pry or drill out the insert as
The extend/retract cylinder (Fig. 9– 66) is located within
required. DO NOT damage the head gland threads. A
the inner boom.
new locking insert will be required for reassembly.
a. Extend/Retract Cylinder Removal 9. Remove the 5/16-18 UNC x 0.63 set screw (5) from
the piston (4). The set screw is used to provide a
Procedures for replacing the extend/retract cylinder secondary lock on the piston.
appear in Section 3.2.1 Inner Boom Replacement.
10. Remove the piston (4) from the rod spacer (8) and
b. Extend/Retract Cylinder Disassembly rod weldment (17). The piston was installed with
Loctite #271 (red) and torqued to 1500-1700 lb/ft
Note: An additional O-ring may be included at the base (2034-2305 Nm).
of the cylinder rod. This additional O-ring may be
discarded, as it served only in a temporarily protective Note: It may be necessary to apply heat to break the
role to keep paint off the rod while the cylinder was bond of the sealant between piston (4) and the rod (17)
painted at the factory. before the piston can be removed. Some parts of cylin-
ders are sealed with a special organic sealant and lock-
1. Clean the extend/retract cylinder (Fig. 9– 66) with a ing compound. Before attempting to disassemble these
suitable cleaner. Remove all dirt, debris and grease parts, remove any accessible seals from the area of the
from the cylinder. bonded joint. Wipe off any hydraulic oil and heat the joint
2. Secure the extend/retract cylinder in a soft-jawed uniformly to break the bond. A temperature of 300° to
vise or other acceptable holding equipment if 400° F (149° to 204° C) will destroy the bond. Avoid over-
possible. DO NOT damage the tube (19). heating or the parts may become distorted or damaged.
Apply sufficient torque or pressure for removal while the
Note: Significant pressure may be trapped inside the parts are still hot. Breakdown of sealant will leave a
cylinder. Exercise caution when removing the counter- white, powdery residue on threads and parts. Clean the
balance valves (18) from the cylinder. residue away with a soft brass wire brush prior to reas-
3. Remove both counterbalance valves (18) from the sembly, and wipe with Loctite T cleaner before reinstalla-
rod weldment (17). tion.
IMPORTANT: DO NOT tamper with or attempt to reset 11. Remove the rod spacer (8).
the counterbalance valve cartridges. If adjustment or 12. Remove both precision wearbands (6) and the
replacement is necessary, replace a counterbalance capped T-seal (7) from the piston (4).
valve with a new one.
Note: The T-seal actually consists of four components; a
4. Extend the rod weldment (17, Fig. 9– 66) as required
wide, flexible inner band, the flexible T-seal band itself,
to allow access to the base of the cylinder.
and two supportive split caps that mount on either side of
5. Using a pin spanner wrench, unscrew the head gland the “T” itself.
(14) from the tube (19). The gland was originally
torqued to 250-300 lb/ft (339-407 Nm), so a 13. Remove the O-ring (9), backup ring (10) and O-ring
considerable amount of force is required. Slide the (11) from the head gland (14). Slide the rings over
gland down along the rod toward the eyelet end, the rod spacer (8) and piston (4) to remove them
away from the cylinder tube (19). from the rod weldment (17).

IMPORTANT: Protect the finish on the rod at all times. 14. Remove the precision wearband (12) and deep Z-
Damage to the surface of the rod can cause seal failure. seal with rod backup (13) from the head gland (14).

6. Carefully pull the rod (17) with all attachments 15. From within the head gland (14), remove the
straight out of the tube (19). precision wearbands (12), the deep Z-seal with
backup (13), and, from the other end, remove the
IMPORTANT: When sliding the rod and piston assembly sealed outside diameter heavy-duty rod wiper (16).
in the tube, prevent the threaded end of the tube from
damaging the piston (4). Keep the rod centered within the 16. From within the piston (4), remove the hytrel backup
tube to help prevent binding. rings (2) and the small O-ring (3).

7. Fasten the rear of the rod in a soft-jawed vise and put

a padded support below and near the threaded end
of the rod to help prevent damage to the rod.

9-94 Model 3606 • Origin 10/99

 Hydraulic System

18
Torque to
150-160 lb/ft.
1 (203-217 Nm)
Torque to 250-300 lb/ft. 16
(339-407 Nm) 15
17
18

Torque to 72-82 lb/in.

14
(8-9 Nm)
13
Apply Loctite #271 and 12
11
Torque to 1500-1700 lb/ft.
10
(2034-2305 Nm) 5 9 20
2 8
6
7
19
6 PF0760
4 21
3

PF0760
PS0600

Figure 9– 66. Extend/retract cylinder.

Extend/Retract Cylinder Legend

1. Extend/Retract Cylinder c. Extend/Retract Cylinder Cleaning
(includes items 2 through 19)
2. Hytrel Backup Ring 1. Remove all hydraulic fluid, dirt and debris from the
inner surface of the cylinder tube (19, Fig. 9– 66).
3. O-Ring
4. Piston 2. Discard all seals, backup rings, O-rings, etc. Replace
5. Setscrew, 5/16-18 UNC x 0.63” with new items from a complete seal kit to help
6. Precision Wearband ensure proper cylinder function.
7. Capped T-Seal, Type 730 3. Clean all metal parts with an approved cleaning
8. Rod Spacer solvent such as trichlorethylene. Carefully clean
9. O-Ring cavities, grooves, threads, etc.
10. Backup Ring Note: If a white, powdery residue is present on threads
11. O-Ring and parts, it can be removed. Clean the residue away
12. Precision Wearband with a soft brass wire brush prior to reassembly, and wipe
13. Deep Z-Seal with Rod Backup with Loctite “T” cleaner before reinstallation.
14. Head Gland
15. Locking Insert d. Extend/Retract Cylinder Inspection
16. Heavy-duty Rod Wiper, Sealed OD 1. Inspect internal surfaces and all parts for wear,
17. Weldment Rod damage, etc. If the inner surface of the tube (19,
18. Counterbalance Valve, set at 4000 psi (276 bar) Fig. 9– 66) does not display a smooth finish, or is
19. Tube scored or damaged in any way, replace the tube.
Most often, dirty hydraulic fluid causes failure of
KITS internal seals and damage to the smooth surface
20. Seal Kit (includes items 2, 3, 6, 7, 9-13, 15, 16) within the tube. Remove slight scratches on the
21. Seal Kit (for item 18) piston, rod, or inner surface of the tube with very fine
grit emery cloth. Use the emery cloth in a rotary
motion to polish out and blend the scratch(es) into
the surrounding surface.

Model 3606 • Origin 10/99 9-95

 Section 9

2. Clean parts with trichlorethylene. IMPORTANT: When sliding the rod (17) and piston
3. Check that the rod (17) is straight. If it is bent, install assembly in the tube, prevent the threaded end of the
a new rod. tube from damaging the piston (4). Keep the rod centered
within the tube to help prevent binding. Protect the finish
e. Extend/Retract Cylinder Assembly on the rod at all times. Damage to the surface of the rod
can cause seal failure.
Note: Follow Section 9.10 c. General Cylinder Assembly
13. Using a pin spanner wrench, thread the head gland
Instructions.
(14) into the tube (19). Torque the gland to 250-300
1. Install a new hytrel backup ring (2, Fig. 9– 66), small lb/ft (339-407 Nm).
O-ring (3) and another hytrel backup ring (2) into 14. Lubricate the counterbalance valves (18) with clean,
forward end of the piston (4). filtered hydraulic oil. Thread both counterbalance
2. Install the capped T-seal (7) and both precision valves into the rod weldment (17). Torque to 150-160
wearbands (6) onto the piston (4). lb/ft (203-217 Nm).
Note: The T-seal actually consists of four components; a IMPORTANT: DO NOT tamper with or attempt to reset
wide, flexible inner band, the flexible T-seal band itself, the counterbalance valve cartridges. If adjustment or
and two supportive split caps that mount on either side of replacement is necessary, replace a counterbalance
the “T” itself. valve with a new one.

3. Install the precision wearbands (12) and the deep Z- 15. Test the cylinder at low operating pressure (100 psi or
seal with backup (13) into the front end of the head 6,9 bar). Verify that the piston and the rod move
gland (14), and, at the rear end, install the sealed freely in both directions.
outside diameter heavy-duty rod wiper (16). 16. Increase the operating pressure to the maximum
4. Install a new O-ring (7), backup ring (10) and O-ring amount for the cylinder (4000 or 275 bar) and again
(11) onto the head gland (14). check for free movement in both directions.

5. Fasten the rear of the rod in a soft-jawed vise and put 17. Retract the rod fully into the tube and cap and plug
a padded support below and near the threaded end the hydraulic hose ports.
of the rod to help prevent damage to the rod.
f. Extend/Retract Cylinder Installation
6. Carefully slide the head gland (14), then the rod
spacer (8) onto the rod weldment (17). Installation procedures are covered in Section 3.2.1 Inner
Boom Replacement.
7. Carefully slide the piston (4) onto the rod spacer (8)
and weldment (17). Apply Loctite Threadlocker #271
g. Extend/Retract Cylinder Pressure Checking and
(red) and torque the piston to 1500-1700 lb/ft (2034-
Circuit Bleeding
2305 Nm).
8. Turn the rod spacer (8) as required to align the piston 1. Attach a 4000 psi (276 bar) gauge to the main control
set screw holes. The set screw is used to provide a valve at the extend base port relief to test the extend/
secondary lock on the piston. Thread the 5/16-18 retract cylinder hydraulic system circuit pressure. The
UNC x 0.63 set screw (5) into the piston (4). Torque unit is equipped with test fittings from the factory.
the set screw to 72-82 lb/in (8-9 Nm). Pressure readings should be 3200 psi ± 100 psi
(220,6 ± 7 bar).
9. Install a new locking insert (15) into its hole in the
head gland threads. 2. With no accessory installed on the quick attach, start
with the hoist and fork tilt cylinders fully retracted.
10. Secure the extend/retract cylinder in a soft-jawed
vise or other acceptable holding equipment if 3. Fully extend the extend/retract cylinder. Hold the
possible. DO NOT damage the tube (19). joystick at full extend while fully raising the hoist
cylinder.
11. Lubricate the inside of the tube (19) and outside of
the piston (4) and head gland (14) with clean, filtered 4. Fully retract the fork tilt cylinder. Hold the fork tilt
hydraulic oil. joystick at full retract while fully retracting the hoist
cylinder.
12. Apply a compression sleeve or other suitable tool to
the head and piston in order to compress the O-rings, 5. Repeat steps 3 and 4 five times.
backup rings and seals while inserting the assembled
piston, rod and head into the tube (19). Carefully
insert the rod (17) with all attachments straight into
the tube (19).

9-96 Model 3606 • Origin 10/99

 Hydraulic System

Orient Fracture In
Bearing Race at Clock
12
11 1 Position Shown
Apply Loctite #271 (red) 10 2
1 and Torque to 9 3 Hoist Cylinder
1550-1750 lb/ft.
(2102-2373 Nm) 8 4
7 5
6 17
8
5
E 7
6 19
5 18
3 16
4 15
20
13
12 PF0760
10
14 21
E
9
15
2 Torque to 300-400 lb/ft
PF0760
11 (407-542 Nm)
Torque to 45-50 lb/ft
(61-68 Nm) PS0590

Figure 9– 67. Hoist/lower cylinder.

Hoist/Lower Cylinder Legend 9.10.4 Hoist/Lower Cylinder

The hoist/lower cylinder (1, Fig. 9– 67) is anchored to the
1. Hoist/Lower Cylinder with Bearing underside of the outer boom and to the vehicle frame.
(includes items 2 through 18)
2. Counterbalance Valve, set at 4000 psi (276 bar) a. Hoist/Lower Cylinder Removal
3. Tube
1. Park the vehicle on a firm, level surface, fully retract
4. Lock Nut, 2.00 - 12 UN
all hydraulic cylinders, ground the attachment (if any),
5. Precision Wearband
place the travel select lever in NEUTRAL (N), engage
6. Piston
the park brake switch and shut the engine OFF.
7. Capped T-Seal
8. O-Ring WARNING: Hot hydraulic fluid can cause
9. O-Ring severe burns. Wait for hydraulic fluid to cool
10. Backup Ring before servicing any hydraulic component.
11. O-Ring 2. Unlatch, unlock and open the engine cover. Allow the
12. Precision Wearband hydraulic fluid to cool.
13. Deep Z-Seal with Rod Backup
14. Head Gland WARNING: Escaping hydraulic fluid under
pressure can penetrate the skin, causing seri-
15. Locking Insert
ous injury. Relieve hydraulic pressure before
16. Heavy-duty Rod Wiper, Sealed OD
servicing any hydraulic component.
17. Self-aligning Bearing
18. Weldment Rod 3. Raise and support the boom to allow removal of the
19. Self-tapping Lube Fitting, 1/8 NPT hoist/lower cylinder (1, Fig. 9– 67). Label or otherwise
mark the hoist/lower cylinder hydraulic hoses.
KITS Disconnect and cap all hoses and fittings.
20. Seal Kit (includes items 5, 7-13, & 15, 16)
21. Seal Kit (for item 2).

Model 3606 • Origin 10/99 9-97

 Section 9

4. Attach a sling to the hoist/lower cylinder and to a damaging the piston (6). Keep the rod centered within the
hoist or an overhead crane. Support the hoist/lower tube to help prevent binding.
cylinder in the sling, and remove both nuts, 9. Fasten the rear of the rod in a soft-jawed vise and put
capscrews and cylinder mount pins from the cylinder. a padded support below and near the threaded end
5. Safely and carefully, remove the hoist/lower cylinder of the rod to help prevent damage to the rod.
from the vehicle. Wipe up any hydraulic fluid spillage 10. Remove both locking inserts (15) from their
in, on, near and around the vehicle. installation holes in the head gland threads. Pry or
drill out the inserts as required. DO NOT damage the
b. Hoist/Lower Cylinder Disassembly head gland threads. New locking inserts will be
Note: An additional O-ring may be included at the base required for reassembly.
of the cylinder rod. This additional O-ring may be 11. Remove the 2.00-12 UN locknut (4) from the rod
discarded, as it served only in a temporarily protective weldment (18). The nut was installed with Loctite
role to keep paint off the rod while the cylinder was #271 (red) and torqued to 1550-1750 lb/ft (2102-
painted at the factory. 2373 Nm).
1. Clean the hoist/lower cylinder (1, Fig. 9– 67) with a Note: It may be necessary to apply heat to break the
suitable cleaner. Remove all dirt, debris and grease bond of the sealant between 2.00-12 UN locknut (4) and
from the cylinder. the rod (18) before the piston (6) can be removed. Some
2. Secure the hoist/lower cylinder in a soft-jawed vise or parts of cylinders are sealed with a special organic seal-
other acceptable holding equipment if possible. DO ant and locking compound. Before attempting to disas-
NOT damage the tube (3). semble these parts, remove any accessible seals from
the area of the bonded joint. Wipe off any hydraulic oil
Note: Significant pressure may be trapped inside the and heat the joint uniformly to break the bond. A temper-
cylinder. Exercise caution when removing the counter- ature of 300° to 400° F (149° to 204° C) will destroy the
balance valve (2) from the eyelet end of the tube (3). bond. Avoid overheating or the parts may become dis-
3. Remove the counterbalance valve (2) from the eyelet torted or damaged. Apply sufficient torque or pressure for
end of the tube (3). removal while the parts are still hot. Breakdown of seal-
ant will leave a white, powdery residue on threads and
IMPORTANT: DO NOT tamper with or attempt to reset
parts. Clean the residue away with a soft brass wire
the counterbalance valve cartridge. If adjustment or
brush prior to reassembly, and wipe with Loctite “T”
replacement is necessary, replace the counterbalance
cleaner before reinstallation.
valve with a new one.
4. If necessary, remove the grease fitting (19) from the 12. Remove the piston (6) from the rod weldment (18).
tapped hole in the end of the rod weldment (18). 13. Remove both precision wearbands (5) and the
5. If the self-align bearing (17) needs replacement, capped T-seal (7) from the piston (6).
support the rod (18) in a soft-jawed vise or other Note: The T-seal actually consists of four components; a
suitable holding device. Carefully press the bearing wide, flexible inner band, the flexible T-seal band itself,
out of the rod eyelet. and two supportive split caps that mount on either side of
6. Extend the rod weldment (18) as required to allow the “T” itself.
access to the base of the cylinder. 14. Remove the O-ring (9), backup ring (10) and O-ring
7. Using a pin spanner wrench, unscrew the head gland (11) from the head gland (14). Slide the rings off over
(14) from the tube (3). The gland was originally the rod (18) and piston (6) to remove them from the
torqued to 300-400 lb/ft (407-542 Nm), so a rod weldment (18).
considerable amount of force is required. Carefully 15. From within the head gland (14), remove the
slide the gland down along the rod toward the eyelet precision wearbands (12), the deep Z-seal with
end, away from the cylinder tube (3). backup (13), and, from the other end, remove the
IMPORTANT: Protect the finish on the rod at all times. sealed outside diameter heavy-duty rod wiper (16).
Damage to the surface of the rod can cause seal failure. 16. From within the piston (6), remove the small O-ring
8. Carefully pull the rod (18) with all attachments (8).
straight out of the tube (3).
IMPORTANT: When sliding the rod and piston assembly
in the tube, prevent the threaded end of the tube from

9-98 Model 3606 • Origin 10/99

 Hydraulic System

c. Hoist/Lower Cylinder Cleaning 6. Carefully slide the head gland (14) onto the rod
weldment (18).
1. Remove all hydraulic fluid, dirt and debris from the
inner surface of the cylinder tube (3, Fig. 9– 67). 7. Carefully slide the piston (6) onto the rod weldment
(18).
2. Discard all seals, backup rings, O-rings, etc. Replace
with new items from a complete seal kit to help 8. Apply Loctite Threadlocker #271 (red) to the threads
ensure proper cylinder function. of the 2.00-12 UN locknut (4). Thread the lock nut
onto the rod weldment (18). Torque to 1550-1750 lb/ft
3. Clean all metal parts with an approved cleaning
(2102-2373 Nm). The threads will deform upon
solvent such as trichlorethylene. Carefully clean
tightening, locking the nut in place.
cavities, grooves, threads, etc.
9. Install two new locking inserts (15) into their holes in
Note: If a white, powdery residue is present on threads the head gland threads.
and parts, it can be removed. Clean the residue away
with a soft brass wire brush prior to reassembly, and wipe 10. Secure the hoist/lower cylinder in a soft-jawed vise or
with Loctite “T” cleaner before reinstallation. other acceptable holding equipment if possible. DO
NOT damage the tube (3).
d. Hoist/Lower Cylinder Inspection 11. Lubricate the inside of the tube (3) and outside of the
piston (6) and head gland (14) with clean, filtered
1. Inspect internal surfaces and all parts for wear,
hydraulic oil.
damage, etc. If inner surface of the tube (3,
Fig. 9– 67) does not display a smooth finish, or is 12. Apply a compression sleeve or other suitable tool to
scored or damaged in any way, replace the tube. the head and piston in order to compress the O-rings,
Most often, dirty hydraulic fluid causes failure of backup rings and seals while inserting the assembled
internal seals and damage to the smooth surface piston, rod and head into the tube (3). Carefully insert
within the tube. Remove slight scratches on the the rod (18) with all attachments straight into the tube
piston, rod, or inner surface of the tube with very fine (3).
grit emery cloth. Use the emery cloth in a rotary IMPORTANT: When sliding the rod (18) and piston
motion to polish out and blend the scratch(es) into assembly in the tube, prevent the threaded end of the
the surrounding surface. tube from damaging the piston (6). Keep the rod centered
2. Clean parts with trichlorethylene. within the tube to help prevent binding. Protect the finish
on the rod at all times. Damage to the surface of the rod
3. Check that the rod (18) is straight. If it is bent, install
can cause seal failure.
a new rod.
13. Using a pin spanner wrench, thread the head gland
e. Hoist/Lower Cylinder Assembly (14) into the tube (3). Torque the gland to 300-400 lb/
ft (407-542 Nm).
Note: Follow Section 9.12 c. General Assembly Instruc-
tions. 14. Lubricate the counterbalance valve (2) with clean,
filtered hydraulic oil. Thread the counterbalance valve
1. Install a new small O-ring (8, Fig. 9– 67) into the into tube (3). Torque to 45-50 lb/ft (61-68 Nm).
piston (6).
IMPORTANT: DO NOT tamper with or attempt to reset
2. Install the capped T-seal (7) and both precision the counterbalance valve cartridge. If adjustment or
wearbands (5) onto the piston (6). replacement is necessary, replace a counterbalance
Note: The T-seal actually consists of four components; a valve with a new one.
wide, flexible inner band, the flexible T-seal band itself, 15. Test the cylinder at low operating pressure (100 psi or
and two supportive split caps that mount on either side of 6,9 bar). Verify that the piston and the rod move
the “T” itself. freely in both directions.
3. Install the deep Z-seal with backup (13) and the 16. Increase the operating pressure to the maximum
precision wearbands (12) into the forward end of the amount for the cylinder (4000 psi, or 276 bar) and
head gland (14), and, at the rear end, install the again check for free movement in both directions.
sealed outside diameter heavy-duty rod wiper (16). 17. Retract the rod fully into the tube and cap and plug
4. Install a new O-ring (9), backup ring (10) and O-ring the hydraulic hose ports.
(11) onto the head gland (14). 18. If the self-align bearing (17) needs replacement,
5. Fasten the rear of the rod in a soft-jawed vise and put support the rod (18) in a soft-jawed vise or other
a padded support below and near the threaded end suitable holding device. Carefully press a new
of the rod to help prevent damage to the rod. bearing into the rod eyelet.

Model 3606 • Origin 10/99 9-99

 Section 9

19. If necessary, install a grease fitting (19) into the 9.10.5 Frame Tilt and Stabilizer Cylinders
tapped hole in the end of the rod weldment (18).
The frame tilt cylinder is attached to the right side of the
Lubricate the self-align bearing (17) in the rod end
frame at the front axle and to a cylinder anchor plate on
through the grease fitting (19) with multi-purpose
the axle.
grease before the boom is operated.
The Stabil-TRAK cylinder is attached to the left side of
f. Hoist/Lower Cylinder Installation the frame at the rear axle and to a cylinder anchor plate
on the axle.
1. Raise and support the boom to allow installation of
the hoist/lower cylinder (1, Fig. 9– 67). Although the cylinders (Fig. 9– 68) do have different man-
ifold blocks, the cylinders themselves are identical and
2. Attach a sling to the hoist/lower cylinder and to a interchangeable. The Stabil-TRAK manifold attached to
hoist or an overhead crane. Safely and carefully, the stabilizer cylinder at the left rear of the vehicle pro-
position the hoist/lower cylinder between the frame vides the operating characteristics for the patented Sta-
rails, aligning the rod and base eyelets with mounting bil-TRAK system.
bosses of the frame and boom.
3. Secure the cylinder with cylinder mount pins, a. Frame Tilt or Stabilizer Cylinder Removal
capscrews and nuts.
1. Park the vehicle on a firm, level surface, fully retract
4. Connect all hoses according to the labels or other all hydraulic cylinders, ground the attachment (if any),
marks used to identify their location during removal. place the travel select lever in NEUTRAL (N), engage
the park brake switch and shut the engine OFF.
WARNING: Escaping hydraulic fluid under
pressure can penetrate the skin, causing seri- WARNING: Hot hydraulic fluid can cause
ous injury. Relieve hydraulic pressure before severe burns. Wait for hydraulic fluid to cool
servicing any hydraulic component. before servicing any hydraulic component.
5. Operate the vehicle to check all boom functions and 2. Unlatch, unlock and open the engine cover. Allow the
for hydraulic system leaks. hydraulic fluid to cool.
6. Wipe up any hydraulic fluid spillage in, on, near and
WARNING: Escaping hydraulic fluid under
around the vehicle. Perform the pressure check and
pressure can penetrate the skin, causing seri-
circuit bleeding procedure below.
ous injury. Relieve hydraulic pressure before
servicing any hydraulic component.
g. Hoist/Lower Cylinder Pressure Checking
and Circuit Bleeding 3. Label or otherwise mark the hydraulic hoses in
1. Attach a 4000 psi (276 bar) gauge to the main control relation to the cylinder being removed. Safely
valve at the extend base port relief to test the hoist/ position suitable supports between the frame and
lower cylinder hydraulic system circuit pressure. The axle to prevent the frame from leaning to one side.
unit is equipped with test fittings from the factory. 4. Disconnect and cap all hoses and fittings, etc.
Pressure readings should be 3200 psi ± 100 psi 5. Use a sling and hoist or other suitable lifting device to
(220,6 ± 7 bar). support the cylinder. Remove the nuts, capscrews,
2. With no accessory installed on the quick attach, start and cylinder mount pins securing the cylinder to the
with the hoist and fork tilt cylinders fully retracted. frame and anchor plate.
3. Fully raise and fully extend the boom. Hold the 6. Remove the cylinder from the vehicle. Wipe up any
joystick at full extend while fully raising the hoist hydraulic fluid spillage in, on, near and around the
cylinder. vehicle.
4. Fully retract the fork tilt cylinder. Hold the joystick at
full retract while fully lowering the boom.
5. Repeat steps 3 and 4 five times.

9-100 Model 3606 • Origin 10/99

 Hydraulic System

1
Torque to 300-400 lb/ft.
15
(407-542 Nm) 14

Manifold Block
Mounting Boss (ref.) 16
10
9
8
13
12
11
Apply Loctite #271 and Torque
to 1100-1250 lb/ft.
(1492-1695 Nm)
7
4
6
5
4
3 17
PF0760
2
PS0570

Figure 9– 68. Frame tilt and/or stabilizer cylinder.

Frame Tilt and Stabilizer Cylinder Legend

1. Frame Tilt/Stabilizer Cylinder b. Frame Tilt or Stabilizer Cylinder Disassembly
(includes items 2 through 16)
2. Tube Note: An additional O-ring may be included at the base
of the cylinder rod. This additional O-ring may be
3. Lock Nut, 1.50 - 12 UN
discarded, as it served only in a temporarily protective
4. Precision Wearband
role to keep paint off the rod while the cylinder was
5. Piston
painted at the factory.
6. Capped T-Seal, Type 730
7. O-Ring 1. Clamp the cylinder (1, Fig. 9– 68) in a soft-jawed vise
8. O-Ring or other holding device, and place a suitable
container beneath the cylinder to catch hydraulic fluid
9. Backup Ring
run-off.
10. O-Ring
11. Precision Wearband 2. Remove the manifold block from the mounting boss
12. Deep Z-Seal with Rod Backup (ref.) as required. Loosen the 3/8-16 x 3-3/4" hex-
head capscrews securing the manifold block to the
13. Locking Insert
cylinder mounting boss in an alternating pattern.
14. Head Gland
15. Heavy-duty Rod Wiper, Sealed OD Note: Significant pressure may be trapped inside the
16. Weldment Rod cylinder. Exercise caution when removing the manifold
block.
KITS
3. Remove the 3/8-16 x 3-3/4" hex-head capscrews, 3/
17. Seal Kit (includes items 4, 6-13, & 15)
8" lockwashers, four SAE 3/8" washers, and O-rings.
Remove the dual pilot-operated check manifold from
the cylinder at the manifold block mounting boss
(ref.).

Model 3606 • Origin 10/99 9-101

 Section 9

4. Remove the locking insert (13) from its hole in the 9. Remove the small O-ring (7).
head gland threads. Pry or drill out the insert as 10. Remove the head gland (14) from the rod (2).
required. DO NOT damage the head gland threads. A
new locking insert will be required for reassembly. 11. Remove both precision wearbands (4) from the
piston (5).
5. Use a pin spanner wrench to unthread the head
gland (14) from the tube (2). 12. Remove the Type 730 capped T-seal (6) from the
piston (5).
Note: The head gland is installed at a torque of 300-400
lb/ft (407-542 Nm). Use suitable tools to remove the head Note: The T-seal actually consists of four components; a
gland. wide, flexible inner band, the flexible T-seal band itself,
and two supportive split caps that mount on either side of
IMPORTANT: Protect the finish on the rod at all times. the “T” seal band.
Damage to the rod can cause premature seal failure.
13. Remove the O-ring (8) from the head gland (14).
6. Carefully withdraw the rod weldment (16) straight out
of the tube (2). Keep the rod straight during 14. Remove the backup ring (9) from the head gland
withdrawal to help avoid scratching, nicking or (14).
damaging the tube. 15. Remove the O-ring (10) from the head gland (14).
IMPORTANT: When sliding the rod and piston assembly 16. Remove the heavy-duty rod wiper (15).
in the tube, DO NOT damage the piston by scraping it
Note: An additional O-ring may be included at the base
against the threads in the tube. Keep the rod in line with
of the rod on some units. This additional O-ring may be
the tube to prevent binding.
discarded, as it served only in a temporarily protective
7. Secure the rod eyelet and remove the 1.50-12 NF nut role to keep paint off the rod while the cylinder was
(3) from the threaded end of the rod. Discard the nut; painted at the factory.
a new nut will be required for reassembly.
17. Remove the precision wearband (11) and deep Z-
Note: Heating the nut to approximately 300° F (150° C) seal with rod backup (12) from inside the head gland
may also be required to break the seal formed by the (14).
Loctite Threadlocker #271 (red) applied to the nut when
installed. The application of significant force is required to Note: Discard all seals and O-rings. Always replace
overcome the 1100-1250 lb/ft (1492-1695 Nm) of torque seals, O-rings, gaskets, etc. with new parts to help
the nut was tightened to when originally installed. ensure proper sealing and operation.

8. Remove the piston (5) from the rod (2).

9-102 Model 3606 • Origin 10/99

 Hydraulic System

c. Frame Tilt or Stabilizer Cylinder Internal Cleaning d. Frame Tilt Cylinder Inspection and Repair
1. Remove all hydraulic fluid, dirt and debris from the In general, inspect all parts for wear, damage, etc. If inner
inner surface of the cylinder. surfaces of the cylinder (1, Fig. 9– 68) do not display an
2. Discard all seals, backup rings and O-rings. Replace ultra-smooth, polished finish, or are damaged in any way,
with new items from a complete seal kit to help replace the damaged part. Most often, dirty hydraulic
ensure proper cylinder function. fluid causes failure of internal seals and damage to the
polished surfaces within the component.
3. Clean all metal parts with an approved cleaning
solvent such as trichlorethylene. Carefully clean 1. Check that the rod weldment (16, Fig. 9– 68) is
cavities, grooves, threads, etc. straight. If the rod is bent, install a new rod.
2. Inspect the inside of the tube (2) for scoring and other
damage. If the tube is damaged, replace it with a new
tube.
3. Remove small scratches on the rod or inside of the
tube with very fine grit emery cloth. Use the emery
cloth in a rotary motion to polish out small
imperfections in the metal
4. Remove any burrs from components with a fine file.
Clean the parts with trichlorethylene after repair.

Model 3606 • Origin 10/99 9-103

 Section 9

e. Frame Tilt or Stabilizer Cylinder Assembly

Note: Follow Section 9.12 c. General Assembly Instruc- 14. Fasten the tube (2) in a soft-jawed vise or other
tions. suitable holding device. DO NOT damage the tube.
1. Install the deep Z-seal with rod backup (12, 15. To aid in installation, lubricate the O-rings and the
Fig. 9– 68) into the head gland. inside of the tube, piston and head gland with clean,
filtered hydraulic oil.
2. Install the precision wearband (11) into the head
gland. IMPORTANT: Use a suitable installation tool or com-
pression sleeve to help prevent twisting or damaging the
3. Install the heavy-duty rod wiper (15) with the raised
seals and O-rings when installing the piston and head
portion of the lip seal oriented toward the rod eyelet
gland into the cylinder. When sliding the rod and piston
as shown.
assembly in the tube, DO NOT damage the piston by
Note: The wiper lip should be toward the outer end of scraping it against the threads in the tube. Keep the rod
the gland and seal lips toward the inner end of the gland. in line with the tube to prevent binding.
Use tools that will not damage the seals. If the backup 16. Keep the rod weldment (16) straight and carefully
ring is not flat on both sides, the side with the arc must be insert the rod weldment into the tube (2). Avoid
toward the O-ring. scratching, nicking or damaging the tube while
4. Install the O-ring (10) onto the head gland (14). installing the rod.
5. Install the backup ring (9) onto the head gland (14). 17. Begin threading the head gland (14) into the tube (2).
Place the locking insert (13) in its hole in the head
6. Install the O-ring (8) onto the head gland (14).
gland threads just before the hole is threaded into the
7. Install the head gland (14) onto the rod (2). If tube. Use a suitable pin spanner wrench to thread the
necessary, use a soft hammer to drive the head head gland (14) completely into the tube (2). Torque
gland onto the rod. to 300-400 lb/ft (407-542 Nm).
8. Install the small O-ring (7) into the piston (5). 18. Attach the dual pilot-operated check manifold to the
9. Install the Type 730 capped T-seal (6) onto the piston cylinder at the manifold block mounting boss with two
(5). new O-rings, four SAE 3/8" washers, 3/8"
lockwashers and 3/8-16 x 3-3/4" hex-head
Note: The T-seal actually consists of four components; a capscrews. In an alternating pattern, slowly tighten
wide, flexible inner band, the flexible T-seal band itself, the bolts securing the valve body to the cylinder.
and two supportive split caps that mount on either side of Torque to 31 lb/ft (42 Nm).
the “T” seal band.
19. Test the cylinder at low operating pressure (100 psi or
10. Install the two precision wearbands (4) onto the 6,9 bar) to verify that the piston and rod move freely
piston (5). in both directions.
11. Install the piston (5) onto the rod (2). 20. Increase the operating pressure to the maximum for
12. Secure the rod eyelet in a soft-jawed vise or other the cylinder (4000 psi or 275 bar) and check for
suitable holding device. Place a padded support external leakage and for free movement in both
below the threaded end of the rod to help prevent directions.
damaging the rod. 21. Retract the piston fully and cap or plug the dual pilot-
13. Apply Loctite Primer “T” and Threadlocker #271 operated check manifold ports.
(red), to a new 1.50-12 NF nut (3) in accordance with
Loctite instructions. Install the nut onto the threaded
end of the rod. Torque the nut to 1100-1250 lb/ft
(1492-1695 Nm).

9-104 Model 3606 • Origin 10/99

 Hydraulic System

f. Frame Tilt or Stabilizer Cylinder Installation g. Frame Tilt or Stabilizer Cylinder

Pressure Checking and Circuit Bleeding
1. Lubricate the 1.5" diameter cylinder pins with multi-
purpose lithium-based grease. 1. Attach a 4000 psi (276 bar) gauge to the main control
2. Use a sling and hoist or other suitable lifting device to valve at the extend base port relief to test the frame
help install the cylinder. Orient the cylinder with the tilt/stabilizer cylinder hydraulic system circuit
cylinder eyelet on top, the rod eyelet on the bottom pressure. The unit is equipped with test fittings from
and the dual pilot-operated check valve facing the the factory. Pressure readings should be 3200 psi ±
rear of the vehicle. 100 psi (220,6 ± 7 bar).

3. Install the upper cylinder pin. Drive the lubricated 2. Start with the frame tilt and stabilizer cylinders
cylinder pin through the cylinder eyelet, frame mount balanced; that is, with the frame level.
and self-aligning bearing. Secure the pin with a 5/16- 3. Tilt the vehicle fully left. Hold the joystick at full tilt left
18 x 3-1/2" capscrew and 5/16-18 hex-lock nut. for several seconds, then tilt the vehicle fully right and
Torque to 18 lb/ft (24 Nm). hold the joystick at full tilt right for several seconds.
4. Use new flat-faced O-rings when installing the upper Observe the readings on the gauge during the frame
and lower hydraulic hoses. Install and tighten the tilt operations.
hoses onto the appropriate fittings on the dual pilot- 4. Level the frame. While leveling the frame, check the
operated check manifold. pressure reading on the gauge.
WARNING: Avoid prolonged engine operation 5. Repeat steps 3 and 4 five times.
in closed areas with inadequate ventilation.
Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.

5. With the help of an assistant, start the engine.

Carefully and slowly, operate the joystick frame tilt
function to properly align the rod with the anchor
plate as required. Turn the engine OFF.
6. Install the lower cylinder pin. Drive the lubricated
cylinder pin through the rod eyelet, anchor plate and
self-aligning bearing. Secure the pin with a 5/16-18 x
3-1/2" capscrew and 5/16-18 hex-lock nut. Torque to
18 lb/ft (24 Nm).
7. Remove all tools, etc. from the vehicle. Carefully
remove the blocking supporting the vehicle frame at
the front and rear axles.
8. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the vehicle or operating any hydraulic
functions. Operate the joystick to fully tilt the frame
left and right at least five times each.
9. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before con-
tinuing. Add hydraulic fluid to the reservoir as needed.
10. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle, work area and tools.

Model 3606 • Origin 10/99 9-105

 Section 9

9.10.6 Swing Carriage (optional)

The optional swing carriage (1, Fig. 9– 69) provides a way
to swing the carriage attachment from side to side. The
swing carriage includes two cylinders that operate to pro-
vide the side to side motion.

Swing Carriage (optional) Legend

1. Carriage 17. Seal, Nose (Not Shown) 30. Shaft, Fork Pivot 52”
2. Cover, Clamp 18. Quick Disconnect, Female, 31. Hub, Lock
3. HHCS, 5/16-18 x 1-1/2” SAE 8-8ORB - female internal 32. HHCS, 5/8-11 x 4”
(Includes Items 19, through 21)
4. Pin, Carriage Pivot 33. Nut, Hex Lock 5/8-11
19. Seal, Nose (Not Shown)
5. Base, Pivot 34. Fork, Pallet 48” x 4” x 2” (4,000 lb
20. Seal, Large, Coupler Body Rating)
6. Pin, Cylinder Pivot (Rod End) (Not Shown) Fork, Lumber (Not Shown)
7. Pin, Cylinder Pivot (Base End) 21. Back-up Ring for Large Seal Fork, Blocking (Not Shown)
8. Shim, 2” I.D. x 10 Ga. (Not Shown) 35. Chart, Capacity
9. Bearing, Self Lube 22. Bearing, Thrust 36. Decal, Danger - Tip Over Hazard
10. Shim, 2” I.D. x 18 Ga. 23. Cap, Dust 37. Nut, SAE 6 - JIC 37°
11. Shim, 1-1/2” I.D. x 10 Ga. 24. Plug, Dust 38. Reducer, Tube End, SAE 6-4 - JIC 37°
12. Connector, Straight, SAE 4 - male JIC 25. Ring, Retaining 39. Elbow, 90° SAE 6-4 - male JIC 37° x
37° x male str. thd. O-ring 26. Hose Assembly male str. thd. O-ring
13. Tie Wrap 27. Elbow, 90° SAE 6-8 - male 40. Reducer, SAE 4-6 - male str. thd.
14. Hose Assembly JIC 37° x male str. thd. O-ring O-ring x female internal O-ring boss
15. Shim, 1-1/2” I.D. x 18 Ga. 28. Elbow, 90° SAE 6 - male 41. Decal, Danger - No Truss Boom
16. Quick Disconnect, Male, SAE 8-8ORB JIC 37° x male str. thd. O-ring 42. Plug, Trim 2-1/2” Diameter
- female internal (Includes Item 17) 29. Clamp, Half

9-106 Model 3606 • Origin 10/99

 Hydraulic System

16 24
17
23 18
12 LH Cylinder 19
20
40 E R 21
27
RH Cylinder
27 38
37
28 38
39 37
R E
14
13 2 3
42 29
12

5 33
See “ Swing
Carriage Cylinder”
35 8
4 9 6
32 41
33 33
42
31 32 25
9 8 11
9 15
10 Mounting plate
22
32 8 7 on carriage
1
25
36
8 12
10 Attach to Port “R” 26
9 RH Cylinder
Attach to Port “R”
LH Cylinder
4
12

30 33

31
32

34
PH0560

Figure 9– 69. Swing carriage (optional).

Model 3606 • Origin 10/99 9-107

 Section 9

a. Swing Carriage Cylinder Removal

1. Level the boom (place the boom in a horizontal 2
boom). 1

2. Swing the carriage to the centered position.

3. Lower the boom until the carriage is resting firmly on
the ground. 1
4. Place the travel select lever in NEUTRAL (N), engage
the park brake switch and shut the engine OFF.
3 R
WARNING: Hot hydraulic fluid can cause E
severe burns. Wait for hydraulic fluid to cool
before servicing any hydraulic component.

5. Unlatch, unlock and open the engine cover. Allow the

hydraulic fluid to cool.
WARNING: Escaping hydraulic fluid under
pressure can penetrate the skin, causing seri-
5
ous injury. Relieve hydraulic pressure before
servicing any hydraulic component.

6. Pull the knob on the manually-operated release valve

(Fig. 9– 70) located at the rear of the frame to relieve
pressure in the auxiliary hydraulic system. Bolt 4
9
Manually-operated 9 8
Release Valve Nut
(for OPTIONAL
Auxiliary Hydraulics) 1 6
10
1
8
9
7 11
6 MA6110

1. Cylinder 7. Cylinder Base-end Pins

OS0360
2. Auxiliary Hydraulic Hoses 8. Rod-end Bearings
Figure 9– 70. Pull the knob on the manually-operated 3. Cylinder Hoses 9. Shims, 2” I.D.
release valve located at the rear of the frame to relieve 4. Center Mounting Pin 10. Shims, 1-1/2” I.D.
pressure in the auxiliary hydraulic system. 5. Pivot Mount 11. Mounting Plates
7. Remove all dirt and grease from the swing carriage 6. Snap Rings (part of carriage)
cylinders (Fig. 9– 71) and their hydraulic lines (2 and
Figure 9– 71. Swing carriage cylinder detail.
3).
8. Label or otherwise mark the hydraulic lines (2 and 3). 12. Identify and mark the location of the 1-1/2” I.D. shims
(9) at the base end of the cylinder.
9. Disconnect and cap all hoses and fittings, etc.
13. Remove the cylinder(s) from the pivot mount and the
10. Use a sling and hoist or other suitable lifting device to mounting plates using the strap sling and hoist or
support the cylinder. Remove the bolt and nut holding other suitable lifting equipment. While removing the
the center mounting pin (4) to the pivot mount (5). cylinder(s), identify the locations of the 2” I.D. shims
Remove the pin. (9) at the rod end(s) of the cylinder(s). DO NOT lose
11. Remove the snap rings (6) and cylinder base end the bearing(s) (8) in the cylinder rod end(s).
pins (7) from the mounting plates on the carriage 14. Wipe up any hydraulic fluid spillage in, on, near and
(11). around the vehicle.

9-108 Model 3606 • Origin 10/99

 Hydraulic System

2 3
1 Apply 4
Loctite
#271 to Torque 11
Inside to
Threads 250 lb/ft.
(339 Nm)
Retract
Port
5
6
“X”
Port 7
14 15
Extend 8
Port
9
Torque to 30-35 lb/ft. 13 16
(40,7-47,5 Nm)

10 PF0760
17
12
PH0441

Figure 9– 72. Swing carriage cylinder (optional).

Swing Carriage Cylinder Legend

1. Swing Carriage Cylinder (OPTIONAL) b. Swing Carriage Cylinder Disassembly
(includes items 2 through 14)
2. Cylinder Tube Note: An additional O-ring may be included at the base
of the cylinder rod. This additional O-ring may be
3. Wear Ring
discarded, as it served only in a temporarily protective
4. Piston Seal
role to keep paint off the rod while the cylinder was
5. Piston
painted at the factory.
6. O-Ring
7. Backup Ring 1. Clean the swing carriage cylinder (1, Fig. 9– 72) with
8. Gland a suitable cleaner to remove dirt, debris, grease, etc.
9. Rod Seal 2. Place the swing carriage cylinder in a soft-jawed vise
10. Wiper or other acceptable holding equipment if possible.
11. Rod DO NOT damage the tube.
12. Counterbalance Cartridge Valve - Preset to 3000 psi Note: Significant pressure may be trapped inside the
(207 bar) cylinder. Exercise caution when removing the counter-
13. Direct-acting Relief Valve, Preset to 2000 psi balance valve (12) and direct-acting relief valve (13).
(138 bar)
14. Orifice, 0.038” diameter 3. Remove the 3000-psi (207-bar) counterbalance
cartridge (12), 2000-psi (138-bar) direct-acting relief
KITS valve (13) and the 0.038" diameter orifice (14) from
15. Swing Carriage Cylinder Seal Kit the swing carriage cylinder. Also remove the O-rings
(includes items 3, 4, 6, 7, 9, & 10) and backup rings from the valves.
16. Valve Seal Kit for item 12
(includes three O-Rings and three Backup Rings) 4. Extend the rod (11) to access the cylinder base.
17. Valve Seal Kit for item 1 (includes two O-Rings, one Backup
Ring and one Gland Ring)

Model 3606 • Origin 10/99 9-109

 Section 9

5. Using a pin spanner wrench, unscrew the gland (8) d. Swing Carriage Cylinder Inspection
from the cylinder tube (2). Slide the gland down along
1. Inspect internal surfaces and all parts for wear,
the rod toward the eyelet, away from the tube (2).
damage, etc. If inner surface of the tube (2,
IMPORTANT: Protect the finish on the rod at all times. Fig. 9– 72) does not display a smooth finish, or is
Damage to the surface of the rod can cause seal failure. scored or damaged in any way, replace the tube.
6. Carefully pull the rod (11) with all attachments Most often, dirty hydraulic fluid causes failure of
straight out of the tube (2). internal seals and damage to the smooth surface
within the tube. Remove slight scratches on the
IMPORTANT: When sliding the rod and piston assembly
piston, rod, or inner surface of the tube with very fine
in the tube, prevent the threaded end of the tube from
grit emery cloth. Use the emery cloth in a rotary
damaging the piston (5). Keep the rod centered within the
motion to polish out and blend the scratch(es) into
tube to help prevent binding.
the surrounding surface.
7. Fasten the eye of the rod in a soft-jawed vise and put
2. Remove any burrs with a fine file. Clean parts with
a padded support below and near the threaded end
trichlorethylene after repair.
of the rod to help prevent damage to the rod.
3. Check that the rod (11) is straight. If it is bent, install
8. Remove piston (5) and gland (8) from rod (11).
a new rod.
Note: Loctite Threadlocker #271 (red) and 250 lb/ft (339
Nm) were applied to the piston when it was installed. It e. Swing Carriage Cylinder Assembly
may be necessary to apply heat to break the bond of the
Note: Follow the information in Section 9.12 c. General
sealant between the piston (5) and the rod (11) before
Cylinder Assembly.
the piston can be unthreaded and removed. Some parts
of cylinders are sealed with a special organic sealant and 1. Install a new rod seal (9), wiper (10), backup ring (7)
locking compound. Before attempting to disassemble and O-ring (6) onto the gland (8). Orient the rod seal
these parts, remove any accessible seals from the area (9) and wiper (10) as shown in Fig. 9– 72.
of the bonded joint. Wipe off any hydraulic oil and heat 2. Fasten the eye of the rod in a soft-jawed vise and put
the joint uniformly to break the bond. A temperature of a padded support below and near the threaded end
300° to 400° F (149° to 204° C) will destroy the bond. of the rod to help prevent damage to the rod.
Avoid overheating or the parts may become distorted or
damaged. Apply sufficient torque or pressure for removal 3. Push the gland (8) onto the rod (11). If necessary,
while the parts are still hot. Breakdown of sealant will use a soft hammer to drive the gland onto the rod.
leave a white, powdery residue on threads and parts. 4. Install a new piston seal (4) and wear ring (3) onto
Clean the residue away with a soft brass wire brush prior the piston (5).
to reassembly, and wipe with Loctite “T” cleaner before 5. Apply Loctite Primer “T” and Threadlocker #271 (red)
reinstallation. to the threads of the piston (5) in accordance with
9. Remove the piston seal (4) and wear ring (3) from the Loctite instructions. Thread the piston onto the rod
piston (5). (11) and torque to 250 lb/ft (339 Nm).
10. Remove the O-ring (6), backup ring (7), wiper (10) 6. Place the cylinder tube (2) in a soft-jawed vise or
and rod seal (9) from the gland (8). other acceptable holding equipment if possible. DO
NOT damage the tube.
c. Swing Carriage Cylinder Cleaning 7. Lubricate the piston (5), gland and the inside of the
1. Remove all hydraulic fluid, dirt and debris from the tube (2) with clean, filtered hydraulic oil.
swing carriage cylinder (1, Fig. 9– 72). 8. Apply a compression sleeve or other suitable tool to
2. Discard all seals, backup rings and O-rings. Replace the gland in order to compress the O-ring (6).
with new items from a complete seal kit to help Carefully insert the rod (11) with all attachments
ensure proper cylinder function. straight into the tube (2). Use a pin spanner wrench
to thread the gland into the tube. Remove the
3. Clean all metal parts with an approved cleaning compression tool.
solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc. IMPORTANT: When sliding the rod and piston assembly
in the tube, prevent the threaded end of the tube from
4. If a white, powdery residue is present on threads and damaging the piston (5). Keep the rod centered within the
parts, it can be removed. Clean the residue away with tube to help prevent binding.
a soft brass wire brush prior to reassembly, and wipe
with Loctite “T” cleaner before reinstallation.

9-110 Model 3606 • Origin 10/99

 Hydraulic System

9. Install new O-rings and backup rings on the g. Swing Carriage Cylinder Installation
counterbalance cartridge (12) and direct-acting relief
1. Install the swing carriage cylinder(s) (1, Fig. 9– 71) on
valve (13). Lubricate the cartridge, valve, and rings
the pivot mount (5). Secure the rod ends to the pivot
with clean, filtered hydraulic oil. Install and torque to
mount using the shims (9) and bearings (8). Insert
30-35 lb/ft (40,7 to 47,5 Nm).
the pin (4) and secure with the bolt and nut.
10. Install the orifice (14) into the valve block.
2. Secure the tube end to the mount plates (11) using
11. Test the cylinder at low operating pressure (100 psi, the shims (10 and pins (7). Secure with snap rings.
or 6,9 bar). Verify that the piston and rod move freely
3. Lubricate the tube ends with multi-purpose lithium-
in both directions.
based grease.
12. Increase the operating pressure to the maximum for
the cylinder (3000 psi, or 207 bar). Verify that the WARNING: Risk of severe personal injury.
piston and rod move freely in both directions. Before starting the engine, verify that all
hydraulic connections are properly tightened
13. Retract the piston fully and cap the hydraulic hose
and that all tools are removed from the vehicle.
ports. Install the cylinder on the carriage.
4. Remove all plugs and caps from the hydraulic lines
f. Swing Tilt Carriage Cylinder Installation and securely tighten the lines to the cylinder(s).
1. Install the swing tilt carriage cylinder onto the swing WARNING: Avoid prolonged engine operation
tilt carriage at the pivot mount. Secure the rod end to in closed areas with inadequate ventilation.
the swing tilt carriage. Failure to properly ventilate exhaust fumes can
2. Secure the tube end to the pivot base with snap result in death or severe personal injury.
rings.
5. Start the engine.
3. Lubricate the pivot pins with multi-purpose grease.
6. Swing the carriage five times through its full range or
WARNING: Risk of severe personal injury. until the operation of the swing carriage is normal (no
Before starting the engine, verify that all jerks or spongy feel).
hydraulic connections are properly tightened
7. Shut the engine OFF. Check the hydraulic level and
and that all tools are removed from the vehicle.
fill as required.
4. Remove all plugs and caps from the hydraulic lines
and securely tighten the lines to the cylinder. h. Swing Carriage Cylinder Pressure Checking
and Circuit Bleeding
5. Start the engine and remove any blocking from the
carriage. 1. Attach a 4000 psi (276 bar) gauge to the main control
valve at the extend base port relief to test the swing
6. Operate the swing carriage five times through its full
carriage cylinder hydraulic system circuit pressure.
range or until operation of the swing tilt carriage is
The unit is equipped with test fittings from the factory.
normal (no jerks or spongy feel).
Pressure readings should be 3200 psi ± 100 psi
7. Shut the engine OFF. Check the hydraulic level and (220,6 ± 7 bar).
fill as required.
2. Start with the swing carriage cylinders balanced; that
is, with the carriage centered.
3. Swing the carriage fully left. Hold the joystick at full
swing left for several seconds, then swing the
carriage fully right and hold the joystick at full swing
right for several seconds. Observe the readings on
the gauge during the carriage swinging operations.
4. Center the carriage. While centering the carriage,
check the pressure reading on the gauge.
5. Repeat steps 3 and 4 five times.

Model 3606 • Origin 10/99 9-111

 Section 9

9.10.7 Side Tilt Carriage Cylinder (optional)

Manually-operated
The optional side tilt carriage cylinder (1, Fig. 9– 75) pro- Release Valve
vides a way to tilt the carriage attachment from side to (for OPTIONAL
side. The side tilt carriage includes a cylinder that oper- Auxiliary Hydraulics)
ates to provide the side tilt motion.

a. Side Tilt Carriage (optional) Removal

1. Level the boom (place the boom in a horizontal
boom).
2. Tilt the carriage (1, Fig. 9– 75) to fully retract the side
tilt carriage cylinder. OS0360

3. Use suitable blocks to support the side tilt carriage Figure 9– 73. Pull the knob on the manually-operated
(1) in this position. release valve located at the rear of the frame to relieve
pressure in the auxiliary hydraulic system.
4. Engage the park brake switch, place the travel select
lever in NEUTRAL (N) and shut the engine OFF. 7. Remove all dirt and grease from the side tilt carriage
cylinder and the auxiliary hydraulic lines.
WARNING: Hot hydraulic fluid can cause
severe burns. Wait for hydraulic fluid to cool 8. Label or otherwise mark the hose assembly (14, Fig.
before servicing any hydraulic component. 9– 74).
9. Disconnect and cap all hoses and fittings, etc.
5. Unlatch, unlock and open the engine cover. Allow the
hydraulic fluid to cool. 10. Remove the snap rings (11) and cylinder base end
pins (6 and 7) from the mounting plates on the
WARNING: Escaping hydraulic fluid under carriage (1) and pivot base (5).
pressure can penetrate the skin, causing seri- 11. Remove the cylinder using a strap sling and hoist or
ous injury. Relieve hydraulic pressure before other suitable lifting equipment.
servicing any hydraulic component.
12. Wipe up any hydraulic fluid spillage in, on, near and
6. Pull the knob on the manually-operated release valve around the vehicle.
(Fig. 9– 73) located at the rear of the frame to relieve
pressure in the auxiliary hydraulic system.

Side Tilt Carriage Legend

1. Carriage, Side Tilt 16. Quick Disconnect, Male, 28. HHCS, 3/8-16 x 2-3/4”
2. Pad, Wear SAE 8-8ORB - female internal 29. Locknut, 3/8-16 ESNA
(Includes Item 17)
3. HHCS, 5/16-18 x 1-1/4” 30. Shaft, Fork Pivot
17. Seal, Nose (Not Shown)
4. Nut, Hex Lock 5/16-18 31. Hub, Lock
18. Quick Disconnect, Female,
5. Base, Pivot SAE 8-8ORB - female internal 32. HHCS, 5/8-11 x 4”
6. Pin, Cylinder. Base (Includes Items 19 through 21) 33. Nut, Hex Lock 5/8-11
7. Pin, Cylinder. Rod 19. Seal, Nose (Not Shown) 34. Fork, Pallet 48” x 4” x 2”
8. Spacer 20. Seal, Large, Coupler Body (4,000 lb Rating)
(Not Shown) Fork, Lumber (Not Shown)
9. Bushing, Self Align Fork, Blocking (Not Shown)
10. Ring, Snap 21. Back-up Ring for Large Seal
(Not Shown) 35. Washer, Flat Heavy
11. Ring, Snap 36. Shim
22. Plug, Pipe Hex Skt 1/8” NPT
12. Connector, Straight SAE 6-6P - male 37. Decal, Capacity Chart
JIC 37° x male str. thd. O-ring 23. Cap, Dust
24. Plug, Dust 38. Plate, Capacity
13. Tie Wrap
14. Hose Assembly 25. Molding
15. Connector, Straight, SAE 6-8 - male 26. Pin, Pivot
JIC 37° x male str. thd. O-ring 27. Collar, Pin Locking

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 Hydraulic System

24
18
19 25
20
21
16
15 23 17
15
14 37

14 13
1
26 8
9 10
See “ Side Tilt 11
Carriage Cylinder” 28
33 7
31
11 27
11
8
6 29
12
32
35

3 5
22 2
36
30

4 38

33

31
32

PA1592
34

Figure 9– 74. Side tilt carriage (optional).

Model 3606 • Origin 10/99 9-113

 Section 9

4
14
13
1 5

12
11
9 3
10
6
15
Torque to 30-35 lb/ft. 15
(40,7-47,5 Nm)

2
Apply Loctite #271 to 8
Threads and Torque to
350 lb/ft. (474,6 Nm) 7
Extend Port
16
Retract Port

PF0760
17
PH0800

Figure 9– 75. Side tilt carriage cylinder (optional).

Side Tilt Carriage Cylinder Legend

1. Side Tilt Carriage Cylinder (OPTIONAL) b. Side Tilt Carriage Cylinder Disassembly
(includes items 2 through 14)
2. Cylinder Tube Note: An additional O-ring may be included at the base
of the cylinder rod. This additional O-ring may be
3. Pilot Check Valve
discarded, as it served only in a temporarily protective
4. Piston
role to keep paint off the rod while the cylinder was
5. Gland
painted at the factory.
6. Rod
7. Piston Nut 1. Clean the side tilt carriage cylinder (1, Fig. 9– 75) with
8. Self-aligning Bearing a suitable cleaner to remove dirt, debris, grease, etc.
9. Rod Seal 2. If necessary, remove both grease fittings (15) from
10. Wiper the cylinder tube eyelet.
11. O-Ring 3. If necessary, press the self-align bearing (8) from the
12. Backup Ring cylinder tube eyelet.
13. O-Ring 4. Place the side tilt carriage cylinder (1) in a soft-jawed
14. Piston Seal vise or other acceptable holding equipment if
15. Grease Fitting possible. DO NOT damage the tube (2).
KITS Note: Significant pressure may be trapped inside the
16. Side Tilt Carriage Cylinder Seal Kit cylinder. Exercise caution when removing the pilot check
(includes items 9-14) valves (3) from the side tilt carriage cylinder.
17. Pilot Check Valve Seal Kit for item 3
5. Remove both pilot check valves (3) from the side tilt
carriage cylinder. Remove the O-rings and backup
rings from the pilot check valves.
6. Extend the rod (6) to allow access to the base of the
cylinder.

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 Hydraulic System

7. Using a pin spanner wrench, unscrew the gland (5) 4. Clean the residue away with a soft brass wire brush
from the cylinder tube (2). prior to reassembly, and wipe with Loctite T cleaner
IMPORTANT: Protect the finish on the rod at all times. before reinstallation.
Damage to the surface of the rod can cause seal failure.
d. Side Tilt Carriage Cylinder Inspection
8. Carefully pull the rod (6) with all attachments straight
out of the tube (2). 1. Inspect internal surfaces and all parts for wear,
damage, etc. If inner surface of the tube (2,
IMPORTANT: When sliding the rod and piston assembly
Fig. 9– 75) does not display a smooth finish, or is
in the tube, prevent the threaded end of the tube from
scored or damaged in any way, replace the tube.
damaging the piston (4). Keep the rod centered within the
Most often, dirty hydraulic fluid causes failure of
tube to help prevent binding.
internal seals and damage to the smooth surface
9. Fasten the eye of the rod (6) in a soft-jawed vise and within the tube. Remove slight scratches on the
put a padded support below and near the threaded piston, rod, or inner surface of the tube with very fine
end of the rod to help prevent damage to the rod. grit emery cloth. Use the emery cloth in a rotary
10. Remove the piston nut (7), piston (4) and gland (5) motion to polish out and blend the scratch(es) into
from the rod (6). the surrounding surface.

Note: Loctite Threadlocker #271 (red) and 350 lb/ft 2. Clean parts with trichlorethylene.
(474,6 Nm) of torque were applied to the piston nut when 3. Check that the rod (6) is straight. If it is bent, install a
it was installed. It may be necessary to apply heat to new rod.
break the bond of the sealant between the piston nut (7)
and the rod (6) before the parts can be removed. Some e. Side Tilt Carriage Cylinder Assembly
parts of cylinders are sealed with a special organic seal-
Note: Follow the general assembly instructions in Sec-
ant and locking compound. Before attempting to disas-
tion 9.12 c. General Cylinder Assembly.
semble these parts, remove any accessible seals from
the area of the bonded joint. Wipe off any hydraulic oil 1. If necessary, press the self-align bearing (8,
and heat the joint uniformly to break the bond. A temper- Fig. 9– 75) into the cylinder tube eyelet. The bearing
ature of 300° to 400° F (149° to 204° C) will destroy the should protrude equally from each side of the eyelet.
bond. Avoid overheating or the parts may become dis- 2. Install the rod seal (9), wiper (10), backup ring (12)
torted or damaged. Apply sufficient torque or pressure for and O-ring (11) into the gland (5). Orient the parts as
removal while the parts are still hot. Breakdown of seal- indicated in Fig. 9– 75.
ant will leave a white, powdery residue on threads and
parts. Clean the residue away with a soft brass wire Note: The wiper lip should be toward the inner end of
brush prior to reassembly, and wipe with Loctite “T” the gland and the rod seal toward the outer end of the
cleaner before reinstallation. gland. Use tools that will not damage the seal. If the
backup ring is not flat on both sides, the side with the arc
11. Remove the piston seal (14) from the piston (4). must be toward the O-ring.
12. Remove the small O-ring (13) from inside the piston
3. Fasten the eye of the rod in a soft-jawed vise and put
(4).
a padded support below and near the threaded end
13. Remove the O-ring (11), backup ring (12), wiper (10) of the rod to help prevent damage to the rod.
and rod seal (9) from the gland (5).
4. Push the gland (5) onto the rod (6). If necessary, use
a soft hammer to drive the gland onto the rod.
c. Side Tilt Carriage Cylinder Cleaning
5. Install a new small O-ring (13) inside the rod end of
1. Remove all hydraulic fluid, dirt and debris from the the piston (4).
inner surface of the cylinder tube (2, Fig. 9– 75).
6. Install a new piston seal (14) on the piston (4).
2. Discard all seals, backup rings and O-rings. Replace
with new items from a complete seal kit to help 7. Apply Loctite Primer “T” and Threadlocker #271 (red)
ensure proper cylinder function. to the threads of the piston nut (7) in accordance with
Loctite instructions. Thread the piston nut onto the
3. Clean all metal parts with an approved cleaning rod (6) and torque to 350 lb/ft (474,6 Nm).
solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc.If a white, powdery 8. Fasten the cylinder tube (2) in a soft-jawed vise or
residue is present on threads and parts, it can be other acceptable holding equipment. DO NOT
removed. damage the tube (2).

9. Lubricate the piston (4), gland (5) and the inside of the tube (2) with clean, filtered hydraulic oil.

Model 3606 • Origin 10/99 9-115

 Section 9

10. Apply a compression sleeve or other suitable tool to 6. Shut the engine OFF. Check the hydraulic level and
the gland in order to compress the O-ring (11). fill as required.
Carefully insert the rod (6) with all attachments
straight into the tube (2). Use a pin spanner wrench g. Side Tilt Carriage Cylinder Pressure Checking
to thread the gland into the tube. Remove the and Circuit Bleeding
compression tool.
1. Attach a 4000 psi (276 bar) gauge to the main control
IMPORTANT: When sliding the rod and piston assembly valve at the extend base port relief to test the swing
in the tube, prevent the threaded end of the tube from carriage cylinder hydraulic system circuit pressure.
damaging the piston seal (14). Keep the rod centered The unit is equipped with test fittings from the factory.
within the tube to help prevent binding. Pressure readings should be 3200 psi ± 100 psi
11. Install new O-rings and backup rings on the pilot (220,6 ± 7 bar).
check valve (3). Lubricate the valve and rings with 2. Start with the side tilt carriage cylinder balanced; that
clean, filtered hydraulic oil. Install and torque to 30-35 is, with the carriage level and centered, not tilted.
lb/ft (40,7 to 47,5 Nm).
3. Tilt the carriage fully left. Hold the joystick at full tilt
12. If necessary, install both grease fittings (15) into their left for several seconds, then tilt the carriage fully
threaded holes in the cylinder tube eyelet. right and hold the joystick at full tilt right for several
13. Test the side tilt cylinder at low operating pressure seconds. Observe the readings on the gauge during
(100 psi, or 6,9 bar). Verify that the piston and rod the carriage tilting operations.
move freely in both directions. 4. Center and level the carriage. While levelling the
14. Increase the operating pressure to the maximum for carriage, check the pressure reading on the gauge.
the cylinder (1750 psi, or 120 bar). Verify that the 5. Repeat steps 3 and 4 five times.
piston and rod move freely in both directions.
15. Retract the piston fully and cap the hydraulic hose 9.10.8 Steer Cylinders
ports. Install the cylinder on the carriage. Lubricate The steer cylinders are secured to the axle assemblies.
the self-align bearing (8) via the grease fittings (15) Steer cylinders are covered in the appropriate manufac-
with multi-purpose grease before operating the side turer's axle literature. Refer to Section 5 Axles, Wheels
tilt carriage on the vehicle. and Tires for further information.

f. Side Tilt Carriage Cylinder Installation

1. Install the side tilt carriage cylinder onto the side tilt
carriage (1, Fig. 9– 74). Secure the rod end to the
side tilt carriage with the cylinder rod pin (7) and snap
rings (11). Secure the tube end to the pivot base (5)
with the cylinder base pin (6) and snap rings (11).
2. Lubricate the pivot pins with multi-purpose grease.
WARNING: Risk of severe personal injury.
Before starting the engine, verify that all
hydraulic connections are properly tightened
and that all tools are removed from the vehicle.

3. Remove all plugs and caps from the hydraulic lines

and securely tighten the lines to the cylinder.
WARNING: Avoid prolonged engine operation
in closed areas with inadequate ventilation.
Failure to properly ventilate exhaust fumes can
result in death or severe personal injury.

4. Start the engine and remove any blocking from the

carriage.
5. Tilt the side carriage five times through its full range
or until operation of the side tilt carriage is normal (no
jerks or spongy feel).

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 Hydraulic System

9.11 TROUBLESHOOTING This section provides an easy reference guide covering

the most common problems that occur during operation
of the hydraulic system.

Hydraulic System Troubleshooting

Problem Cause Remedy

1. Cannot lower elevated 1. Ruptured hoist or extend hose. 1. Lower load using Emergency
load. Boom Lowering instructions in
Section 3 Boom.
2. Loss of engine power or 2. Lower load using Emergency
hydraulic pump failure. Boom Lowering instructions in
Section 3 Boom.
3. Faulty components in hoist/lower 3. Lower load using Emergency
circuit. Boom Lowering instructions in
Section 3 Boom. Troubleshoot
components; repair or replace.
4. Failed selector valve solenoid. 4. Replace selector valve
solenoid.
5. Failed joystick pilot valve. 5. Replace joystick pilot valve
assembly.
2. Cavitation and noise. 1. Fluid level in reservoir is low. 1. Add fluid. Refer to Section 2
General Information,
Specifications and Maintenance
Instructions.
2. Filter/breather is clogged. 2. Clean or replace filter/breather.
3. Air leaks in suction line. 3. With the engine running, apply
a small amount of hydraulic
fluid on each joint of the suction
line and tighten any joint where
fluid stopped the noise. Double
clamp if necessary.
4. Loose pump mounting 4. Torque the capscrews to 75 lb/ft
hardware. (102 Nm).
5. Loose pump sections. 5. Determine cause of looseness.
Disassemble, clean, inspect,
repair and replace parts as
required. Torque pump
capscrews to proper
specification.
6. Defective pump. 6. Repair or replace pump.
3. Ruptured hose. 1. Hose damaged due to tight 1. Replace hose; install without
bend(s) or twists. tight bends or twists.
2. Excessive pressure. 2. Check and adjust pressure to
proper specification.
4. Hose cover separated 1. Hose twisted at fitting during 1. Replace hose. Prevent hose
from hose casing. installation. from twisting or turning as
fittings are tightened.
5. Hose fittings have dam- 1. Connections were cross- 1. Replace hose. Install and
aged threads. threaded or over-tightened. torque properly.

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 Section 9

Hydraulic System Troubleshooting

Problem Cause Remedy

6. Boom hoist or extend 1. External fluid leakage at tubes, 1. Check and tighten connections.
function slow or malfunc- hoses or fittings. Repair or replace faulty hose(s).
tioning. 2. Adjust pressure to proper
2. Faulty relief valve setting. setting.
3. Repair cylinders as required.
3. Internal leakage in cylinders. 4. Repair control valve as
4. Internal leakage in main control required.
valve. 5. Repair control circuit.
5. Control valve not fully shifted. 6. Repair pump.
6. Defective hydraulic pump. 7. Check and replace as required.
7. Malfunctioning pilot valve. 8. Check and replace as required.
8. Malfunctioning unloader valve.
7. Boom hoist or extend 1. Defective counterbalance valve 1. Repair or replace
function drifts. or cylinder seals. counterbalance valve or seals
as required.
2. External fluid leakage at tubes, 2. Check and tighten connections.
hoses or fittings. Repair or replace faulty hose(s).
3. Adjust pressure to proper
3. Faulty relief valve setting. setting.
4. Repair cylinders as required.
4. Internal leakage in cylinders. 5. Repair control valve as
5. Internal leakage in main control required.
valve. 6. Repair pump.
6. Defective hydraulic pump.
8. Attachment tilt slow or 1. Defective counterbalance valve 1. Repair or replace
malfunctioning. or seals. counterbalance valve or seals
as required.
2. External fluid leakage at tubes, 2. Check and tighten connections.
hoses or fittings. Repair or replace faulty hose(s).
3. Adjust pressure to proper
3. Faulty relief valve setting. setting or replace valve.
4. Repair cylinders as required.
4. Internal leakage in cylinders. 5. Repair control valve as
5. Internal leakage in main control required.
valve. 6. Repair pump.
6. Defective hydraulic pump. 7. Check and replace as required.
7. Malfunctioning pilot valve. 8. Check and replace as required.
8. Malfunctioning unloader valve.
9. Attachment tilt drifts. 1. Defective attachment tilt or slave 1. Repair or replace cylinder.
cylinder(s). 2. Repair or replace
2. Defective counterbalance valves. counterbalance valves.

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 Hydraulic System

Hydraulic System Troubleshooting

Problem Cause Remedy

10. Frame tilt slow or malfunc- 1. External fluid leakage at tubes, 1. Check and tighten connections.
tioning. hoses or fittings. Repair or replace faulty hose(s).
2. Adjust pressure to proper
2. Faulty relief valve setting. setting or replace valve.
3. Repair cylinders as required.
3. Internal leakage in cylinders. 4. Repair control valve as
4. Internal leakage in main control required.
valve. 5. Repair pump.
5. Defective hydraulic pump. 6. Check and replace as required.
6. Malfunctioning pilot valve. 7. Check and replace as required.
7. Malfunctioning unloader valve.
11. Frame tilt drifts. 1. Defective check valves or frame 1. Repair or replace check valves
tilt cylinder. or frame tilt cylinder.
12. Service brakes grab. 1. Excessive hydraulic pressure. 1. Adjust pressure reducing valve.
13. Service brakes spongy. 1. Air in brake line. 1. Bleed brake lines.
2. Insufficient hydraulic pressure. 2. Check and/or adjust pressure
reducing valve.
14. Service brakes fail to 1. Brake pedal binding. 1. Correct condition.
release. 2. Faulty brake valve. 2. Replace brake valve.
15. Service brake failure. 1. Ruptured hydraulic hose. 1. Replace hose.
2. Faulty brake valve. 2. Replace brake valve.
3. Pressure reducing valve failure. 3. Replace pressure reducing
valve.
4. Insufficient pressure at auxiliary 4. Adjust pressure at auxiliary
function manifold. function manifold or replace
pressure reducing valve
cartridge.
5. Defective brake discs or leakage 5. Check manufacturer’s
within brake section of axle. information and specifications
(refer to Section 5 Axles,
Wheels and Tires).
16. Park lock brake fails to 1. Ruptured hydraulic hose. 1. Replace hose.
release. 2. Defective park lock switch. 2. Replace park lock switch.
3. Park lock solenoid valves fail to 3. Check for proper operation of
shift. solenoids or valves. Check
electrical schematic (Section
10) and test electrical circuit.
4. Defective park lock assembly in 4. Repair park lock per
front axle. manufacturer’s information and
specifications (refer to Section 5
Axles, Wheels and Tires).

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 Section 9

Hydraulic System Troubleshooting

Problem Cause Remedy

17. Park lock brake fails to set. 1. Defective solenoids and/or 1. Refer to the appropriate
valves. electrical schematic in Section
10 Electrical System. Check
and/or replace solenoids and
valves.
2. Defective switch. 2. Check electrical schematic
(Section 10) and test electrical
circuit and switch. Repair wiring
or replace switch as required.
3. Defective or weak springs in 3. Repair park lock assembly per
park lock assembly of front axle. manufacturer’s information and
specifications (refer to Section 5
Axles, Wheels and Tires).
18. Power steering fails com- 1. Ruptured hydraulic hose. 1. Replace hose.
pletely. 2. Faulty steering unit. 2. Replace steering unit.
3. Insufficient (low) hydraulic 3. Troubleshoot and correct cause
pressure. of low pressure. Adjust steering
relief valve.
4. Unloader valve malfunction. 4. Check and replace as required.
19. No four-wheel or crab 1. Defective solenoid in steer select 1. Repair steer select valve.
steering, or steering mode valve.
change does not occur. 2. Faulty steer select switch or 2. Repair or replace steer select
wiring. switch or wiring.
3. Broken spring in steer select 3. Replace steer select valve.
valve.
20. Steering slow or sluggish. 1. Steer relief valve not set 1. Check and set relief valve to
correctly. proper specification.
2. Defective steer relief valve. 2. Install new cartridge or replace
valve.
3. Steering cylinder leakage. 3. Repair or replace steering
cylinder. Refer to
manufacturer’s information and
specifications (see Section 5
Axles, Wheels and Tires).
4. Unloader valve malfunction. 4. Check and replace as required.
21. Front or rear wheels not 1. Wheels not properly indexed. 1. Index wheels per procedure in
parallel in two-wheel or Owners/Operators Manual.
four-wheel steering mode. 2. Wheel misalignment. 2. Check and adjust wheels
properly per manufacturer’s
information and specifications
(see Section 5 Axles, Wheels
and Tires).
3. Internal steering unit leakage. 3. Replace steering unit.
4. Defective steer select valve. 4. Check and repair or replace
steer select valve.

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 Hydraulic System

Hydraulic System Troubleshooting

Problem Cause Remedy

22. Steering is “ spongy” or 1. Air in steering lines. 1. Check and tighten loose
noisy. connections. Operate steering
lock-to-lock several times to
purge air from system.
2. Faulty steering unit. 2. Replace steering unit.
23. Auxiliary equipment oper- 1. External fluid leakage. 1. Check and tighten connections;
ates slowly or malfunc- replace defective hoses, etc.
tions. 2. Faulty relief valve setting. 2. Check and set relief valve to
proper specification.
3. Internal cylinder leakage. 3. Repair cylinder as required.
4. Internal leakage in main or 4. Repair control valve as
auxiliary control valve. required.
5. Insufficient flow of oil. 5. Check flow and pressure from
pump through entire auxiliary
hydraulic circuit. Repair or
replace parts as required.
6. Pilot valve malfunction. 6. Check and replace as required.
24. Auxiliary equipment drifts 1. Leakage in auxiliary cylinder. 1. Repair or replace cylinder or
or creeps. check valve.
25. Pump fails to deliver fluid 1. Low hydraulic fluid in reservoir. 1. Check fluid level and add fluid
to unloader valve. as required.
2. Hydraulic oil reservoir breather 2. Clean or replace the breather.
is dirty.
3. Suction strainer is clogged. 3. Clean suction strainer.
4. Suction line is restricted or 4. Clean or replace suction line
loose. and/or tighten if loose.
5. Fluid viscosity is too heavy to 5. Check working temperature and
allow pump to be primed. service as required. Change
fluid to proper viscosity as
required. Refer to Section 2
General Information,
Specifications and
Maintenance.
6. Worn, broken or stuck parts 6. Troubleshoot and correct true
within pump. cause of pump failure and
repair or replace pump.
26. Cylinder fails to move 1. Faulty hose. 1. Repair or replace hose.
when control valve is actu- 2. Insufficient flow of oil. 2. Check hydraulic pump.
ated.
3. Damaged cylinder. 3. Repair or replace cylinder.
4. Defective control valve. 4. Inspect and repair as required.
5. Pilot selector malfunction. 5. Check and replace as required.
6. Pilot valve malfunction. 6. Check and replace as required.

Model 3606 • Origin 10/99 9-121

 Section 9

Hydraulic System Troubleshooting

Problem Cause Remedy

27. Cylinder movement is 1. Air trapped in cylinder or in 1. Inspect fluid for foam or
jerky. hydraulic line. Low oil level in bubbles. Check and tighten
hydraulic oil reservoir. connections. Bring hydraulic
fluid up to operating
temperature and cycle vehicle
functions several times through
full range of motion to remove
(purge or “bleed”) air from
system.
2. Binding of cylinder rod or piston. 2. Repair or replace cylinder.
3. Rod seal installed improperly. 3. Replace seal. Properly install
new seal.
4. Binding of bearing at base end 4. Eliminate bind and repair or
or rod end. replace bearing and other
components as required.
5. Defective counterbalance 5. Replace counterbalance
cartridge (hoist/lower cylinder). cartridges.
28. Cylinder movement is 1. Control valve not fully shifted. 1. Engage control valve fully.
slow or sluggish; cycle Check that valve pressures are
times are slow. set as specified and that
applicable circuit hoses are not
restricted, bent, kinked,
damaged, etc.
2. Internal leakage or binding 2. Repair or replace cylinder.
within cylinder.
3. Insufficient flow of oil. 3. Check flow throughout hydraulic
circuit, starting at main pump.
4. Unloader valve malfunction. 4. Check and replace as required.
5. Pilot valve malfunction. 5. Check and replace as required.
29. Cylinder piston rod drifts 1. Worn piston seals. 1. Install new seal kit.
or creeps. 2. Tube is out-of-round. 2. Replace tube.
30. Main relief valve doesn’t 1. Spring is broken or worn (“has 1. Replace relief valve assembly.
hold pressure setting. taken a set”).
2. Poppet stuck due to dirt or 2. Replace relief valve assembly.
deposits.

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 Hydraulic System

Hydraulic System Troubleshooting

Problem Cause Remedy

31. Directional control valve 1. Broken internal parts. 1. Disassemble control valve and
difficult to shift. replace broken parts.
2. Scored valve body bore, 2. Inspect bore. Replace valve
producing leakage between section if scored.
spool and body.
3. Broken centering spring. 3. Replace spring.
32. Movement of joystick fails 1. Faulty joystick, joystick switch, 1. Troubleshoot and repair as
to cause spool in control wiring, or solenoid valve. required. Refer to Section 10
valve to shift. Electrical System.
2. Insufficient pressure to move 2. Check pilot pressure.
spool.
3. Check main control valve for 3. Replace as required.
stuck spool.

Model 3606 • Origin 10/99 9-123

 Section 9

9-124
 Section 10
Electrical System

Contents

PAR. TITLE PAGE

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
General Overview (Cab Harness). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
General Overview (Engine Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.1 SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.3 EFFECTIVE GROUND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.4 WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.4.1 Cab Harness, S/N 8249 and Before . . . . . . . . . . . . . . . . . . . . . 10-12
10.4.2 Cab Harness, S/N 8250-9398 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
10.4.3 Cab Harness, S/N 9399 and After. . . . . . . . . . . . . . . . . . . . . . . 10-26
10.4.4 Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
10.4.5 Closed Cab Harness (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
10.5 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.5.1 Fuse and Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
10.6 ENGINE START CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
10.6.1 Testing the Starter on the Engine . . . . . . . . . . . . . . . . . . . . . . . 10-39
10.6.2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
10.6.3 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
10.7 CHARGING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
10.7.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
10.7.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
10.8 ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
10.8.1 Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
10.8.2 Operators Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
10.8.3 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
10.8.4 Thermo-Start Plug (optional for Perkins engines only) . . . . . . . 10-56
10.8.5 Fuel Run Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
10.8.6 Hydraulic Oil Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . 10-58
10.8.7 Hydraulic Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . 10-59
10.8.8 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
10.8.9 Service Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
10.8.10 Transmission Shift Control Switch (Travel Select Lever) . . . . . . 10-62
10.8.11 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
10.8.12 Attachment Tilt Mode Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
10.8.13 Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
10.8.14 Logic Board Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
10.8.15 Boom Sensor (Proximity Switch) . . . . . . . . . . . . . . . . . . . . . . . . 10-69
10.8.16 Stabil-TRAK System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70

Model 3606 • Origin 10/99 10-1

 Section 10

10.8.17 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73

10.8.18 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
10.8.19 Engine Low Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . 10-77
10.8.20 Transmission High Temperature Sender . . . . . . . . . . . . . . . . . . 10-79
10.8.21 Engine Coolant High Temperature Sender . . . . . . . . . . . . . . . . 10-79
10.8.22 Engine Block Heater (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
10.8.23 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . 10-81
10.8.24 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
10.9 ELECTRICAL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 10-84

10-2 Model 3606 • Origin 10/99

 Electrical System

Introduction
The electrical system produces, stores and distributes The wiring diagrams in this section indicate electrical cir-
electricity in the operation of the vehicle. cuits and components respective of their approximate
An engine-driven, 65-amp alternator equipped with an location on the vehicle.
internal, solid-state voltage regulator produces electricity. The information in this section has been developed from
Current from the alternator charges the battery and pow- the perspective that all wires are connected and routed
ers electrical system components. as they were when the vehicle left the factory. Take into
The battery provides power for starting the engine and account any disconnected or re-routed wires before
supplements the output of the alternator during periods beginning to diagnose a circuit. Refer to the wiring dia-
of peak demand. grams to test circuits for continuity or for shorts using a
conventional test light, ohmmeter, multimeter or low-
The vehicle is equipped with two separate but connected reading voltmeter.
wiring harnesses, an engine harness and a cab harness.
A multiple or “bulkhead” connector at the end of each The text discusses each circuit and component, as well
harness joins the two together. as component function and replacement. A brief trouble-
shooting table appears at the conclusion of this section.
Each wire within a harness has color-coded insulation Keep in mind that the various systems on the vehicle
and is marked with a number to aid in identifying and include both electrical and hydraulic components; what at
tracing each circuit and in making proper connections. first may appear to be an electrical problem may turn out
Fuses and relays are included with the cab harness to to be a hydraulic problem.
help protect the electrical system and its components.

Model 3606 • Origin 10/99 10-3

 Section 10

Legend for Cab Harness (S/N 8249 and before)

1. Cab Harness 15. Hourmeter 26. Hex-lock Elastic Nut, #10-24
2. Back-up Alarm 16. Machine Bushing Washer, 27. Flat Washer, 1/4”
3. Hex-lock Elastic Nut, 1/4-20 0.63” I.D. 28. Lockwasher, 1/4”
4. Flat Washer, 1/4” 17. Ignition Switch 29. Hex Nut, 1/4-20
5. Boom Sensor 18. Ignition Key 30. Plastic Tie
6. Service Brake Switch 19. Fuse, 7.5 Amp 31. Hex Jam Nut, M6-1 Cl4
7. Logic Board 20. Fuse, 40 Amp 32. Lockwasher, M6
8. Button-head Capscrew, #10-32 x 3/4 21. Fuse, 15 Amp 33. Signal Horn
(optional Perkins cold start only)
9. Well Nut, #10-32 34. Tube Clip
22. Sealed Relay, 12 Volt, 40 Amp
10. Steer Select Switch 35. Hex Locknut, 1/2-13
23. Slotted Pan-head Screw,
11. Switch Bezel #10-24 x 3/4” 36. Attachment Tilt Mode Switch
12. Operators Display Panel 24. Narrow Flat Washer, #10 37. Attachment Tilt Direction Harness
13. Park Brake Switch 25. Slotted Pan-head Screw,
14. Round-head Wood Screw, #6 x 1/2” #10-24 x 5/8”

10-4 Model 3606 • Origin 10/99

 Electrical System

General Overview (Cab Harness)

3
2
4

Connects to engine harness 5

34
35

11
7
8
10
33
9

11 36
32 31 12
8

22 19
9
13
11
27 28 29 20

15
24 16 37
30
14
17
25 23
18
24 21
22
26

Typical fuse block

shown; see text.
PS0791

Figure 10–1. Typical cab harness (S/N 8249 and before; see text).

Model 3606 • Origin 10/99 10-5

 Section 10

General Overview (Engine Harness)

MS1590

17 17
24
23 18 21
Front 20
22 19
22
23
21

17 20

17 18 19 25 24 15

16 16

15

14

14

Perkins

Cummins

10

3
9 11
12

8 13

7 1

3
5 4
2
PS0801

Figure 10–2. Engine harness.

10-6 Model 3606 • Origin 10/99

 Electrical System

Legend for Engine Harness

1. Engine Harness 14. Transmission Temperature Switch,
2. Conduit, 3/4” diameter x 10” long 250° F (121° C)
3. Hex-lock Elastic Nut, 3/8-16 15. Engine Water Temperature Switch
4. Tube Clip 16. Engine Oil Pressure Switch
5. Hex-lock Elastic Nut, 1/2-13 17. Hex Nut, 1/4-20
6. Flat Washer, 3/8” 18. Lockwasher, 1/2”
7. Hex Locknut 19. Hex Nut, #10-32
8. Battery Ground Cable 20. Hex-head Capscrew, 1/4-20 x 3/4”
9. Positive (+) Battery Cable, 21. Starter Relay
w/protective cover 22. Hex-lock Elastic Nut, 1/4-20
10. Hex-head Capscrew, 23. Maintenance Reset Switch
3/8-16 x 9-11/2” 24. Fuel Shut-off Solenoid
11. Battery Hold-down Strip 25. Perkins Cold-start Temperature Switch
12. Battery, 12 Volt, 1000 CCA
13. Negative (-) Battery Cable,
w/protective cover

10.1 SERVICE WARNINGS WARNING: All lead-acid batteries generate

hydrogen gas, which is highly flammable. If
General ignited by a spark or flame, the gas may
explode violently, causing spraying of acid,
WARNING: DO NOT disconnect any wiring fragmentation of the battery, and possible
without first stopping the engine, turning all severe personal injuries, particularly to the
electrical switches to the OFF position and dis- eyes.
connecting the battery ground cable from the
battery. WARNING: Avoid battery acid. Battery acid
can cause chemical burns or other serious
WARNING: DO NOT cause a short circuit by injury. In case of contact with battery acid, flush
connecting leads to incorrect terminals. Always immediately with water.
identify a lead and its correct terminal. A short
circuit or wrong connection creating reverse WARNING: Charge the battery in a well-venti-
polarity will immediately and permanently ruin lated area only. Always turn battery chargers
transistors and diodes within the electrical sys- OFF before connecting to or disconnecting
tem. from a battery.

WARNING: DO NOT momentarily or "flash" WARNING: DO NOT disconnect the battery

connect a terminal to check for current flow. No while the engine is running. This will cause a
matter how brief the contact, the transistors voltage surge in the alternator charging system
may be ruined. that will immediately ruin the diodes or transis-
tors.
Battery
WARNING: DO NOT connect a battery into
WARNING: Wear safety glasses when work- the system without checking for correct polarity
ing near the battery. and voltage.

Model 3606 • Origin 10/99 10-7

 Section 10

10.2 SPECIFICATIONS
Electrical system specifications are listed in Section 2
General Information, Specifications and Maintenance
Instructions.

10.3 EFFECTIVE GROUND CONNECTIONS

Effective ground connections are essential to the efficient
operation of electrical components. If an inadequate
ground is suspected or determined, establishing another
ground may be desired. Also, in the event a factory-
authorized accessory is being installed, it is necessary to
follow the proper sequence for providing an electrical
ground. The sequence for installing or attaching a com-
ponent to an electrical ground is shown in Figs. 10–3 and
10–4.

1
1
2
2
3 A 3
4
A 5 B

MA0871 MA0881
A. Stud, bolt or capscrew. A. Partial sectional view of part to be grounded.
B. Eliminate paint, rust, etc. from the area around the base of B. Stud, bolt or capscrew.
the stud, equivalent to outside diameter of lockwasher (5).
1. Hex nut or lock nut
1. Hex nut or lock nut
2. Tooth- or slot-type lockwasher, or locking nut with slotted
2. Tooth- or slot-type lockwasher type lockwasher
3. Flat washer 3. Flat washer
4. Electrical ground(s)
5. Tooth-type lockwasher
Figure 10–4. Recommended parts sequence for electri-
cally grounding a component at a mechanical support.
Figure 10–3. Recommended parts sequence
for grounding an electrical wire.

10-8 Model 3606 • Origin 10/99

 Electrical System

10.4 WIRING HARNESSES use the correct gauge size wiring, and NEVER replace a
wire with a smaller gauge wire.
Wiring on the vehicle is contained within two separate
wiring harnesses, an engine harness and a cab harness. c. Cleaning and Drying
There are several figures in this section that depict the
different wiring harnesses. Clean a wire harness with a natural bristle brush and the
same detergent used to clean the vehicle. Allow the har-
A harness consists of black-nylon woven braiding, provid-
ness to air dry. DO NOT allow surface temperatures to
ing a protective cover to bundle numerous wiring groups,
exceed 300° F (149° C).
splices, terminals, connectors, and, where applicable,
diodes. Each harness is identified with a Trak part num-
d. Inspection and Repair
ber when the vehicle leaves the factory.
One engine harness has been used throughout the pro- Replace a harness only if it is damaged or unusable. If a
duction history of this vehicle. splice or repair must be made to a wire, always use rosin
core solder to bond wires together. Use heat-shrink tub-
Note: There are currently three cab harnesses in use on ing or insulating electrical tape to cover all splices or bare
this vehicle. The initial harness covered serial numbers wires.
8249 and before. The addition of wiring for limited acces-
sories on the next production harness covers serial num- e. Installation
bers 8250 through 9398. The current harness covers
serial numbers 9399 and after and includes additional The wiring harnesses are held securely in place by wire
wiring for all planned accessory items. tie wraps, clips or other devices to help prevent chafing or
wearing of the insulation and entanglement with moving
Check the cab wiring harness on the vehicle respective parts. Sections of ribbed plastic conduit have been
of the serial number information above to determine installed where wiring or harnesses pass through open-
which harness the vehicle is equipped with. ings in the vehicle frame. Always install tie wraps, clips,
Each wire is identified by a wire number on each end of conduit, etc., in their original locations to help prevent
the individual wire, and by the color and gauge size of the damage to the wiring or harnesses.
wire. The wire numbers and color codes are also identi-
fied on the appropriate electrical schematic. All circuits f. Wire Code and Color
have been electrically tested for continuity, and all diodes The chart below indicates the wire code abbreviation and
have been tested for correct biasing. Where several indi- color as used on the electrical schematics.
vidual connectors appear, the wiring leading to a particu-
lar connector can help identify the specific circuit. For WIRE CODE COLOR
some circuits, a colored band (tie wrap) is present, BLK Black
affixed to the connector wiring and used as a color-code BLU Blue
indicator. For ease of identification, detailed illustrations BRN Brown
of each type of connector also appear in this section.
DK BLU Dark Blue
If wiring ever needs to be replaced, use the correct DK GRN Dark Green
gauge size wiring. NEVER replace a wire with a smaller
GRN Green
gauge wire.
GRY Grey
a. Removal and Replacement LGT BLU Light Blue
LGT GRN Light Green
Remove a wiring harness only if damaged or unusable.
ORN Orange
Install a new harness one terminal at a time as the old
harness is removed. Label or tag the terminal locations of PNK Pink
all wires, harness clips, tie wraps and conduit as the old PUR Purple
harness is removed to allow correct installation of the RED Red
new harness. TAN Tan
YEL Yellow
b. Disassembly
WHT White
Disassembly of the wiring harness is not recommended
due to the precise arrangement of wires and splice
requirements. If it becomes necessary to replace wires,

Model 3606 • Origin 10/99 10-9

 Section 10

Bulkhead
Connector
GR
Y/O
RN
BL 30
K
RE 2K
RE D
18 D/ 3
GR
GR BR N
19 Y/G 35
RN N/
GR
YE N
11 L/B
LK 42
10 PU B
A R/
PN 10 WH
K/G T
14 RN PN
K/G
WH 12 RN
34 T/B RE
44 RN D/
YE BL
L/P U
46 GR
31 Y/B UR
PN LU
32 K/B
LU

26 BL
K
2E

23 32 41 39 38 37
OR 44 Lo Joy 36
N/
BL 34
gic st
U 21
Pa ick 40
31 12 ne
25
24 l
Horn 11 10
Button TA
N 14 RN
46
LU L/G PN
50 32 Y/B 10
A YE K/B
GR UR 18
LU
U L/P
BL 44
D/ YE BL
U 43
RE D/ 19 26
LT 34 RE WH
U
GR BL Seat Belt T/B 46
N/
WH LT R G 12 RN 23
LU
T 25 L/O Y/G Switch 4
49 YE T GR 2S
WH RE
31 R/ RN D/ 45 YE
PU GR L/B
T/B Y OR LU
Horn 11 WH RN N/
14 K/G WH
T 26
PIN Fuel Level
A
1 0
Steer Sender 27
T 18 21
WH 49 A Select 24 YE
N/ YE 2D L/B
GR 18 19 Switch OR L/BL 45 4 LU
LT N/ U T 2 OR
BL 4
A 2F U WH U N/
10 19 N/ L DK
34 12 PIN OR N/B WH BL
44 YE
RE K/G DK OR T/P U
D/ RN BL 24 LU UR 71
32 GR L/P BL
U LK 27 U/O 53 DK K/B 23
Y/B UR RN EL/B RN N BL PN 73
TA LU Y/G Y BR PN GR U/O RE
N
GR 9A N/ K/W N/ RN D/
GR BR 21 GR
N HT

To Trans. Relays
A 1 49 Y
18 LT 17 53
N GR 27
GR N/
N/ T WH 49 56
17
BR WH
N/ D T A
27 OR RE 46
R/ 60 RN
45 PU N/G U
25 Dash Display 7 Service TA K/BL
5
LT PN
BL
U
Panel 46
A Brake 59 LU 9
Switch 58 56 BR TB N
47 A N/ K/L GR RN
25
A A 46 WH PN G
T LT LU
26 TA YE D/ HT
24 A 29 GR N/
GR WH L/B RE RY/B N/W
LT 53
A WH Y/B N 56 RN G GR HT TA
GR
LU T/G N/ N/W
T/B
OR A RY DK N /W 17
N/ 46 OR 9 GR HT
BL LU D OR
N
49
25 U KB T
A LU 76 48 59
A 60 /WH N
/RE D YE 56
51 72
D 47A RE L/R
LT 69 74 59 ED 6
25 DK LT GR
BL N/ B 58 PU 5
BL U RE 47 R
LT U/ D 6
BL WH 29 59 BR 77
U T DK N
T GR
T 47
29
29 D/
WH Ignition N
7
Shrans
48
A 48
42
C RE Switch 15
TO K 2U
DK ift mi SP 9 AC
GR Sw ss LIC BL
N/
WH itc ion E
OR
h 52 N/R
T SE 8
59 8
ED FU L 59 K
TO ANE PN 16
YE P RN
L/B PNK L/B 8
51 68
RN Park Brake YE NK
RN
20
P L
RE 0
2 Switch T/O
N/
YE 8
48
DK
BL D/ B WH B R 6
BL RN 8 16 K
U/
WH K /YE BL 51
L D/
T RE T
W H 28
LU/ RN
B
DK L/G 30
48
A 51 YE
DK 68 20 51 RN
DK GR RY/O 48
N/ G
GR WH HT
N/ T /W 48
A
WH 48 G RN
T
DK HT
Hourmeter N/W
GR
DK

MS1220

Figure 10–5. Cab wiring diagram (S/N 8249 and before), left side.

10-10 Model 3606 • Origin 10/99

 Electrical System

41
41
HT 39
N/W
GR D GR
/R E 38 N/W
N HT
GR T 39
DK /WH 37 DK
LU
B GR
LT RN 36 N/R 2J
N/G 40 ED
OR
ED 40 LT
T/R BL 2J
WH U/W Aux. Hyd.
EL HT
D/Y 37
RE
WH 2J Attachment
T/R Tilt
36 ED
OR 2J Frame
Backup N/G
RN Tilt
40
Alarm 2T
RE 2J Extend/
D/Y Retract
BL EL
22 K
DK 2J Hoist/
F GR Lower GR
BR ROM N/W OU
AK 30 ND
E S PAR 35 3
2K HT GR Attachment
SP
WI K 42 G OU Tilt Fore/Aft LIC
TC
H
B BL RY/O ) ND E3
RE K RN LK SP 5
42 BR RE (B
C N/G D/G D ND 66
LIC
E3 66
RN RN OU 5
BR
N/G GR GR GR
Y/P Y/P
RN UR 66 UR
63 GR 2J
22 LT Y/P J
A GR 63 UR
42 48 N/W LT
48 48 A 62 HT GR 2H
2K N/W H
3 K OR 63 HT
BL N/P LT 2G
RE K UR GR
D G
HT 35 N/W
N/W 48 48 HT
GR A RE 2F
43 DK DK D/G F
GR DK RN
GR N/W GR
A 46
Y/B 48 Boom HT N/W 2E
E 5
46 RN RN HT
PN PN
K/G Proximity
K/B
LU 2A
64 Switch 4
4 HT DK
UR N/W BL
Y/P GR R U/W
GR LT U WH
T
65 HT 3
63 N/P LU/
66 OR B OR
48 43 DK N/B
A 62 LK Stabil-TRAK 2
42 64
66 65 Soleniods
4
OR 1
63 62 N/B
71 LK
64
HT HT
Bo 46 N/W RN/W
om K GR G
PN D D K
Re K/B
LU 48 A
lay 48
s
Tra RN D
n D/G RE
9 RED/WHT
Re smis 35
RE
3
lay sio NK LU BLK
s n L/P /B N/
53 DK BLU/ORN T YE PNK OR
WH 61 RN
17 PNK/WHT U/ 46 65
BL Y/O
GR
70
49 LT GRN/WHT 30
56 TAN/GRN
6 ORN
5 YEL/RED
nel
77 PUR
e Pa
us
7 BRN
15 F
K
PN RN
8 T/O
WH EL
16 N /Y
BR LK
20 D/B WHT
RE /
68 B LU
DK
51 RN
L /G
YE RN
28 Y/O
GR HT
N/W T
30 G R H
DK N /W
48 GR
DK
A
48

MS1230

Figure 10–6. Cab wiring diagram (S/N 8249 and before), right side.

Model 3606 • Origin 10/99 10-11

 Section 10

10.4.1 Cab Harness, S/N 8249 and Before

Use this chart for vehicles with S/N 8249 and before.
WIRE No. COLOR GAUGE FUNCTION
2B BLK 16 Hourmeter to Ground Splice 40
2C BLK 16 Shift Control Relays to Cab Ground Stud
2D BLK 16 Fuel Level Sender to Ground Splice 50
2E BLK 14 Joystick Logic Board to Ground Splice 40
2F BLK 16 Steer Select Lamp (Terminal 7) to Ground Splice 40
2G BLK 16 Display Panel to Ground Splice 40
2H BLK 16 Display Panel to Ground Splice 40
2J BLK 16 Boom Function Solenoids to Ground Splice 35
2K BLK 10 Ground Splice 45 to Ground Splice 50
2S BLK 16 Seat Belt Switch to Ground Splice 50
2T BLK 16 Backup Alarm to Ground Splice 35
2U BLK 16 Ground Splice 40 to Park Brake Lamp (Terminal 7)
2V BLK 12 Ground Splice 40 to Cab Ground Stud
2Y BLK 10 Ground Splice 35 to Ground Splice 50
2AA BLK 10 Ground Splice 50 to Cab Ground Stud
2BB BLK 10 Ground Jumper for Neutral Relay
2CC BLK 16 Ground Splice 40 to Stabil-TRAK Relays
2EE BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #3
2FF BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #4A
2GG BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #4B
2HH BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #2A
2JJ BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #2B
2KK BLK 16 Ground Splice 35 to Boom Proximity Switch
2LL BLK 16 Ground Splice 40 to Relay 1
2MM BLK 16 Ground Splice 40 to Neutral Relay
3 RED 10 Starter (+) Power to (+) Grid (fuse panel bus)
4 YEL/BLU 16 Neutral Relay to Starter Relay
5 YEL/RED 14 Ignition Switch (Terminal 4) to 7.5-amp Fuses
6 ORN 10 Ignition Switch to 40-amp Main Fuse
7 BRN 10 Ignition Switch to (+) Grid (fuse panel bus)
8 PNK 16 7.5-amp Fuse to Park Brake Switch (Terminal 5)
9 RED/WHT 16 Park Brake Switch (Terminal 6) to Neutral Relay
10 PNK/GRN 16 Alternator Indicator Terminal to CUMMINS Indicator Logic
10A PNK/GRN 16 Alternator Indicator Terminal to PERKINS Indicator Logic
11 PUR/WHT 16 Oil Pressure Logic to Oil Pressure Switch
12 RED/BLU 16 Engine Coolant Temperature Logic to Engine Coolant Temperature Switch
14 WHT/BRN 16 Hydraulic Oil Temperature Logic to Hydraulic Oil Temperature Switch
15 DK GRN 16 Ignition Switch to 7.5-amp Fuse for Shift Control
16 WHT/ORN 16 7.5-amp Fuse to Park Brake Switch (Terminal 2)
17 PNK/WHT 16 7.5-amp Fuse to Steer Select Switch (Terminal 2)
18 GRY/GRN 16 Steer Select Switch (Terminal 1) to Steer Select Solenoid (C)
18A GRY/GRN 16 Steer Select Switch (Terminal 1) to Steer Select Logic
19 YEL/BLK 16 Steer Select Switch (Terminal 3) to Steer Select Solenoid (Terminal 4)
19A YEL/BLK 16 Steer Select Switch (Terminal 3) to Steer Select Logic
20 BRN/YEL 14 7.5-amp Fuse to Shift Control Switch (Terminal 8)
21 YEL/BLU 16 Shift Control Relay to Reverse Clutch Solenoid
22 DK GRN/WHT 16 Splice 20 to Backup Alarm
23 RED/GRY 16 Shift Control Relay to Forward Clutch Solenoid
24 ORN/BLU 16 Transmission Shuttle Solenoid to Splice 8
24A ORN/BLU 16 Splice 80 to Transmission Logic
25 LT BLU 16 Transmission Shift Control Switch to First Gear Clutch Solenoid
25A LT BLU 16 First Clutch Shift Control to Transmission Logic

10-12 Model 3606 • Origin 10/99

 Electrical System

WIRE No. COLOR GAUGE FUNCTION

26 WHT/BLU 16 Splice 12 to Second Gear Clutch Solenoid
26A WHT/BLU 16 Second Clutch Shift Control to Transmission Logic
27 BRN/GRN 16 Fuel Gauge Logic to Fuel Level Sender
28 YEL/GRN 16 7.5-amp Fuse to Hourmeter Power (+) Terminal
29 DK BLU/RED 16 Park Brake Switch (Terminal 3) to Park Brake Logic
30 GRY/ORN 16 Oil Pressure Switch (Terminal B) to Hourmeter Ground (-) Terminal
31 YEL/ORN 16 Air Filter Logic to Air Filter Switch
32 TAN 16 Transmission Temperature Logic to Transmission Temperature Switch
34 YEL/PUR 16 Hydraulic Oil Filter Logic to Hydraulic Oil Pressure Switch
35 RED/GRN 16 Ignition Fuse to Fuel Shutoff Solenoid
36 ORN/GRN 14 Lift Solenoid to Logic Board
37 WHT/RED 14 Extend Solenoid to Logic Board
38 LT BLU/WHT 14 Frame Tilt Solenoid to Logic Board
39 DK GRN/RED 14 Attachment Tilt (side-to-side) Solenoid to Logic Board
40 RED/YEL 14 Auxiliary Hydraulics "1" to Logic Board
41 DK GRN/WHT 14 Auxiliary Hydraulics "2" to Logic Board
42A PNK/GRN 16 Splice 10 to Shift Control Relays
42B BRN/GRN 16 Splice 10 to Splice 15
42C BRN/GRN 16 Splice 10 to Park Brake Switch (Terminal 1)
43 GRY/BRN 16 Joystick Logic (Terminal 7/A) to 7.5-amp Fuse
44 GRY/BLU 16 Maintenance Reset Switch to Bulkhead Connector to Maintenance Indicator
45 ORN/WHT 16 Seat Switch to Seat Belt Logic
46 PNK/BLU 10 Cold Start to 15-amp Fuse
46A PNK/BLU 16 Cold Start to Logic Panel
47 GRY/BLU 16 Shift Control to Shift Control Relay (F)
47A GRY/BLU 16 (F) Shift Control to Transmission Logic Indicator
48 DK GRN/WHT 16 Shift Control to Shift Control Relay (R)
48A DK GRN/WHT 16 Shift Control to Shift Logic
49 LT GRN/WHT 16 7.5-amp Fuse to Horn (+) Power Terminal
50 RED/BLU 16 Horn (-) Terminal to Horn Button (on steering wheel)
51 DK BLU/WHT 16 7.5-amp Fuse to Indicator Panel Logic
52 ORN/RED 16 Park Brake Lamp (Terminal 8) to Fuse Panel
53 DK BLU/ORN 16 Steer Select Lamp (Terminal 8) to 7.5-amp Fuse
56 TAN/GRN 16 Service Brake Switch to Fuse Panel
57 PUR/RED 16 Service Brake Switch to Splice 5
58 WHT/GRY 16 Park Brake Splice to Splice 5
59 YEL/BRN 16 Transmission Shift Switch Out to NEUTRAL Splice to Splice 5
59A ORN/WHT 16 Transmission Shift Switch Splice to NEUTRAL Relay
60 BRN/WHT 16 Splice 5 to Stabilizer Lock Relay
61 YEL/PNK 16 Boom Proximity Splice to Fuse Panel
62 ORN/PUR 16 Stabilizer Lock Relay to Stabilizer Valve (Coil 5)
63 LT GRN/WHT 16 Stabilizer Lock Relay to Stabilizer Valve (Coil 4)
64 DK BLU/WHT 16 Boom Proximity Switch to Boom Switch Relay
65 ORN/BLU 16 Boom Proximity Splice to Boom Switch Relay
66 GRY/PUR 16 Boom Switch Relay to Stabilizer Valve (Coil 2)
67 RED/GRN 16 Stabilizer Valve (Coil 3) to Stabil-TRAK Logic Input
68 RED/BLK 16 7.5-amp Fuse to Shift Control Switch Neutral
69 GRN 16 Shift Control Switch (Terminal 3) to Relay 1 (Terminal 85)
70 BLU/WHT 16 Fuse Panel 7.5-amp Fuse to Transmission Relay 1 (Terminal 30)
71 ORN/DK BLU 16 Relay 1 (Terminal 87) to Splice 12 to Transmission 2nd Gear Solenoid
72 LT GRN/RED 16 Shift Control to Shuttle Clutch Solenoid
73 WHT/PUR 16 Transmission Relay 3 (Terminal 87) to Splice 8
74 RED/LT GRN 16 Forward Splice to Transmission Relay 3 (Terminal 30)
75 WHT/BLU 16 Shift Control Switch to 2nd Gear Clutch Solenoid
76 PNK/LT BLU 16 4TH Gear (optional--if equipped) Splice to Transmission Relay 2 (Terminal 85)
77 PUR 10 Ignition Switch (Terminal 5) to 15-amp Fuse

Model 3606 • Origin 10/99 10-13

 Section 10

DK GRN/WHT LT BLU LT BLU LT BLU

48 25 25 25
DK BLU/WHT DK BLU/WHT
51 51
DK GRN/WHT

HOUR 25A
ETER RED/BLK TAN
68 32
LT BLU
30 BRN/YEL TRANSISSION 25A YEL / ORG 31
28 20 DASH

LT BLU
SHIFT SWITCH 72 LT GRN/RED
YEL/BRN 24A ORN/BLU TRANS. DISPLA STEER GRY/BLU
GRY/ORN

44
YEL/GRN

59

YEL / ORG
TAN
WHT / BLU CONTROL SELECT PUR / WHT
8
PNK PNK
47 75 26A WHT / BLU LOGIC PANEL LOGIC 11
48 69

GRY/BLU
PAR BRAE 76 WHT / BRN 34 25
DK BLU/RED
29

PUR / WHT
SWITCH 29 29 YEL/PUR 32
GRY/BLU GRY/BLU 14
30 28 8 47A
WHT/ORN DK GRN/WHT 46A RED / BLU 31
16 42C 48A 48A 12
47 76 45 27 PNK/GRN
TAN/GRN 10A 44
59 52 DK BLU/RED 69 56
9 48A 18A PNK/GRN HORN
ORN/RED 29 42C 74 SERVICE 10 11

ORN/WHT
RED/WHT

BRN/GRN
BRAE 19A 50
DIODE 56 50
YEL/BRN

29

GRY / GRN

RED/BLU
WHT/GRY SWITCH
PNK

PAR 49

YEL / BLK
58 58 57

LT GRN/WHT
BRAE HORN 34
LAP 59 59 59
YEL/BRN BUTTON 14
12

YEL/PUR
59 DIODE 69 48A 58 10A

WHT / BRN
2U 59A 59 25
8 76 60 10

RED / BLU
42C 74
49 BULHEAD

PNK/GRN
PNK IGNITION 6 BRN/WHT 60 BRN/WHT

LT BLU
CONNECTOR

PNK/GRN
SWITCH 9 LT GRN/WHT
49 PIN LOCATION

DK GRN/WHT
DK GRN GRY/BLU ORN/WHT
RED/LT GRN
GRN
1

PNK/LT BLU
BRN/GRN

15 3 2 60 45
49 BRN/GRN 46A
BRN 4 5 27
7 59A STEER SELECT
PUR 19A 24 J3
77 6 56 SWITCH
YEL/RED YEL / BLK 24
5 19
ORN 42C GRY / GRN
6 17 18
TAN/GRN

ORN/BLU
56 53 18A
LT GRN/WHT
49 STEER SELECT

GRY / GRN
PNK/WHT

YEL / BLK
F PNK/WHT

PNK/BLU
17 17 INDICATOR 25 J7

ORN/WHT
BRN/GRN
U 2F LAP
S
E 42A
42B
YEL/BRN
59A ORN/BLU
48A 24 24
P YEL / BLU
A 9 21 21 21 H4
N FUEL LEVEL 19
DK GRN/WHT
BRN/GRN

ORN/BLU

60 SENDER 46A
E 45 18
L
27
RED / GRY
24 2D
70 SEAT BELT 23 23 H8
RED / GRY RED / GRY SWITCH 32
BLU / WHT

23
TRANSISSION WHT / PUR ORN/WHT
73 45

TAN
RELAS
46
DIODE 2S
70 ORG / DK BLU WHT / BLU WHT / BLU
65 61 71 26 26 26 J9
35 YEL / BLU YEL / BLU
4 31 4 C8
YEL/PNK

YEL / ORG
PNK/BLU

48A
ORN/BLK

30
RED/GRN

42B

PNK/BLU
DK GRN/WHT

TAN D3
BRN/GRN

32
GRY/ORN

BOO
RELAS
RED

44
61 64 63 48

GRY/BLU
66 43 46A 19 YEL / ORG
62
18 31 D5
PNK/BLU
46 PNK/BLU 46 PNK/BLU 46

PNK/BLU 46
DK BLU/WHT

E8
GRY/BRN GRY/BRN OSTIC
43 LOGIC 11
YEL / BLK

43
PANEL
GRY / GRN

48A GRY/BLU

PUR / WHT
35 44 B3
42B
64
3 ORN/BLK
65
GRY / ORG GRY / ORG GRY / ORG
30 30 30 D7
48A 2E
DK GRN/WHT
GRY/PUR

42B
41
LT GRN/WHT

39 PUR / WHT
65 11 G3
DK GRN/WHT

38
RED/GRN

BLK
ORN/PUR

37
18 19
GRN/WHT
DK GRN/RED

48A
RED

48 36 YEL / BLK
LT BLU/WHT

42B BAC-UP 19 H2
DK GRN/WHT 40
66 ALAR
ORN/GRN

BOO 2E
WHT/RED

48 PRO 63 DK GRN/WHT
RED/YEL

3 35 22 GRY / GRN
18 G9
ORN/BLK 62
65
DK BLU/WHT 22
64 BLK BRN/GRN
2T 42B B7
DK GRN/WHT 2T BRN/GRN BRN/GRN
48 42B 42B
RED/GRN RED/GRN RED/GRN
35 35 35 D9
RED RED 3
3
BLK BLK BLK
2KK 2K 2K
ORN/PUR
62
LT GRN/WHT RED
63 2E 3 F8
GRY/PUR BLK 40 14 34
66 2E
2J 12
YEL/PUR
WHT / BRN

PILOT SELECT 10A

STABIL TRA SOLENOIDS 10
BLK

RED / BLU

SOLENOIDS YEL/PUR
PNK/GRN

RED/YEL 34 D1
40
PNK/GRN

ORN/PUR
62 36
5 2J
2EE
FORTILT WHT / BRN
14 G7
FORE/AFT
ORN/GRN BLK
LT GRN/WHT 36 2K 2K F2
63 37
4 2J
2FF RED / BLU
12 G5
LIFT
WHT/RED PNK/GRN H6
10A
LT GRN/WHT 37 38
63
3 2J PNK/GRN
2GG 10 G1
ETEND

LT BLU/WHT
GRY/PUR 38 39
66
2 2J
2HH
FRAE TILT

DK GRN/RED
GRY/PUR 39
66
1 2J
2JJ 41
FOR TILT
GRN/WHT
41
2J

AU. HD. MS1250

Figure 10–7. Cab wiring schematic, S/N 8249 and before.

10-14 Model 3606 • Origin 10/99

 Electrical System

Head-on views; wires exit at the rear of each component.

JUMPER JUMPER
2BB
66 23
DOUBLE TERMINAL 67 62 21 4

2CC 2C 59A

63
9
60 48 42A
64 47 42A
65

Stabilier Lock Relay Boom Switch Relay

Shift Control Neutral
Relays (2) Relay
71
JUMPER
2LL
73

69

70
74
76

Trans. Trans. Trans.

Relay 1 Relay 2 Relay 3

ENGINE HARNESS CAB HARNESS

20 16 17 49

1 3 5 7 9 9 7 5 3 1

K
7
K
J 24 25 26 26 25 24 J
H 19 21 10A 23 23 10A 21 19 56 65 61 52 53 70
H
G 10 11 12 14 18 18 14 12 11 10
G
2K 3
F 3 2K F

E 46 E
46
D
6
34 32 31 30 35 35 31 32 34
30
D
93 4 C JUMPER
4
C
44 42B B
WIRES 3
B 42B 44

A A

35 51 43 68

5
ENGINE CAB
BULHEAD BULHEAD 15 46

CONNECTOR CONNECTOR
8 28 77

FUSE BLOC MS1320

Figure 10– 8. Cab harness relays, bulkhead connector and fuse panel, S/N 8249 and before.

Model 3606 • Origin 10/99 10-15

 Section 10

Bulkhead
Connector

GR
Y/O
RN
BL 30
K
RE 2K
RE D
18 D/G 3
GR RN
19 Y/G BR 35
RN N/G
YE RN
11 L/B
LK 42
10 PU B
A R/W
PN 10 HT
K/G
14 RN PN
K/G
WH 12 RN
34 T/B RE
44 RN D/B
YE LU
GR L/P
46 Y/B UR
31
PN LU
32 K/B
LU

26 BL
K
2E

23 32 41 39 38
44 Lo Joy 36
OR 37
N/B gic st
LU 21 34 Pa ick 40
31 12
ne
25
24 l
Horn 11 10
Button N 14 RN
46
TA LU L/G PN
50 32 Y/B 10
A YE 13 K/B
GR UR 18
8 LU
LU 13
D/B 44 L/P 7 GR
43
RE YE LU 26 LT N/B
4 D/B 19 Seat Belt BL LU
LT 3 RE U/O
GR BL
U Switch BL WH RN 46
N/W LT RG 12 RN 23 K T/B

139
HT 25 L/O Y/G LU 4
49 YE HT GR RE
2S 2PP
31 R/W RN D/G 45 YE
PU L/B
T/B RY OR LU
Horn 11 WH RN N/W
14 K/G HT Attach. Tilt
PIN Fuel Level Diode
10
A
Sender Mode Switch
27
HT 49
18
A
Steer 24 21 YE
N/W Select YE 2D 53 L/B
GR 18 OR L/BL 45 LU
LT 19 Switch N/B U
HT /ORN OR 4
9A LU N/D
12
10 1 RN/W BLU K
34 PIN 2F O WH BL
44 RE K/G DK T/P U
YE D/B 53 24 UR 71
32 GR L/P LU
RN
LK 27 53 LU U 23
Y/B UR RN EL/B 24 K/B /BL
RN PN RN 73
TA
N LU Y/G Y BR PN
N/G K/W N/G O RE
GR 9A BR
D/G

To Trans. Relay
1 49 RN HT A 21 RY
A 46
18 LT
RN GR 27
N/G HT
N/W 17
BR N/W
HT
27 OR ED
R/R 60
45 PU LU
25 K/B
LT
Dash Display 46
57 Service PN
BL
U Panel A Brake 59 LU 17 9
BR K/B GRN HT
25 47 Switch 58 N/W PN RN D/W
LT A A 56 HT TG U RE
BL
U 26 TA YE D/L L RN
A A 29 GR N/G L/B RE RY/B N/G LT
48 24 Y/B WH RN G BR GR 17
A WH
LU
RN T/G HT TA
N/G N/W
OR T
N/B /BLU 46
A RY N/W HT
LU DK
BR OR R
OR N
25 N/W 49
A BL 59
A 60 N
DK U/R 76 HT
YE
GR 51 72 L/R 56
N/W ED 47
LT A 69 74 59 ED 6
HT 25 LT GR 58
DK B C
BL LU N/RE 42 PU
R 5
LT U/W B
BL D 29 47 29 59
6 BR 77
U HT DK N
U HT Ignition GRN 7
T 47 BL 29 D/W
48
A Shrans 8 DK HT
/W 9
RE Switch 15
ift mi
Sw ssi 2U
itc on 52
DK
h
8
GR 59 59 K
N/W PN 16
HT YE RN
L/B PNK L/B 8
51 68
RN Park Brake YE
PN
K
RN
20
2 Switch T/O EL
DK RE 0 WH N/Y 68
BL D/B BR BR K
U/W LK N/YE L
48 48 HT L D/B 51
A RE T
DK H 28
GR
N/W LU/W RN
DK B
GR H DK L/G 30
N/W T YE N
51 R
HT
R Y/O 48
G
HT
N/W 48
A
48 GR
A DK H T
Hourmeter N /W
GR
DK

MS1200

Figure 10– 9. Cab wiring diagram, S/N 8250-9398, left side (refer to the appropriate wire code chart).

10-16 Model 3606 • Origin 10/99

 Electrical System

41
41
HT 39
N/W
GR D GR
/R E 38 N/W
N HT
GR T 39
DK /WH 37 DK
LU
B GR
LT RN 36 N/R 2J
N/G 40 ED
OR
ED 40 LT
T/R BL 2J
WH U/W Aux. Hyd.
EL HT
D/Y 37
RE
WH 2J Attachment
T/R Tilt
36 ED
OR 2J Frame
Backup N/G
RN Tilt
40
Alarm 2T
RE 2J Extend/
D/Y Retract
BL EL
22 K
DK 2J Hoist/
F GR Lower GR
BR ROM N/W OU
AK 30 N
E S PAR 3
2K HT GR Attachment DS
WI K 42 35 G OU Tilt Fore/Aft PL
ICE
TC
H
B BL RY/O ) N DS
RE K RN LK 35
42 BR RE (B PL
C N/G D/G D ND 66 ICE
66
RN RN OU 35
BR
N/G GR GR GR
Y/P Y/P
RN UR 66 UR
63 GR 2J
22 LT Y/P J
A GR 63 UR
42 48 N/W LT
48 48 A 62 HT GR 2H
2K N/W H
3 K OR 63 HT
BL N/P LT 2G
RE K UR GR
D G
HT 35 N/W
N/W 48 48 HT
GR A RE 2F
43 DK DK D/G F
GR DK RN
GR N/W GR
A 46
Y/B 48 Boom HT N/W 2E
E 5
46 RN RN HT
PN PN
K/G Proximity
K/B
LU A 64 Switch 4
42 HT DK
UR N/W BL
Y/P GR R U/W
GR LT U HT 65 HT 3
63 N/P U/W
66 OR K BL OR
48 43 D N/B
A 62 LK Stabil-TRAK 2
42 64
66 65 Soleniods
4
OR 1
63 62 N/B
71 LK
64
HT HT
Bo 46 N/W RN/W
om GR G
PN DK DK
Re K/B
LU 48 A
lay 48
s
Tra RN D
n D/G RE
9 RED/WHT
Re smis 35
RE
3
lay sio NK LU BLK
s n L/P /B N/
53 DK BLU/ORN T YE PNK OR
WH 61 RN
17 PNK/WHT U/ 4 6 65
BL Y/O
GR
70
49 LT GRN/WHT 30
56 TAN/GRN
6 ORN
5 YEL/RED
el
77 PUR an
7 BRN s eP
15 Fu
K
PN RN
8 T/O
WH EL
16 /Y
B RN K
20 L
D/B WHT
RE U/
68 BL
DK
51 RN
L/G
YE RN
28 Y/O
GR HT
/W
30 GRN HT
DK RN/W
48 G
DK
A
48

MS1210

Figure 10– 10. Cab wiring diagram, S/N 8250-9398, right side (refer to the appropriate wire code chart).

Model 3606 • Origin 10/99 10-17

 Section 10

10.4.2 Cab Harness, S/N 8250-9398

Use this chart for vehicles with S/N 8250-9398.
WIRE No. COLOR GAUGE FUNCTION
2 BLK 16 Generic Ground
2B BLK 16 Hourmeter to Ground Splice 40
2C BLK 16 Shift Control Relays to Cab Ground Stud
2D BLK 16 Fuel Level Sender to Ground Splice 50
2E BLK 14 Joystick Logic Board to Ground Splice 40
2F BLK 16 Steer Select Lamp (Terminal 7) to Ground Splice 40
2G BLK 16 Display Panel to Ground Splice 40
2H BLK 16 Display Panel to Ground Splice 40
2J BLK 16 Boom Function Solenoids to Ground Splice 35
2K BLK 10 Ground Splice 45 to Ground Splice 50
2S BLK 16 Seat Belt Switch to Ground Splice 50
2T BLK 16 Backup Alarm to Ground Splice 35
2U BLK 16 Ground Splice 40 to Park Brake Lamp (Terminal 7)
2V BLK 12 Ground Splice 40 to Cab Ground Stud
2Y BLK 10 Ground Splice 35 to Ground Splice 50
2AA BLK 10 Ground Splice 50 to Cab Ground Stud
2BB BLK 10 Ground Jumper for Neutral Relay
2CC BLK 16 Ground Splice 40 to Stabil-TRAK Relays
2EE BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #5
2FF BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #4
2GG BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #3
2HH BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #2
2JJ BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #1
2KK BLK 16 Ground Splice 35 to Boom Proximity Switch
2LL BLK 16 Ground Splice 40 to Relay 1
2MM BLK 16 Ground Splice 40 to Neutral Relay
3 RED 10 Starter (+) Power to (+) Grid (fuse panel bus)
4 YEL/BLU 16 Neutral Relay to Starter Relay
5 YEL/RED 14 Ignition Switch (Terminal 4) to 7.5-amp Fuses
6 ORN 10 Ignition Switch to 40-amp Main Fuse
7 BRN 10 Ignition Switch to (+) Grid (fuse panel bus)
8 PNK 16 7.5-amp Fuse to Park Brake Switch (Terminal 5)
9 RED/WHT 16 Park Brake Switch (Terminal 6) to Neutral Relay
10 PNK/GRN 16 Alternator Indicator Terminal to CUMMINS Indicator Logic
10A PNK/GRN 16 Alternator Indicator Terminal to PERKINS Indicator Logic
11 PUR/WHT 16 Oil Pressure Logic to Oil Pressure Switch
12 RED/BLU 16 Engine Coolant Temperature Logic to Engine Coolant Temperature Switch
14 WHT/BRN 16 Hydraulic Oil Temperature Logic to Hydraulic Oil Temperature Switch
15 DK GRN 16 Ignition Switch to 7.5-amp Fuse for Shift Control
16 WHT/ORN 16 7.5-amp Fuse to Park Brake Switch (Terminal 2)
17 PNK/WHT 16 7.5-amp Fuse to Steer Select Switch (Terminal 2)
18 GRY/GRN 16 Steer Select Switch (Terminal 1) to Steer Select Solenoid (C)
18A GRY/GRN 16 Steer Select Switch (Terminal 1) to Steer Select Logic
19 YEL/BLK 16 Steer Select Switch (Terminal 3) to Steer Select Solenoid (Terminal 4)
19A YEL/BLK 16 Steer Select Switch (Terminal 3) to Steer Select Logic
20 BRN/YEL 14 7.5-amp Fuse to Shift Control Switch (Terminal 8)
21 YEL/BLU 16 Shift Control Relay to Reverse Clutch Solenoid
22 DK GRN/WHT 16 Splice 20 to Backup Alarm
23 RED/GRY 16 Shift Control Relay to Forward Clutch Solenoid
24 ORN/BLU 16 Transmission Shuttle Clutch Solenoid to Splice 8
24A ORN/BLU 16 Splice 80 to Transmission Logic
25 LT BLU 16 Transmission Shift Control Switch to First Gear Clutch Solenoid

10-18 Model 3606 • Origin 10/99

 Electrical System

WIRE No. COLOR GAUGE FUNCTION

25A LT BLU 16 First Clutch Shift Control to Transmission Logic
26 WHT/BLU 16 Splice 12 to Second Gear Clutch Solenoid
26A WHT/BLU 16 Second Clutch Shift Control to Transmission Logic
27 BRN/GRN 16 Fuel Gauge Logic to Fuel Level Sender
28 YEL/GRN 16 7.5-amp Fuse to Hourmeter Power (+) Terminal
29 DK BLU/RED 16 Park Brake Switch (Terminal 3) to Park Brake Logic
30 GRY/ORN 16 Oil Pressure Switch (Terminal B) to Hourmeter Ground (-) Terminal
31 YEL/ORN 16 Air Filter Logic to Air Filter Switch
32 TAN 16 Transmission Temperature Logic to Transmission Temperature Switch
34 YEL/PUR 16 Hydraulic Oil Filter Logic to Hydraulic Oil Pressure Switch
35 RED/GRN 16 Ignition Fuse to HOLD Lead Fuel Shutoff Solenoid
36 ORN/GRN 16 Lift Solenoid to Logic Board
37 WHT/RED 16 Extend Solenoid to Logic Board
38 LT BLU/WHT 16 Frame Tilt Solenoid to Logic Board
39 DK GRN/RED 16 Attachment Tilt (side-to-side) Solenoid to Logic Board
40 RED/YEL 16 Auxiliary Hydraulics "1" to Logic Board
41 DK GRN/WHT 16 Auxiliary Hydraulics "2" to Logic Board
42A PNK/GRN 16 Splice 10 to Shift Control Relays
42B BRN/GRN 16 Splice 10 to Splice 15
42C BRN/GRN 16 Splice 10 to Park Brake Switch (Terminal 1)
43 GRY/BRN 16 Joystick Logic (Terminal 7/A) to 7.5-amp Fuse
44 GRY/BLU 16 Maintenance Reset Switch to Maintenance Internal Logic Indicator
45 ORN/WHT 16 Seat Switch to Seat Belt Logic
46 PNK/BLU 10 Cold Start to 15-amp Fuse
46A PNK/BLU 16 Cold Start to Logic Panel
47 GRY/BLU 16 Shift Control to Shift Control Relay (F)
47A GRY/BLU 16 (F) Shift Control to Transmission Logic Indicator
48 DK GRN/WHT 16 Shift Control to Shift Control Relay (R)
48A DK GRN/WHT 16 Shift Control to Shift Logic
49 LT GRN/WHT 16 7.5-amp Fuse to Horn (+) Power Terminal
50 RED/BLU 16 Horn (-) Terminal to Horn Button (on steering wheel)
51 DK BLU/WHT 16 7.5-amp Fuse to Indicator Panel Logic
52 ORN/RED 16 Park Brake Lamp (Terminal 8) to Splice 200
53 DK BLU/ORN 16 Steer Select Lamp (Terminal 8) to Splice 200
56 TAN/GRN 12 Service Brake Switch to Fuse Panel
57 PUR/RED 16 Service Brake Switch to Splice 5
58 WHT/GRY 16 Park Brake Splice to Splice 5
59 YEL/BRN 16 Neutral Switch Out to Neutral Splice to Splice 5
59A ORN/WHT 16 Neutral Switch Splice to Neutral Relay
60 BRN/WHT 16 Splice 5 to Stabilizer Lock Relay
61 YEL/PNK 16 Boom Proximity Splice to Fuse Panel
62 ORN/PUR 16 Stabilizer Lock Relay to Stabilizer Valve (Coil 5)
63 LT GRN/WHT 16 Stabilizer Lock Relay to Stabilizer Valve (Coil 2)
64 DK BLU/WHT 16 Boom Proximity Switch to Boom Switch Relay
65 ORN/BLU 16 Boom Proximity Splice to Boom Switch Relay
66 GRY/PUR 16 Boom Switch Relay to Stabilizer Valve (Coil 2)
67 RED/GRN 16 Stabilizer Valve (Coil 3) to Stabil-TRAK Logic Input
68 RED/BLK 16 7.5-amp Fuse to Shift Control Switch Neutral
69 GRN 16 Shift Control Switch (Terminal 3) to Relay 1 (Terminal 85)
70 BLU/WHT 16 Fuse Panel 7.5-amp Fuse to Transmission Relay 1 (Terminal 30)
71 ORN/DK BLU 16 Relay 1 (Terminal 87) to Splice 12 to 2 Solenoid
72 LT GRN/RED 16 Shift Control to Shuttle Clutch Solenoid
73 WHT/PUR 16 Transmission Relay 3 (Terminal 87) to Splice 8
74 RED/LT GRN 16 Forward Splice to Transmission Relay 3 (Terminal 30)
75 WHT/BLU 16 Shift Control Switch to "2ND" Clutch Solenoid

Model 3606 • Origin 10/99 10-19

 Section 10

WIRE No. COLOR GAUGE FUNCTION

76 PNK/BLU 16 4TH Gear (optional--if equipped) Splice to Transmission Relay 2 (Terminal 85)
77 PUR 10 Ignition Switch (Terminal 5) to 15-amp Fuse
92 TAN/PUR 16 Splice 200 to Lamp Fuse
93 LT BLU/PUR 16 Splice 110 to Cummins Cold Start Switch (optional)
137 LT BLU/ORN 16 Attachment Tilt Switch (Terminal 2) to +12V Logic
138 GRN/BLU 16 Attachment Tilt Switch (Terminal 3) to Signal
139 ORN/GRY 16 Attachment Tilt Switch (Terminal 8) to Splice 200

10-20 Model 3606 • Origin 10/99

 Electrical System

DK GRN/WHT LT BLU LT BLU

48 25 25 25
DK BLU/WHT DK BLU/WHT
51 51
DK GRN/WHT

HOUR 25A
ETER DK GRN/WHT
RED/BLK 48A TAN
68 32
LT BLU
30 28 BRN/YEL TRANSISSION 25A YEL / ORG 31
20

LT BLU
YEL/BRN SHIFT SWITCH 72 LT GRN/RED 24A ORN/BLU TRANS. DASH STEER GRY/BLU
GRY/ORN

44
YEL/GRN
59 DISPLA

YEL / ORG
TAN
WHT / BLU CONTROL SELECT PUR / WHT
8
PNK PNK
47 75 26A WHT / BLU LOGIC PANEL LOGIC 11
48 69

GRY/BLU
PAR BRAE 76 WHT / BRN 34 25
DK BLU/RED

PUR / WHT
SWITCH 29A 29A 32
YEL/PUR 14
30 28 GRY/BLU GRY/BLU
WHT/ORN 8 47A RED / BLU
16 TAN/GRN 46A 12 31
42C 56
47B 76 45 27 PNK/GRN
138A 10A 44
59 52 DK BLU/RED 69 48A SERVICE PNK/GRN
9 BRAE 18A 10 11 HORN
29

ORN/RED
56

ORN/WHT
RED/WHT

BRN/GRN
SWITCH 19A 50
57 50
YEL/BRN
29A

GRY / GRN

RED/BLU
PNK

WHT/GRY 49

PUR/RED

YEL / BLK
58

LT GRN/WHT
HORN 34
YEL/BRN YEL/BRN BUTTON
59B 14
12

YEL/PUR
59
47B 69 48A 58 10A

WHT / BRN
2U 59B 25
8 76 60 10

RED / BLU
42C 74
IGNITION 49 BULHEAD

PNK/GRN
PNK BRN/WHT 60 BRN/WHT
6

LT BLU
SWITCH CONNECTOR

PNK/GRN
LT GRN/WHT
60 49 PIN LOCATION

BRN / GRN
GRY / BLU
RED / LT GRN
DK GRN ORN/WHT

DK GRN / WHT
1
45

PNK / BLU
15 3 2

GRN
4
BRN/GRN 46A
BRN 5 27
7 STEER SELECT
PUR 19A 138A 24 J3
77 SWITCH
YEL/RED 42C YEL / BLK 24
FUSE 5 19
ORN 17 GRY / GRN
PANEL 6 18
TAN/GRN

ORN/BLU
56 53 18A
LT GRN/WHT
49

GRY / GRN
DK BLU/ORN
PNK/WHT

YEL / BLK
PNK/WHT

GRN/BLU
PNK/BLU
17 17 25 J7

ORN/WHT
BRN/GRN
2F

ORN/BLU
24 24
YEL / BLU
21 21 21 H4
FUEL LEVEL 19
SENDER 46A
53 18
138A
DK BLU/ORN
27
RED / GRY
2D
SEAT BELT 23 23 H8

DK BLU/ORN
71 RED / GRY RED / GRY SWITCH 32
23
61 TRANSISSION WHT / PUR ORN/WHT
73 45

TAN
RELAS
93
46 2S
ORG / DK BLU WHT / BLU
ORN/DK BLU

65 71 26 26 J9
35 YEL / BLU YEL / BLU
4 31 4 C8
YEL/PNK

DK BLU/ORN
3 BRN/GRN 53

YEL / ORG
PNK/BLU
ORN/BLK

30 137 LT BLU/ORN
RED/GRN

42B GRN/BLU BOO

PNK/BLU
53 138 LOGIC
DK GRN/WHT

TAN D3
32
BRN/GRN
GRY/ORN

BOO ATTACH. TILT

71 RELAS ORN/GRY
RED

139 ODE 44
61 64 63 48B SWITCH

GRY/BLU
66 2PP 46A 19
62 43 YEL / ORG
18 31 D5
93 PNK/BLU 93 PNK/BLU 93 PNK/BLU
46 46 46
PNK/BLU 93
DK BLU/WHT

OSTIC E8
GRY/BRN 46
GRY/BRN LOGIC 11
43

YEL / BLK
43
PANEL
GRY / GRN
GRY/BLU

PUR / WHT
35 44 B3

64
3 ORN/BLK
65
GRY / ORG GRY / ORG GRY / ORG
30 30 30 D7
2E
DK GRN/WHT
GRY/PUR

41
LT GRN/WHT

39 PUR / WHT
65 11 G3
DK GRN/WHT

38
RED/GRN

ORN/PUR

BLK

37
18 19
GRN/WHT
DK GRN/RED

48A
RED

48B 36 YEL / BLK

LT BLU/WHT

42B BAC-UP 19 H2
DK GRN/WHT 40
BOO 66 ALAR
ORN/GRN
WHT/RED

PROIIT 63 DK GRN/WHT
48
RED/YEL

3 35 22 GRY / GRN
SWITCH 18 G9
ORN/BLK 62
65
DK BLU/WHT 22
64 BLK BRN/GRN
2T 42B B7
DK GRN/WHT 2T BRN/GRN BRN/GRN
48 42B 42B
RED/GRN RED/GRN RED/GRN
35 35 35 D9
RED RED
3 3
BLK BLK BLK
2KK 2K 2K
ORN/PUR
62
LT GRN/WHT RED
63 3 F8
66
GRY/PUR 40 14 34
2E 12
YEL/PUR
WHT / BRN

PILOT SELECT 10A

STABIL TRA SOLENOIDS 10
BLK

RED / BLU

SOLENOIDS YEL/PUR
PNK/GRN

RED/YEL 34 D1
40
PNK/GRN

ORN/PUR
62 36
5 2J
2EE
FORTILT WHT / BRN
14 G7
FORE/AFT
ORN/GRN BLK
LT GRN/WHT 36 2K 2K F2
63 37
4 2J
2FF RED / BLU
12 G5
LIFT
WHT/RED PNK/GRN H6
10A
LT GRN/WHT 37 38
63
3 2J PNK/GRN
2GG 10 G1
ETEND

LT BLU/WHT
GRY/PUR 38 39
66
2 2J
2HH
FRAE TILT

DK GRN/RED
GRY/PUR 39
1 66
2J
2JJ 41
FOR TILT
GRN/WHT
41
2J

AU. HD. MS1240

Figure 10– 11. Cab wiring harness schematic, S/N 8250-9398 (refer to the appropriate wire code chart).

Model 3606 • Origin 10/99 10-21

 Section 10

This page is intentionally blank.

10-22 Model 3606 • Origin 10/99

 Electrical System

Head-on views; wires exit at the rear of each component.

GROUND GROUND
71 JUMPER JUMPER 62 67 DOUBLE TERMINATE
2LL 2BB
7 3 24 23 66
21
4
2C

69
59A

70 9 63
76 74 48 42A 42A 60
47 64
61
JUMPER

Trans. Trans. Trans. Neutral JUMPER

Relay 1 Relay 2 Relay 3 Relay Shift Control Stabilier Boom Switch

Relays (2) Lock Relay Relay
ENGINE HARNESS
1 3 5 7 9

J 24 25 26
H 19 21 10A 23

G 10 11 12 14 18

2K 3
F

E 46

34 32 31 30 35
D
93 4
C
44 42B
B
52
20 16
70 35 28 6 46
A
A
7 7 7 5 5 3 77
61
B 56 65
92 51 15
ENGINE 8
BULHEAD C
132 17 43
CONNECTOR
D
90 49 68
CAB HARNESS E

92
F
9 7 5 3 1

K
26 25 24 J
23 10A 21 19
H
18 14 12 11 10
G

3 2K F

46 E

D
FUSE BLOC
35 30 31 32 34
C
4 93
B
42B 44
A

BUL HEAD
MS1300
CONNECTOR
Figure 10– 12. Cab harness relays, bulkhead connector and fuse panel, S/N 8250-9398.

Model 3606 • Origin 10/99 10-23

 Section 10

Bulkhead
Connector

GR
Y/O
RN
BL 30
K
RE 2K
RE D
18 D/G 3
GR RN
19 Y/G BR 35
RN N/G
YE RN
11 L/B
LK 42
10 PU B
A R/W
PN 10 HT
K/G
14 RN PN
K/G
WH 12 RN
34 T/B RE
44 RN D/B
YE LU
GR L/PU
46 Y/B
31 R
PN LU
32 K/B
LU

26 HT BL
R/W K
PU 2E
11
23 32 41 39 38
OR 44 Boom 36
37
N/B
LU 21 34
Logic
40
24 31 12
Horn 25
11 10
Button 8A 46
N 14 RN 13 13
TA 8A
LU L/G GR PN
50 32 Y/B 10
A YE 13 N/B K/BL
GR UR 19
8 U
LU 13 LU
D/B 44 L/P U 7 GR
43
RE YE LU L N/B
D/B 18 N/B 26 LT
B LU
LT 34 RE GR LU
/O
GR B LU 8A RN 46
LT 13 WH
N/W
RG 12 RN Seat Belt T/B

139
HT 25 L/O Y/G 23
Switch LU 4
49 YE HT GR RE
2S 2PP
31 R/W RN D/G 45 YE
PU L/B
T/B RY OR LU
11 WH RN LU N/W
Horn K/G N/B HT Attach. Tilt
14 PIN GR
8A
Fuel Level Diode Mode Switch
10
A 13 Sender 27
HT 49 18
A 24 21 YE
N/W YE 2D 53
GR 19
Steer Select OR L/B 5
L/B
LU
LT 18
Switch N/B LU RN T 4 N OR
A LU N/G H OR N/D
4
10 19 2F BR RN/W LU/ KB
11 34 12 PIN O B WH
44 RE K/G 53 DK T/P LU
Y 53 LU 71
32 OR PUR EL/P D/B
LU
RN
LK 27 K/B 23
UR
N/W /WH UR RN EL/B A PN
LU 92 TA 73
TA
N 31 HT T N/B Y/G Y BR PN
N/G K/W
N /PU RE
YE GR GR A R 21
D/G
19 49 RN HT 24 RY
8A

To Trans. Relay
L/O A
RG 13 18 LT
RN GR 27 17 92
A
N/G HT
N/W
BR N/W
HT
A
27 OR ED 46
R/R 60
45 PU LU
25 K/B
LT
Dash Display 57 Service PN
17 92
46
BLU Panel A Brake 59 LU A HT 9
Switch 58
B BR TB N D/W
47 N/W K/L GR RN RE
25
A A HT PN TG
TA D/L LU RN
26 N YE 92A
48
A
24 A 29 GRY
/G
RN WH L/B RE RY/B N/G LT
RN G BR GR 17
A W A /BL T/G RN TA
OR HT/B U A RY L/B N/G N/W
N/B LU 46 BR YE RN HT
25 LU D KB N/W 5 9A OR 49
DK A LU 76 HT N
GR 72 /RE YE 56
N/W 51 47 60 L/R
HT LT D A 69 74 59
B ED 6
25 DK LTB G 58
RN C
BL LU /RE 47
B 42 PU
R 5
LT U/W D 29 6
BL HT A A 59 BR 77
U 29 DK N
HT Ignition GRN 7
T 47 29 D/W
48
A Shrans 8 RE Switch 15
ift mi 9
Sw ss 2U
itc ion
DK h 52
GR 8
N/W 59 59 K
PN 16
HT YE RN
L/B PNK L/B 8
51 68
RN Park Brake YE
PN
K
RN
20
2 Switch T/O EL
DK RE 0 WH N/Y 68
BL D/ BR BR K
U/W BLK N/Y L
48 48 HT EL D/B 51
A RE T
DK H 8
GR /W N 2
DK N/W B LU R
GR HT DK L/G 30
N/W YE N
HT 5 1 R
Y/O 48
GR
HT
N /W 8A
4
48
A GR
DK HT
Hourmeter R N/W
G
DK
MS0990

Figure 10– 13. Cab wiring harness diagram, S/N 9399 and after, left side (refer to the appropriate wire code chart).

10-24 Model 3606 • Origin 10/99

 Electrical System

41
41
HT 39
N/W
GR D GR
/RE 38 N/W
N HT
GR T 39
DK /WH 37 DK
U
BL GR
LT RN 36 N/R 2J
N /G 40 ED
OR
ED 40 LT
T/R BL 2J
WH U/W Aux. Hyd.
/YEL 37 HT
D
RE
WH 2J Attachment
T/R Tilt
36 ED
OR 2J Frame
2K 30 Backup N/G
RN Tilt
40
41 42 35 3 G Alarm 2T
B BL RY/O RE 2J Extend/
RE RE K RN Retract
39 BR D/G D
D/Y
N/G EL
37 RN RN 22 BL
K
38 DK 2J Hoist/
36 GR Lower
N/W
40 HT Attachment
Tilt Fore/Aft

66 66
GR GR
Y/P Y/P
UR 66 UR
63 GR 2IJ
LT Y/P
GR 63 UR
N/W LT
62 HT GR 2H
2K N/W H
3 K OR 63 HT
BL N/P LT 2G
RE K UR GR
D N/W G
8B 35
RN 4
48 48 HT
R N/G HT
T A RE 2F
D/G
B N/W H DK F
B GR N/W GR DK RN
42 DK GR N/W GR
LT HT N/W 2E
46
A 46 43 P UR 63 Boom HT E 5
B Y/
PN GR 48 GR Proximity
K/B
LU
Y/B
RN UR HT 64 Switch 4
66 N/P U/W DK
OR BL BLU
DK K
62
/W
HT BL 3
64 K
2K
43 Stabil-TRAK
B 2
42 48B Soleniods
4 66
1
63 62
71
64
HT HT
46 LK N/W RN/W
Bo N/B GR
om PN
K/B
OR DK DK
G
Re LU 65 48 A
lay 48

T
9 RED/WHT Borans RN
D/G RED
om . R LU RE
Re elay K B NK LU
N/D EL/P K/B N/B
LK 35 3 Y/O
RN

92A TAN/PUR
lay OR Y PN OR GR
71 61 46 65 30
17 PNK/WHT
RN
49 LT GRN/WHT D/B
RE
56 TAN/GRN
6 ORN 92
5 YEL/RED l
ne
77 PUR
Pa
7 BRN se
15 Fu
K
PN RN
8 T/O
WH EL
16 N /Y
BR LK
20 D/B WHT
RE U/
68 K BL
D
51 RN
E L/G
Y RN
28 Y/O
GR HT
30 N/W
K GR WHT
D RN/
48 G
DK
A
48

MS1180

Figure 10– 14. Cab wiring harness diagram, S/N 9399 and after, right side (refer to the appropriate wire code chart).

Model 3606 • Origin 10/99 10-25

 Section 10

10.4.3 Cab Harness, S/N 9399 and After

Use this chart for vehicles with S/N 9399 and after.
WIRE No. COLOR GAUGE FUNCTION
2 BLK 16 Generic Ground
2B BLK 16 Hourmeter to Ground Splice 40
2C BLK 16 Shift Control Relays to Cab Ground Stud
2D BLK 16 Fuel Level Sender to Ground Splice 50
2E BLK 14 Joystick Logic Board to Ground Splice 40
2F BLK 16 Steer Select Lamp (Terminal 7) to Ground Splice 40
2G BLK 16 Display Panel to Ground Splice 40
2H BLK 16 Display Panel to Ground Splice 40
2J BLK 16 Boom Function Solenoids to Ground Splice 35
2K BLK 10 Ground Splice 45 to Ground Splice 50
2S BLK 16 Seat Belt Switch to Ground Splice 50
2T BLK 16 Backup Alarm to Ground Splice 35
2U BLK 16 Ground Splice 40 to Park Brake Lamp (Terminal 7)
2V BLK 12 Ground Splice 40 to Cab Ground Stud
2Y BLK 10 Ground Splice 35 to Ground Splice 50
2AA BLK 10 Ground Splice 50 to Cab Ground Stud
2BB BLK 10 Ground Jumper for Neutral Relay
2CC BLK 16 Ground Splice 40 to Stabil-TRAK Relays
2EE BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #5
2FF BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #4
2GG BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #3
2HH BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #2
2JJ BLK 16 Ground Splice 35 to Stabil-TRAK Solenoid #1
2KK BLK 16 Ground Splice 35 to Boom Proximity Switch
2LL BLK 16 Ground Splice 40 to Relay 1
2MM BLK 16 Ground Splice 40 to Neutral Relay
3 RED 10 Starter (+) Power to (+) Grid (fuse panel bus)
4 YEL/BLU 16 Neutral Relay (Terminal 87) to Starter Relay (coil positive terminal)
5 YEL/RED 14 Ignition Switch (Terminal 2) to Switched Grid (fuse panel bus)
6 ORN 10 Ignition Switch to 30-amp Main Fuse
7 BRN 10 Ignition Switch (Terminal 4) to (+) Grid (fuse panel bus)
7A BRN/WHT 10 Closed Cab Relay (Terminal 85) to Splice 65
8 PNK 16 7.5-amp Fuse to Park Brake Switch (Terminal 5)
9 RED/WHT 16 Park Brake Switch (Terminal 6) to Neutral Relay (Terminal 30)
10 PNK/GRN 16 Alternator Indicator Terminal to CUMMINS Input (10GY/D)
10A PNK/GRN 16 Alternator Indicator Terminal to PERKINS Input (10GY/F)
11 PUR/WHT 16 Oil Pressure Input (Terminal 10/C) to Oil Pressure Switch (Terminal A)
12 RED/BLU 16 Water Temperature Logic (10/B) to Water Temperature Switch
14 WHT/BRN 16 Hydraulic Oil Temperature Logic (10GY/A) to Hydraulic Oil Temperature Switch
15 DK GRN 16 Ignition Switch (Terminal 3) to 7.5-amp Fuse
16 WHT/ORN 16 7.5-amp Fuse to Park Brake Switch (Terminal 2)
17 PNK/WHT 16 7.5-amp Fuse to Steer Select Switch (Terminal 2)
18 GRY/GRN 16 Steer Select Switch (Terminal 1) to Steer Select Solenoid (Terminal 4)
19 YEL/BLK 16 Steer Select Switch (Terminal 3) to Steer Select Solenoid (Terminal 4)
19A YEL/BLK 16 Steer Select Switch (Terminal 3) to Steer Select Logic (Terminal 6/E)
20 BRN/YEL 14 7.5-amp Fuse to Shift Control Switch (Terminal 8)
21 YEL/BLU 16 Reverse Relay (Terminal 87) to Reverse Clutch Solenoid
22 DK GRN/WHT 16 Splice 20 to Reverse Alarm
23 RED/GRY 16 Forward Relay (Terminal 87) to Forward Clutch Solenoid
24 ORN/BLU 16 Transmission Relay 3 (Terminal 87) to Shuttle Clutch Solenoid
24A ORN/BLU 16 Splice 80 to Fourth Gear (optional--if equipped) Input (Terminal 6/C)
25 LT BLU 16 Transmission Shift Control Switch (through Splice 60) to 1st Clutch Solenoid

10-26 Model 3606 • Origin 10/99

 Electrical System

WIRE No. COLOR GAUGE FUNCTION

25A LT BLU 16 Splice 60 to First Gear Input (Terminal 6/A dash indicator)
26 WHT/BLU 16 Diode to Second Gear Clutch Solenoid
26A WHT/BLU 16 Splice 70 to Second Gear Input (Terminal 6/B)
27 BRN/GRN 16 Fuel Gauge Input (Terminal 10/A) to Fuel Level Sender
28 YEL/GRN 16 7.5-amp Fuse to Hourmeter Power (+) Terminal
29 DK BLU/RED 16 Park Brake Switch (Terminal 3) to Diode
29A DK BLU/RED 16 Diode to Park Brake Input (Terminal 10GY/E)
30 GRY/ORN 16 Oil Pressure Switch (Terminal B) to Hourmeter Ground (-) Terminal
31 YEL/ORN 16 Air Filter Input (10GY/C) to Air Filter Switch
32 TAN 16 Transmission Temperature Input (10/E) to Transmission Temperature Switch
34 YEL/PUR 16 Hydraulic Oil Filter Input (10GY/B) to Hydraulic Oil Pressure Switch
35 RED/GRN 16 Ignition Fuse to HOLD Lead Fuel Shutoff Solenoid (A)
36 ORN/GRN 16 Lift Solenoid to Logic Board (7/E)
37 WHT/RED 16 Extend Solenoid to Logic Board (7/G)
38 LT BLU/WHT 16 Frame Tilt Solenoid to Logic Board (7/C)
39 DK GRN/RED 16 Attachment Tilt (side-to-side) Solenoid to Logic Board (7/F)
40 RED/YEL 16 Attachment Tilt (fore/aft) to Logic Board (7/D)
41 DK GRN/WHT 16 Auxiliary Hydraulics to Logic Board (3/C)
42A PNK/GRN 16 Splice 10 to Shift Control Relays
42B BRN/GRN 16 Splice 10 to Park Brake Solenoids
42C BRN/GRN 16 Splice 10 to Park Brake Switch (Terminal 1)
43 GRY/BRN 16 Joystick Logic (Terminal 7/A) to 7.5-amp Fuse
44 GRY/BLU 16 Maintenance Reset Switch to Maintenance Input (Terminal 10/J)
45 ORN/WHT 16 Seat Switch to Seat Belt Input (Terminal 10/K)
46 PNK/BLU 10 Cold Start to 15-amp Fuse
46A PNK/BLU 16 Cold Start to Logic Panel
47 GRY/BLU 16 Shift Control Switch (Terminal 1) to Splice 30
47A GRY/BLU 16 Splice 30 to Forward Input (Terminal 4/C)
47B GRY/BLU 16 Splice 30 to Forward Relay (Terminal 30)
48 DK GRN/WHT 16 Shift Control Switch (Terminal 7) to Splice 20
48A DK GRN/WHT 16 Splice 30 to Reverse Input (Terminal 4/A)
48B DK GRN/WHT 16 Splice 30 to Reverse Relay (Terminal 30)
49 LT GRN/WHT 16 7.5-amp Fuse to Horn (+) Power Terminal
50 RED/BLU 16 Horn (-) Terminal to Horn Button
51 DK BLU/WHT 16 7.5-amp Fuse to Indicator Panel Input (B/B)
52 ORN/RED 16 Park Brake Lamp (Terminal 8) to Fuse Panel
53 DK BLU/ORN 16 Steer Select Lamp (Terminal 8) to Splice 200
56 TAN/GRN 12 Service Brake Switch to Fuse Panel
57 PUR/RED 16 Service Brake Switch to Diode
57A PUR/RED 16 Service Brake Switch to Stop Lights Connector
57B PUR/RED 16 Diode to Splice 5
58 WHT/GRY 16 Diode to Splice 5
59 YEL/BRN 16 Shift Control Switch (Terminal 5) to Diode
59A ORN/WHT 16 Neutral Relay (Terminal 85) to Diode
59B YEL/BRN 16 Diode to Splice 5
60 BRN/WHT 16 Splice 5 to Stabilizer Lock Relay (Terminal 85)
61 YEL/PNK 16 Boom Switch Relay (Terminal 30) to Fuse Panel
62 ORN/PUR 16 Stabilizer Lock Relay (Terminal 87) to Stabilizer Valve (3)
63 LT GRN/WHT 16 Stabilizer Lock Relay (Terminal 87A) to Stabilizer Valve (4)
64 DK BLU/WHT 16 Boom Switch Relay (Terminal 8) to Boom Proximity Switch (B)
65 ORN/BLU 16 7.5-amp Fuse to Boom Switch Relay
66 GRY/PUR 16 Boom Switch Relay (Terminal 8) to Stabilizer Valve (2)
67 RED/GRN 16 Stabilizer Lock Relay (Terminal 87) to Stabil-TRAK Input (10/J)
68 RED/BLK 16 7.5-amp Fuse to Shift Control Switch (Terminal 6)
69 GRN 16 Splice 70 to Transmission Relay 1 (Terminal 85)

Model 3606 • Origin 10/99 10-27

 Section 10

WIRE No. COLOR GAUGE FUNCTION

70 BLU/WHT 16 Fuse Panel 7.5-amp Fuse to Transmission Relay 1 (Terminal 30)
71 ORN/DK BLU 16 Relay 1 (Terminal 87) to Diode
72 LT GRN/RED 16 Boom Switch Relay (Terminal 87) to Stabilizer Valve (Solenoid 2)
73 WHT/PUR 16 Transmission Relay 3 (Terminal 87) to Diode
74 RED/LT GRN 16 Splice 30 to Transmission Relay 3 (Terminal 30)
75 WHT/BLU 16 Shift Control Switch (Terminal 3) to Splice 70
76 PNK/BLU 16 Splice 80 to Transmission Relay 2 (Terminal 85)
77 PUR 10 Ignition Switch (Terminal 5) to 15-amp Fuse
92 TAN/PUR 16 Female Metri-Pack Connector (for Auxiliary Hydraulics) to 7.5-amp Fuse
92A TAN/PUR 16 Splice 200 to Female Metri-Pack Connector (for Auxiliary Hydraulics)
93 LT BLU/PUR 16 Splice 110 to Cummins Cold Start Switch (optional)
113 PUR/BLU 16 Splice 200 to 2-way Connector (Cavity A)
123 ORN/BLK 16 Splice 20 to Back-up Lights Input Connector (Cavity B)
124 DK BLU/GRY 10 Door Window Power to Fuse Panel (see Fig. 10– 16)
132 BRN/YEL 16 Accessory Power to Light Switch Input (see Fig. 10– 16)
134 TAN/WHT 14 Fuse Panel to Light Module Power (see Fig. 10– 16)
134A TAN/WHT 14 Fuse Panel to Light Module Power (see Fig. 10– 16)
135 BLU/YEL 10 Fuse Panel to Starter (+) Terminal (see Fig. 10– 16)
136 LT GRN/RED 10 Power Relay to Starter (+) Terminal (see Fig. 10– 16)
137 LT BLU/ORN 16 Attachment Tilt Switch (Terminal 2) to +12V Logic
138 GRN/BLU 16 Attachment Tilt Switch (Terminal 3) to Signal
138A GRN/BLU 16 Attachment Tilt Switch (Terminal 3) to Dash (10/H)
139 ORN/GRY 16 Attachment Tilt Switch (Terminal 8) to Splice 200
140 RED/GRY 10 Fuse Panel to Starter (+) Terminal (see Fig. 10– 16)
141 RED/BLU 10 Fuse Panel to Power Relay (see Fig. 10– 16)
142 YEL/GRN 10 Fuse Panel to Blower Switch (+) Connection (Cavity C) (see Fig. 10– 16)
143 ORN/YEL 16 7.5-amp C.B. to Connector (Cavity A) (see Fig. 10– 16)
149 YEL/ORN 14 Connector (Cavity B) to 7.5-amp C.B. Fuse (see Fig. 10– 16)
150 GRY/PNK 16 Splice 200X to Closed Cab Connector (see Fig. 10– 19)
150A GRY/PNK 16 One-way Female Connector to Closed Cab Lamp Connector (see Fig. 10– 19)
153 GRY/YEL 16 One-way 56-series Connector to 7.5-amp C.B. Rear Wiper Fuse (see Fig. 10– 19)
164 LT GRN/PNK 10 Fuse to Window Switch (Terminal 2) Connector (Cavity E) (see Fig. 10– 19)

10-28 Model 3606 • Origin 10/99

 Electrical System

DK GRN/WHT LT BLU LT BLU

48 25 25 25
DK BLU/WHT DK BLU/WHT
51 51
DK GRN/WHT

HOUR 25A DASH DISPLA PANEL

ETER DK GRN/WHT
RED/BLK 48A TAN
68 32
LT BLU
30 28 BRN/YEL TRANSISSION 25A YEL / ORG 31
20

LT BLU
SHIFT SWITCH 72 LT GRN/RED
YEL/BRN 24A ORN/BLU TRANS. STEER GRY/BLU
GRY/ORN

44

YEL/GRN
59

YEL / ORG
TAN
WHT / BLU CONTROL SELECT PUR / WHT
8
PNK PNK
47 75 26A WHT / BLU LOGIC LOGIC 11
48 69

GRY/BLU
PAR BRAE 76 WHT / BRN 34 25
DK BLU/RED

PUR / WHT
SWITCH 29A 29A 32
YEL/PUR 14
30 28 GRY/BLU GRY/BLU
WHT/ORN 8 47A RED / BLU
16 TAN/GRN 46A 12 31
42C 56
47B 76 45 27 PNK/GRN
138A 10A 44
59 52 DK BLU/RED 69 48A SERVICE PNK/GRN
9 BRAE 18A 10 11 HORN
29

ORN/RED
56

ORN/WHT
RED/WHT

BRN/GRN
SWITCH 19A 50
57 50
YEL/BRN
29A

GRY / GRN

RED/BLU
PNK

WHT/GRY 49

PUR/RED

YEL / BLK
58

LT GRN/WHT
HORN 34
YEL/BRN YEL/BRN 57A BUTTON
59B 14
12

YEL/PUR
59
47B 69 48A 58 10A

WHT / BRN
2U 59B 25
8 76 60 10

RED / BLU
42C 74
IGNITION 49 BULHEAD

PNK/GRN
PNK BRN/WHT 60 BRN/WHT
6

LT BLU
SWITCH CONNECTOR

PNK/GRN
LT GRN/WHT
60 49 PIN LOCATION

DK GRN/WHT
BRN/GRN
DK GRN ORN/WHT

GRY/BLU
RED/LT GRN
1

PNK/LT BLU
45

DK GRN
15 3 2
4
BRN/GRN 46A
BRN 5 27
7 STEER SELECT
PUR 19A 138A 24 J3
77 SWITCH
YEL/RED 42C YEL / BLK 24
FUSE 5 19
ORN 17 GRY / GRN
PANEL 6 92A 53 18
TAN/GRN

ORN/BLU
56 18A
LT GRN/WHT 53
49

GRY / GRN
DK BLU/ORN
PNK/WHT

YEL / BLK
PNK/WHT

ORN/WHT
BRN/GRN

GRN/BLU
PNK/BLU
17 17 25 J7
TAN/PUR TAN/PUR 2F
92
92A

ORN/BLU
24 24
YEL / BLU
21 21 21 H4
FUEL LEVEL 19
SENDER 46A
53 18
138A
DK BLU/ORN
27
RED / GRY
2D
SEAT BELT 23 23 H8

DK BLU/ORN
RED / GRY RED / GRY SWITCH 32
71 23
61 TRANSISSION WHT / PUR ORN/WHT
73 45

TAN
RELAS
46
2S
65 ORG / DK BLU WHT / BLU
ORN/DK BLU

71 26 26 J9
35 YEL / BLU
4 YEL / BLU 4
31 C8
YEL/PNK

3 DK BLU/ORN
BRN/GRN 53

YEL / ORG
PNK/BLU
ORN/BLK

30 137 LT BLU/ORN
RED/GRN

42B GRN/BLU BOO

PNK/BLU
53 138 LOGIC
DK GRN/WHT

TAN D3
32
BRN/GRN
GRY/ORN

BOO ATTACH. TILT

71 RELAS ORN/GRY
RED

139 ODE 44
61 64 63 48B SWITCH

GRY/BLU
66 2PP 46A 19
62 43 YEL / ORG
18 31 D5
PNK/BLU PNK/BLU 46 PNK/BLU
46 46

PNK/BLU 46
DK BLU/WHT

E8
GRY/BRN GRY/BRN HDRAULIC
43 OSTIC 11

YEL / BLK
43
LOGIC

GRY / GRN
GRY/BLU

PUR / WHT
35 44 B3

64
3 ORN/BLK
65
GRY / ORG GRY / ORG GRY / ORG
30 30 30 D7
2E
DK GRN/WHT
GRY/PUR

41
LT GRN/WHT

39 PUR / WHT
65 11 G3
DK GRN/WHT

38
RED/GRN

ORN/PUR

BLK

37
18 19
GRN/WHT
DK GRN/RED

48A
RED

48B 36 YEL / BLK

LT BLU/WHT

42B BAC-UP 19 H2
DK GRN/WHT 40
66 ALAR
ORN/GRN

BOO
WHT/RED

48 PRO 63 DK GRN/WHT
RED/YEL

3 35 22 GRY / GRN
18 G9
ORN/BLK 62
65
DK BLU/WHT 22
64 BLK BRN/GRN
2T 42B B7
DK GRN/WHT 2T BRN/GRN BRN/GRN
48 42B 42B
RED/GRN RED/GRN RED/GRN
35 35 35 D9
RED RED 3
3
BLK
2KK
ORN/PUR
62
LT GRN/WHT RED
63 3 F8
66
GRY/PUR 40 14 34
2E 12
YEL/PUR
WHT / BRN

PILOT SELECT 10A

STABIL TRA SOLENOIDS 10
RED / BLU

SOLENOIDS YEL/PUR
PNK/GRN

RED/YEL 34 D1
40
PNK/GRN

ORN/PUR
62 36
5 2J
2EE
FORTILT WHT / BRN
14 G7
FORE/AFT
ORN/GRN
LT GRN/WHT 36 37
63
4 2J
2FF RED / BLU
12 G5
LIFT
WHT/RED PNK/GRN H6
10A
LT GRN/WHT 37 38
63
3 2J PNK/GRN
10
2GG G1
ETEND

LT BLU/WHT
GRY/PUR 38 39
66
2 2J
2HH
FRAE TILT

DK GRN/RED
GRY/PUR 39
66
1 2J
2JJ 41
FOR TILT
GRN/WHT
41
2J

AU HD
MS1260
Figure 10– 15. Cab wiring harness schematic, S/N 9399 and after (refer to the appropriate wire code chart).

Model 3606 • Origin 10/99 10-29

 Section 10

Head-on views; wires exit at the rear of each component.

GROUND GROUND
71 JUMPER DOUBLE TERMINATE
JUMPER 62 67
2LL
7 3 24 23 66
21
4
2C

69
59A

70 9
63
76 74 48 42A 60
47 64
JUMPER (WHITE) 61
TRANSMISSION JUMPER (WHITE)
Trans. Trans. Trans. Neutral SWITCH RELAY BOOM SWITCH
RELAY
Relay 1 Relay 2 Relay 3 Relay Shift Control Stabilier Boom Switch
Relays (2) Lock Relay Relay
CAB HARNESS
9 7 5 3 1

TERMINAL WIRE
K TERMINAL WIRE
A 132 A 143
26 25 24 J B 134 B 149
23 10A 21 19 C 134A C 142
H D 135 D 124
18 14 12 11 10 E 140 E 164
G

3 2K F

46 E

D
35 30 31 32 34
C 143
4 93
B 149 153
42B 44 136
A
142
132 134 134A
135 140 124
164

BUL HEAD
CONNECTOR
52
ENGINE HARNESS 140 A
20 16
70 35 3 77

5 6 46
61
1 3 5 7 9 B 56 65
142 51 8
K
141 15
J 24 25 26
7A
C
H
132 17 143 43 124
19 21 10A 23
G 10 11 12 14 18 164
D
F
2K 3 90 49 149 68 140 135

E
E 134 134A
46

34 32 31 30 35 70 92 153 28
D
F
93 4
C
44 42B
B

ENGINE
BULHEAD CONNECTOR FUSE BLOC MS1310

Figure 10– 16. Cab harness relays, bulkhead connector and fuse panel, S/N 9399 and after.

10-30 Model 3606 • Origin 10/99

 Electrical System

RE
D
Fuel
34 Shut Off
34 BL
YE B K
Hydraulic 14 L/P WH RED LK
UR T /G
RN
Pressure WH 33 2L
T/B 35
Switch RN Battery Engine
30 GE Coolant
RE B LKU
GA UG
E
GR Hydraulic WH D/G LK OB GA Temp.
Y/O T RN O
11 RN Temp. K BL
K Switch
BL 35 2L D
2P PU Switch 33 RE
R/ 2
WH
T
Oil Pressure Maintenance Reset
Switch 44 Switch
T
UR RN WH
L/P T/B G/ BL
YE WH OR E K
UG
34 GA
14 44 O
2L 2

N U K
44 GR K BL BL
CU D T D/ BL D/
MM OR RE WH RE RE K K
PE I 34 G/ BL BL K
32 RK NS WH 33 35 2
12 BL
IN T
TA Cold Start S LT BLU 14
YE
L/P UG
E
2X B
N
PN /P WH UR GA 2L
Switch K/B UR T/B
O
LU 93 RN D
46 D-

Transmission T E
Cummins
WH UG Alternator
Temp. Switch R/ GA HT
PU O
N W N
11
R GR
Y/O K/
N GR RED 12 PN GR
N
TA 10 LT
30 Starter RE 2
44 D
32 34 BL /BLU 1
O K
K
14 YE RG/W
BL 35 WH L/P HT
2X T/B UR
RE RN
D/G
RN
O LT
GA
UG OR
G
RE RN
Air Filter
E RE N D Indicator
PN D /BL 1
K/B K
OG RN 3 1 Switch
AUG 55
E RE
D 54 RN 2P
BL
K D/G K
RE BL
Ground Stud 2A
35 RN
G
On Frame OR
TAN

T/B L/
BL
K
WH YE
PUR/WHT

14 / PUR 31
L
YE
32

T
34
GRY/ORN

WH
G/ Park Brake
OR
44 R N Solenoids
11

K/G
PN
T

54 55 3
2A BLK
K D 10 LU RG
BL
30

N/ K RE D/B L/O
Starter RN OR BL RE YE 42
K/B
G
PB
PB

2M
PN 12 31 2M
Relay
4
LU
L/B BL 42
YE K 42 N
GR
N/
2M BR

24
U
BL
N/ B
OR 25 42
Transmission N
24 U GR
Solenoids BL 21
BR
N/
LT
LU 23
2R L/B
YE
25 RY 26
SHUTTLE D/G Bulkhead 2
RE 11
LU
T/B Connector BL
K
WH HT
2R 21 R/W 32
FIRST PU
N
TA
UR
U/P U
BL L
2R 23 RN LT K/B
Y/O PN
REVERSE GR 93
30 46

2R 26 LK N
L/B R
YE RY/G
FORWARD Steer Select
19

G
Solenoids
18

2
2N

2R
K
SECOND BL
2N

MS0980

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

10.4.4 Engine Harness

Use the chart below for the engine harness diagram (Fig.
10– 17) and engine harness schematic (Fig. 10– 18).

WIRE No. COLOR GAUGE FUNCTION

1 LGT GRN 10 Power, Starter to Alternator (Cummins)
1A LT GRN/BLK 10 Power, Starter to Alternator (Perkins)
1B LT GRN/BLK 10 Power, Starter to Alternator (Perkins)
2 BLK 10 Main Ground Alternator to Ground Splice 45
2A BLK 16 Starter Relay to Ground Splice 45
2K BLK 10 Ground Splice 45 to Ground Splice 50 (in cab harness)
2L BLK 12 Fuel Shutoff Solenoid to Alternator Bolt (housing ground)
2M BLK 16 Park Brake Solenoids to Ground Splice 45
2N BLK 16 Steer Select Solenoids to Ground Splice 45
2P BLK 16 Air Filter to Ground Splice 45
2Q BLK 16 Maintenance Reset Switch to Ground Splice 45
2R BLK 16 Transmission Shift Solenoids to Ground Splice 45
2X BLK 10 Ground Splice 45 to Ground Stud
3 RED 10 Power, Starter to (+) Grid (fuse panel bus)
4 YEL/BLK 16 Transmission Shift Switch to Starter Relay
10 PNK/GRN 16 Alternator Indicator to Alternator Indicator Logic (Cummins-operators display panel)
10A PNK/GRN 16 Alternator Indicator to Alternator Indicator Logic (Perkins-operators display panel)
11 PUR/WHT 16 Oil Pressure Logic (operators display panel) to Oil Pressure Switch
12 RED/BLU 16 Water Temperature Logic (operators display panel) to Water Temperature Switch
14 WHT/BRN 16 Hydraulic Oil Temperature Logic (operators display panel) to Hydraulic Oil Temperature Switch
18 GRY/GRN 16 Steer Select Switch to Steer Select Solenoid (terminal C)
19 YEL/BLK 16 Steer Select Switch to Steer Select Solenoid (terminal 4)
21 YEL/BLU 16 Shift Control Relay to Reverse Clutch Solenoid
23 RD/GRY 16 Shift Control Relay to Reverse Clutch Solenoid
24 ORN/BLU 16 Shift Control to Shuttle Clutch Solenoid
26 WHT/BLU 16 Shift Control to '2nd' Clutch Solenoid
30 GRY/ORN 16 Oil Pressure Switch (terminal B) to Hourmeter (-)
31 YEL/ORN 16 Air Filter Logic to Air Filter Switch
32 TAN 16 Transmission Temperature Logic (display indicator) to Transmission Temperature Switch
33 WHT 12 Fuel Shutoff Solenoid to Starter Motor
34 YEL/PUR 16 Hydraulic Filter Logic (display indicator) to Hydraulic Oil PSI Switch
35 RED/GRN 16 Ignition Fuse to Fuel Shutoff Solenoid
42 BRN/GRN 16 Splice 15 to Park Brake Solenoids
42B BRN/GRN 16 Splice 10 to Splice 15
44 GRY/BLU 16 Maintenance Reset Switch to Bulkhead Connector to Maintenance Indicator (display panel)
46 PNK/BLU 10 Cold Start to 15-amp Fuse
54 PNK/BRN 10 Starter Relay to Starter Power
55 ORN/BLK 10 Starter Relay to Starter Power
93 LT BLU/PUR 16 Splice 110 to Cold Start Control (optional)

10-32 Model 3606 • Origin 10/99

 Electrical System

BULHEAD
CONNECTOR
PIN LOCATION
TRANSISSION
SOLENOIDS
ORN/BLU ORN/BLU
24 24
2R

SHUTTLE

LT BLU LT BLU
25 25

2R

FIRST

YEL/BLU YEL/BLU
21 21

2R

REVERSE

RED/GRY RED/GRY
23 23
2R

FORWARD

WHT/BLU WHT/BLU
26 26
YEL/BLU YEL/BLU 2R
4 4

TRANS. TEP. SECOND

2R
SWITCH
TAN TAN
32 32 4
54
AIR
YEL/ORN YEL/ORN
31 31 FILTER STARTER
COLD START SWITCH RELA
SWITCH BLK BLK

PNK/BRN
LT BLU/PUR 93 CUMMINS 2P 2P
PNK/BLU PERKINS 55
46

ORN/BLK
2A

BLK
ORG/WHT ORG/WHT
44 44
AINTENANCE
RESET SWITCH

BLK
54
ORG/WHT
44 55
2P 33
GRY/ORG GRY/ORG

WHT
30

CUMMINS ONLY
1B
30 STARTER
B ENGINE 2Q 1A
33 2A
PUR/WHT OIL PRES.
11 A SWITCH

WHT
PERKINS
PAR BRAE

BLK
STEER SELECT SOLENOIDS
1 2 2X
YEL/BLK SOLENOIDS

O GAUGE
19 42

LT GRN
LT GRN/BLK
2N 3
BLK
GRY/GRN
18 42
BRN/GRN 33

BLK
1 2 GROUND STUD
BLK

2M ON FRAME

LT GRN/BLK
BRN/GRN BRN/GRN
42B 42B
WHT

42 O GAUGE 1
2
RED/GRN RED/GRN WHT 1B
33 BLK

RED
35 35
FUEL WHT
SHUT-OFF 33 1A
2L SOLENOID
RED RED RED
3 3 3
HD. OIL
FILTER PRES. HD. OIL
RED

SWITCH TEP.SWITCH
YEL/PUR YEL/PUR
BLK

34 34

14 2
WHT/BRN WHT/BRN WHT/BRN
O GAUGE

14 14
BLK BLK
2 2
O GAUGE

CUMMINS ONLY
PERKINS ONLY
PERKINS ONLY

ENGINE
RED/BLU RED/BLU
12 12 COOLANT TEP.
SENDER (210)
RED

PNK/GRN
10A PERKINS ONLY
2L
PNK/GRN
BLK

10 CUMMINS ONLY

LT GRN/BLK
1A 1A PERKINS ONLY 1A 1A
LT GRN/BLK
1B 1B PERKINS ONLY 1B 1B
LT GRN
1 CUMMINS ONLY 1 1
PNK/GRN

PNK/GRN

1
LT GRN/BLK

LT GRN/BLK

O GAUGE
BLK
LT GRN

10 10A
O GAUGE

1A D+
1B
1 PERKINS
RED

10 OPTION
2L
PERKINS B+
OPTION
BATTER
ALTERNATOR
RED BLK
+

O GAUGE
MS0960

Figure 10– 18. Engine wiring harness schematic (refer to the appropriate wire code chart).

Model 3606 • Origin 10/99 10-33

 Section 10

10.4.5 Closed Cab Harness (Option)

A closed cab option was being finalized shortly before
completion of this manual. Use the wiring schematic
below (Fig. 10– 19 and Fig. 10– 20) as needed when
troubleshooting closed cab electrical problems.

BUSS BARS
ACCESSORY POWER (2)
BATTERY (+) POWER
SWITCHED POWER
ACCESSORY POWER

7.5A 7.5A 7.5A

CIRCUIT CIRCUIT CIRCUIT 7.5A
BREAKER BREAKER BREAKER FUSE

CAB STRUCTURE
#92 WIRE
#143 TAN/PUR #92A #113 2/B
ORN / YEL 5/B 1/A 16 PUR/BLU
16 #143A 16

C
ORN/GRN

O
FROM POSITION

N
16 SPLICE 205 LIGHTS

N
.
5/A #148 200
130 TO ATTACHMENT
PNK/PUR TILT MODE SWITCH

.
N
16

N
TO STEER
111 SELECT SWITCH

O
#144 #150

C
DK BLU/GRN GRN/PNK TO AUXILIARY
16 16 176 DETENT SWITCH
#149 #153 SPLICE
#155 #150A TO BEACON
YEL/ORN GRY/GRN GRY/YEL 200X SWITCH
14 16 PNK/TAN GRN/PNK
14 16 16 TO RIGHT
STABILIER SWITCH
TO LEFT
+9 5 2 +8 2 5 7/E 2 +8 STABILIER SWITCH

118 TO 2-MODE
STEER SWITCH
2 1 1 1

-7 6 4 3 1 -7 3 6 3 -7
FRONT WIPER SWITCH ROOF WIPER/WASHER SW. FRONT WASHER SWITCH
1A, 1000V REAR
#145 DIODES #151 WIPER M #154
#145 TAN/RED PUR/YEL MOTOR LT GRN/BLU
LT BLU/WHT 16 #147 14 16 #2AN
16 #152
WHT/GRN DK GRN/WHT BLK
16 16 16
A4
L 7/D

ROOF
P H WASHER FRONT
M M PUMP WASHER
FRONT M ROOF PUMP M
WIPER WIPER
MOTOR MOTOR 2/A
X
#2AP #2YY #2AM #2BB #2 #2DD
BLK BLK BLK BLK BLK BLK
16 16 16 16 14 16

G45 G46 G47 G48 G49 G50 G51

220 221 222 223 224 225 226 228 230 232 234 236 238 240 241 242 243 244 245 246 247 248

CLOSED CAB
G48 G53 G50
G54 G46 G55 G52 G51 G49 G47 G45 OPTION

S18 #2AK
BLK
C2 14
#2K S19
BLK CAB STUD
14 GROUND

C1

ENGINE STUD
GROUND MS2570

Figure 10– 19. Enclosed cab option electrical schematic, left side.

10-34 Model 3606 • Origin 10/99

 Electrical System

BUSS BARS
ACCESSORY POWER (2)
BATTERY (+) POWER
SWITCHED POWER
ACCESSORY POWER
#141 5/D
RED/BLU
10 #124
ACCESSORY DK BLU/GRY DOOR POWER
RELAY 10 RELAY
25 A 85 87A 87 85 87A 87
FUSE
30 A

86 30 5/E 86 30
CAB STRUCTURE
2/B #2AC
5/C BLK G55 #27A
12 BRN/WHT
16 #2XX
BLOWER BLK #182
MOTOR 1/A
#142 M 16 ORN
COMPRESSOR YEL/GRN 149 #136 10
CLUTCH 10 FROM LT GRN/RED
M 10
SPLICE
BLOWER 65
MOTOR
#165 L M H DRIVE G34
LT GRN/ORN
16
VALVE
POTENTIOMETER #164
PRESSURE P LT GRN/PUR
SWITCH A B C 10 JUMPER
7/C 7/B 7/A WIRES
2/A
7/F #156 #157 #158 #161 #162 #163
#160 YEL RED ORN BLU WHT BRN
BLU/RED 14 14 14 16 16 16 1 3 4 6
16
B1
VALVE DRIVE
A B C MODULE
L M H
THERMOSTAT T 2 5
GRD. POS. DOOR WINDOW
SWITCH
B C
7/G
BLOWER
#159 SWITCH #142A
WHT/BLU RED/YEL
16 SPLICE 75 16 C4 #1 #2

4 2 DOOR 2/B
1 WINDOW M
AIR
CONDITIONING #2CC MOTOR
SWITCH BLK
16 #2AD
3 1
GRY BLK
#2AB 16 10
BLK
16
G54
G52 G53

249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273

MS2580

Figure 10– 20. Enclosed cab option electrical schematic, right side.

Model 3606 • Origin 10/99 10-35

 Section 10

10.5 FUSES AND RELAYS

Fuses and relays help to protect the electrical system. In
general, a blown fuse is a symptom of another electrical
problem. Address the true problem, not just the symp- Typical
tom. Simply replacing the fuse often will not solve the Fuse and
problem. Blown fuses are usually due to simple causes, Relay Panel
including loose or corroded connections, or a defective Location
relay. There are two main causes of blown fuses; a
shorted or grounded wire in the applicable circuit, or a
defective electrical component. Visually check the condi-
tion of the fuse, wires, connections and components in
the involved circuit before replacing a fuse. Check the cir-
cuit for shorts, grounding, or defective electrical compo-
nents. Keep in mind that many parts in the electrical
system work with components of the hydraulic system; a
careful inspection of the related hydraulic components
may help in solving problems.
OS1092
For access to the fuse and relay panel, remove the four
Figure 10– 22. The fuse and relay panel is mounted under
screws securing the lower dash panel (Fig. 10– 21) to the the lower left side of the operators console
cab. The fuses and relays are mounted under the lower behind the lower dash panel (typical).
left side of the operators console (Fig. 10– 22).
The fuse and relay panels are part of the cab harness.
Check illustrations Fig. 10– 24 (S/N 8249 and before),
Fig. 10– 26 (S/N 8250-9398), and Fig. 10– 27 (S/N 9399
and after) on the following pages to determine which type
of fuse and relay panel is being addressed.

Electrical
Fuse and
Relay Panel

Lower
Dash
OS1093
Panel
Figure 10– 21. Remove the lower dash panel to gain access
to the electrical fuse and relay panel.

10-36 Model 3606 • Origin 10/99

 Electrical System

10.5.1 Fuse and Relay Replacement Vehicles Stamped with S/N 8249 and Before
Shut off the engine and disconnect the negative (-) bat- Perkins Cold
tery cable at the negative (-) battery terminal (Fig. 10– 23) Hourmeter Start (optional)
before checking the electrical system. Use an ohmmeter Neutral Relay/Starter
to check the resistance of wires and components.
Fuel Shut-off
Display Panel Neutral
Main Fuse Sense
Logic
Switch Lamps Panel
Stabil-TRAK Solenoid Trans-
Negative (-) mission
Terminal Stabilizer Lock Relay
Relay

Horn
Steer
Trans- Solenoids
mission
Solenoids Park Brake
OS1040 Sense
Figure 10– 23. Disconnect the negative (-) battery cable.
Different fuse and relay panels exist. Vehicles with serial
number 8249 and before use the fuse and relay panel
shown in Fig. 10– 24. Vehicles with serial number 8250 Neutral Relay
through 9398 use the fuse and relay panel shown in Fig. Forward Relay
10– 26. Vehicles with serial number 9399 and after use Reverse Relay
the fuse and relay panel shown in Fig. 10– 27. Trans. Relay 1
Before checking a malfunctioning electrical circuit, exam- Trans. Relay 2
ine the applicable wiring diagram to help identify the Trans. Relay 3
components involved. Noting whether other components, Boom Switch
including hydraulic system components, related to the Stabilizer Lock Relay OS1113
circuit are functioning properly can often aid in identifying Figure 10– 24. Vehicles with S/N 8249 and before use the
problems. When several components or circuits fail at fuse and relay panel shown above.
one time, the problem is probably related to a poor
ground connection, because several circuits may share
OFF RUN
that same connection. Examine the appropriate ground
connection(s) and make sure a contact capable of con-
ducting full voltage is available. PREHEAT

10.6 ENGINE START CIRCUIT

START
When the ignition key switch (Fig. 10– 25) is turned to
START the engine with the transmission in NEUTRAL
(N), the starting circuit activates the starter relay, starter
solenoid, and fuel run solenoid. The fuel run solenoid
opens a valve that supplies fuel to the injection pump. OF0390

The starting circuit functions as follows: Figure 10– 25. Ignition key switch positions.
1. Current from the battery flows through the positive
(+) battery cable to the starter solenoid.
3. When the key is turned to the START position (Fig.
2. Current then flows to the fuse box, through the main 10– 25), current flows through contacts in the ignition
fuse, to terminal "1" of the ignition switch. switch to the park brake switch.

Model 3606 • Origin 10/99 10-37

 Section 10

Vehicles Stamped with S/N 8250 through 9398 Vehicles Stamped with S/N 9399 and After

Neutral *Light Pkg (B)

Neutral Display Logic *Window Logic *Light Pkg
Relay/Starter Panel Panel Neutral Relay/Starter Motor Panel (A) Neutral
*Cold Start Sense
*Cold Start Sense Hourmeter
Main 15 7.5 20
Main 15 7.5
*Front
30 Display 30 30 20

Hourmeter 7.5 Panel Wiper

7.5 7.5 7.5 7.5 7.5
Fuel Shut-Off 7.5 7.5 7.5 7.5
*Switch Lamps Fuel *Skylight
Shut-Off Wiper/Washe
*Blower Motor *Rear Wiper
25 7.5 7.5 7.5
Trans. Relay Horn Stabil-TRAK
7.5 7.5
Solenoid Horn
7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5 7.5

Park Brake 7.5 7.5 7.5 *Aux. Park Brake 7.5 7.5 7.5 15
*Switch
Sense Relay Detent Sense Relay Lamps
Mode Trans.
Transmission Trans.
Steer Relay
Solenoids Solenoids *Aux.
Solenoids Detent
Stabil-TRAK Mode
Solenoid Steer
Stabilizer Lock Relay Solenoids
*Power Accessory Stabilizer *Power Window
Reverse Relay Relay (40 Amp) Lock Relay Motor Relay (40 Amp)
Neutral Relay Reverse Relay
Forward Relay Neutral Relay
Trans. Relay #3 Forward Relay
Stabilizer Lock Trans. Relay #3
Trans. Relay #2 Relay Stabilizer Lock
Boom Switch Trans. Relay #2 Relay
Trans. Relay #1
Relay Boom Switch
Trans. Relay #1
Relay
*Optional
OS1770
*Optional OS2190
Figure 10– 26. Vehicles with serial number 8250 through
9398 use the fuse and relay panel shown here. Figure 10– 27. Vehicles with serial number 9399 and after
use the fuse and relay panel shown here.

4. If the park brake is set, current flows through

contacts in the brake switch to the neutral start 9. As the engine runs it operates an alternator that
circuit. recharges the battery used during the starting cycle.
5. If the transmission select lever is in NEUTRAL (N), 10. When the ignition key switch is released after starting
current flows through the neutral start circuit to the engine, the key switch returns to a neutral
energize the coil of the starter relay. The relay closes position where it directs current to the fuse panel that
internal contacts that allow current to flow to the distributes electrical current for the operation of
starter solenoid and starter. vehicle controls, including the joystick, gauges and
other equipment.
6. The starter solenoid engages a gear on the starter
pinion shaft to mesh with the flywheel, and the starter
pinion and gear begin to spin, in turn rotating the PERKINS COLD START OPTION ONLY: When starting
flywheel, crankshaft and related components within in a cold environment (when temperatures are at or
the engine. below freezing), turning the ignition key switch (Fig. 10–
7. When the ignition key switch was initially turned, the 25) to the PREHEAT position between RUN and START
fuel run solenoid opened a valve to supply to the fuel for a few moments (usually 15-20 seconds, or up to 30
injection pump. As the starter rotated the engine seconds during extreme cold) before starting will supply
components, the fuel injection pump and related lines current to a thermo-start plug in the intake manifold. The
and injectors supplied fuel to the cylinders. plug ignites a fuel-air mixture in the intake manifold to
facilitate cold weather starting.
8. When the pistons compress injected fuel, ignition
occurs, the engine starts and the starter pinion
retracts.

10-38 Model 3606 • Origin 10/99

 Electrical System

10.6.1 Testing the Starter on the Engine 10.6.2 Starter

If the starter does not engage when the ignition key is The starter (Fig. 10– 29) is located on the left side of the
turned, check the following: engine (the right side of the vehicle), just inboard of the
1. The main fuse may be blown, requiring replacement. hydraulic oil reservoir.
Check for the cause of the blown fuse. The starter operates when the attached starter solenoid
2. There may be a defect in the ignition switch, ignition engages a gear on the starter pinion shaft to mesh with
wiring, or starter solenoid. the flywheel, and the starter pinion and gear begin to
spin, in turn rotating the flywheel, crankshaft and related
3. Check battery condition. Clean the battery posts and components within the engine.
the connectors at each end of the battery cables.
Also check the ground cable behind the starter The starter is grounded indirectly via the negative (-)
mounting bolt and the frame ground stud, just above battery. The cable is routed from the battery to the main
the hydraulic oil reservoir fill cap. ground stud, located on a triangular weldment
(Fig. 10– 29) above the hydraulic reservoir. Other ground
4. Check for broken wiring and damaged insulation on wires are connected to this stud, including the starter
the wiring. Replace all broken or damaged wiring. ground cable, secured to the engine by one of the starter
5. Check all connections at the starter solenoid, key mounting bolts.
switch, and wiring harness plugs. Clean and tighten
all connections. a. Starter Removal
6. If the starter still does not operate after these checks Remove the starter only if it fails. To remove the starter:
have been performed, check the starting circuit.
1. Disconnect the negative (-) battery cable at its
battery terminal (Fig. 10– 28).
Starter Circuit Checks
1. Check wires and connections for looseness,
corrosion, damage, etc.
2. If a "whirring" noise is heard, but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes Negative (-)
the drive forward to engage the flywheel may be Terminal
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the engine.
3. If the starter only "clicks", it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the battery
state of charge and battery condition first, then check
OS1040
the cables and cable connections.
Figure 10– 28. Disconnect the negative (-) battery cable.
2. Label and disconnect the positive (+) battery cable
and other wiring from the starter solenoid. Note how
the wires are installed for ease of installation later.
3. Loosen, but DO NOT remove, the three hex fasteners
securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will
fall if not supported.
4. Support the starter and remove the fasteners
securing the starter to the engine. Remove the
negative (-) ground cable from its starter mounting
bolt (Fig. 10– 28).
5. Remove the starter from the vehicle.

Model 3606 • Origin 10/99 10-39

 Section 10

10.6.3 Starter Relay

The starter relay (Figs. 10–30 and 10–31) is a non-ser-
viceable part and must be replaced if defective. The
starter relay consists of a movable contact, not unlike a
solenoid, with a fixed coil in a weatherproof case.

PERKINS ENGINE
4 1 2
3
2
5
8
9

8 6 11 7 2
9 10

Remove bolt
and cable

MS2400
Figure 10–29. Disconnect the ground cable (from the
chassis ground stud) at the starter mounting bolt
(Cummins engine shown).

b. Starter Cleaning and Drying

1. While the starter is out, wipe away any grease or dirt
that has accumulated around the starter mounting
opening. 16 15 6 12
2. If reinstalling the starter, clean the exterior of the
starter with an approved solvent. DO NOT submerse 14
the starter or allow the solvent to contact the starter
bushings.
13
3. Dry the starter with a clean, lint-free cloth.
16
c. Starter Periodic Maintenance
A starter requires no routine maintenance beyond the MS1620
occasional inspection of the electrical connections, which 1. Starter Relay 8. Lockwashers
must be clean and tight. The starter is not serviceable; 2. Mounting Hardware 9. Hex Nuts
replace a defective starter with a new unit.
3. Flat Washer 10. “Small” Lockwashers
4. Wire #2A BLK Ground 11. “Small” Hex Nuts
d. Starter Installation
5. Wire #55 ORG/BLK 12. Starter
1. Position the starter in its mounting opening on the Ignition Wire 13. Ground (-) Cable
flywheel housing. Position the ground cable over the 6. Wire #54 PNK/BRN 14. Positive (+) Battery Cable
correct starter mounting fastener boss. Secure the to Starter
15. Wire #10 GRN Starter to
starter with three hex fasteners. Torque hex nuts to 7. Wire #4 YEL/BLU Alternator (B+) Terminal
3.4 lb/ft (4,6 Nm) and torque hex-head capscrews to Transmission Neutral
Switch to Starter Relay 16. Attaching Hardware
32 lb/ft (43 Nm).
2. Connect all the wires to the starter solenoid. Figure 10–30. Perkins starter relay.

3. Connect the positive (+) battery cable to the positive

battery terminal and the negative (-) battery cable to
the negative battery terminal.

10-40 Model 3606 • Origin 10/99

 Electrical System

a. Starter Relay Removal

CUMMINS ENGINE 1. Disconnect the negative (-) battery cable at the
2
4 1 battery.
3 2. Remove the hex nut (9), lockwasher (8) and the
2
2 orange/black wire #55 (5) from the relay.
5
3. Remove hex nut (9), lockwasher (8) and the pink and
8
9 brown wire #54 (item 6) from the relay terminal stud.
2
10 4. Remove small hex nut (11), small lockwasher (10)
8 6 11 7
9 and the yellow and blue wire #4 (item 7) from the
relay terminal stud.
5. Remove the two 1/4-20 x 3/4 hex-head capscrews,
(2) 1/4-20 hex-lock elastic nuts securing the starter
relay to the mount bracket. Remove the flat washer
(3) the black ground wire #2A (4) from one of the
capscrews.
6. Remove the relay from the vehicle.
The starter relay is a non-serviceable part and must be
replaced if defective.

b. Starter Relay Inspection and Testing

Inspect the general condition of the starter relay casing
and terminals. Replace the relay if it is cracked or dam-
aged in any way.
MS1630
To test the operation of the starter relay, connect a 12-volt
1. Starter Relay 7. Wire #4 YEL/BLU DC positive lead to the positive terminal (the “top” termi-
2. Mounting Hardware Transmission Neutral
Switch to Starter Relay nal). Connect the negative lead to the mounting bracket,
3. Flat Washer listening for a “click” sound as the contacts close.
8. Lockwashers
4. Wire #2A BLK Ground Replace the relay if the contacts do not close.
9. Hex Nuts
5. Wire #55 ORG/BLK
Ignition Wire 10. “Small” Lockwashers
c. Starter Relay Installation
6. Wire #54 PNK/BRN 11. “Small” Hex Nuts
to Starter 1. Position the black ground wire #2A (4) on a 1/4-20 x
3/4 hex-head capscrew (2). Insert the capscrew
Figure 10– 31. Cummins starter relay. through the left mount hole on the starter relay (1).
Secure the relay to the relay mount plate with the
The relay is internally grounded and is equipped with two
other 1/4-20 x 3/4 hex-head capscrew and two 1/4-20
large terminals and one small terminal. The two large ter-
hex-lock elastic nuts. Torque to 9 lb/ft (12 Nm).
minals are for connection between the battery and the
starter. The small terminal is located on the lower side of 2. Install the yellow/blue wire #4 (7) onto the relay
the relay is for connection to the ignition key switch. terminal stud. Secure with the small lockwasher (10)
and small hex nut (11).
Turning the ignition key switch with the transmission in
NEUTRAL (N) allows current to flow through the relay 3. Install the pink/brown wire #54 (6) onto the relay
coil via terminal to the ground point on the casing. The terminal stud. Secure with lockwasher (8) and hex
flow of current energizes the coil, forming a magnetic nut (9).
field that attracts a movable contact. When the contacts 4. Install the orange/black wire #55 (5) onto the relay
fully close, current from the battery is allowed to flow to terminal stud. Secure with lockwasher (8) and hex
the starter through the relay. nut (9).
When the ignition switch is released, the flow of current 5. Connect the negative (-) battery cable at the battery.
to the coil is stopped. The magnetic field is broken, and
the return spring opens the contacts, stopping current
flow from the battery to the starter.

Model 3606 • Origin 10/99 10-41

 Section 10

10.7 CHARGING CIRCUIT The alternator includes an internal voltage regulator that
limits alternator voltage to a pre-set value and helps pre-
The charging circuit consists of the battery and a belt- vent circuit overloads, power surges, etc. during peak-
driven alternator with an internal voltage regulator. These voltage output.
components work together to provide electrical power for
the vehicle, including the starting system, operators dis- Beyond inspecting the fan belt every 1,000 hours of
play panel, horn, solenoids, back-up alarm, joystick, logic engine operation, there is no periodic maintenance
panel and all accessories. Examine the appropriate wir- required for the charging circuit. When inspecting the fan
ing diagrams and schematics earlier in this section to belt, also check the electrical wiring and connectors.
understand the wiring circuits involved. Under normal conditions the alternator will have no prob-
Current flows from the positive post of the battery to the lem keeping the battery charged. The only condition in
BATT terminal on the starter motor. which the battery may cause a problem is when it has
been completely discharged for an extended period of
When the ignition switch is in the RUN position, current time. In this condition, the alternator may be unable to
flows from the instrument cluster terminal to the alterna- recharge the battery, and a battery charger will be
tor D+ terminal, and is used to excite the field windings required for recharging.
and the alternator begins emitting a charge. Current
flows from the alternator B+ terminal to the starter motor Before using a battery charger, an attempt can be made
B terminal, then through the positive (+) battery cable to to recharge the battery by jump starting the vehicle (refer
the battery. The circuit in the instrument panel connects to Section 2.12.15 Battery, sub-paragraph C. Jump Start-
to the battery positive terminal through the fuse panel ing). Allow the engine to run, which enables the alterna-
and detects field voltages in excess of 16 volts or system tor to charge the battery.
voltages less than 2 to 4 volts less than battery voltage.
WARNING: DO NOT charge a frozen battery.
Either of these conditions will cause the warning light in
A frozen battery may explode and cause seri-
the operators display panel to illuminate.
ous personal injury. Allow the battery to thaw
The warning indicator (A, Fig. 10– 32), a battery-shaped before “jump starting” the vehicle or connecting
icon on the operators display panel, illuminates for three a battery charger.
seconds when the engine is started and will remain illu-
minated if the engine is not running. The warning indica- If the alternator charging warning indicator illuminates,
tor illuminates when the battery is at a low state of perform the following checks:
charge, and when the alternator is no longer able to 1. Check the battery cable connections at the battery
charge the battery. and verify that they are clean and tight.
2. Check the external alternator wiring and connections
and verify that they are in good condition.
1 2 3 4 3. Check the fan belt condition and tension (refer to
F
Section 2.12.8 Engine Fan Belt).
D N 4. Verify that the alternator mounting hardware is tight.
R
5. Run the engine and check the alternator for noise. A
loose drive pulley, loose mounting hardware, worn or
A MS0540 dirty internal alternator bearings, a defective stator or
defective diodes can cause noise. Replace a worn or
Figure 10– 32. The battery warning indicator (A) is located defective alternator.
on the operators display panel.
The negative (-) post of the battery is connected to the
main chassis ground, a stud located on a triangular weld-
ment at the hydraulic reservoir. Other ground leads
routed directly from the main chassis ground are pro-
vided to the alternator, fuel shutoff switch, maintenance
reset switch and spliced within the wiring harness to
other electrical system grounds.

10-42 Model 3606 • Origin 10/99

 Electrical System

10.7.1 Alternator
There are two types of 65-amp alternators used. Vehicles Ground
equipped with Perkins engines use a Perkins alternator. wires
Vehicles equipped with Cummins engines use a Bosch Alternator
alternator.

PERKINS ENGINE

a. Perkins Alternator Removal

1. Disconnect the negative (-) battery cable (Fig. 10– 33)
at the negative (-) battery terminal.
Three-wire plug
MS1560

Figure 10– 34. Label and disconnect the alternator wire

connector and both ground wires.
4. Loosen the upper hex-head capscrew (1, Fig. 10– 35)
and lower hex-head capscrew (10) slightly. In order to
Negative (-) loosen the lower screw (10), a wrench may need to
Terminal hold the self-locking nut (8) in position. Rotate the
alternator toward the engine and move the fan belt
(20) out of the way.
5. Remove the screw (1), lockwasher (2), and flat
washer (3) securing the lever (6) to the tapped hole in
the alternator (22).
OS1040
6. Remove the screw (4), lockwasher (5), lever (6) and
Figure 10– 33. Disconnect the negative (-) battery cable spacer (7) from the tapped hole in the engine block.
at the negative (-) battery terminal.
7. While supporting the alternator (22) so it does not
2. Label all wiring at the rear of the alternator. fall, remove the self-locking nut (8), washer (9), screw
Disconnect the three-wire plug at the rear of the (10), and two sleeves (11 and 12). Remove the
alternator. alternator from the vehicle.
3. Label or tag the alternator wires. Remove the nut 8. If required, remove the hex nut (13), lockwasher (14),
securing the two ground wires to the alternator. Move flat washer (15) bracket (16) and stud (17).
the three-wire plug and the two ground wires out of 9. If required, remove hex nut (18), lockwasher (19), belt
the way. (20), and pulley (21).

Model 3606 • Origin 10/99 10-43

 Section 10

6
22

3
7
1
2
5
4
22
20

21
9
19 8
18 13 12
14
15
16

11
10 MA1111
17

1. Screw 5. Lockwasher 9. Washer 13. Nut 17. Stud 21. Belt Pulley
2. Lockwasher 6. Lever 10. Screw 14. Washer 18. Hex Nut 22. Alternator
3. Washer 7. Spacer 11. Sleeve 15. Washer 19. Washer
4. Bolt 8. Self-locking Nut 12. Sleeve 16. Bracket 20. Belt

Figure 10– 35. Perkins alternator mounting detail.

b. Perkins Alternator Installation 6. Install the flat washer (3), lockwasher (2) and screw
(1) securing the lever (6) to the tapped hole in the
1. If required, install pulley (21, Fig. 10– 35), belt (20),
alternator (22).
lockwasher (19), and hex nut (18).
7. Rotate the alternator toward the engine and place the
2. If required, install the stud (17), bracket (16), flat
fan belt (20) into position. In order to tighten the lower
washer (15), lockwasher (14), and hex nut (13).
screw (10), use a wrench to hold the self-locking nut
3. Slide the sleeve (11) over the hex-head capscrew (8). Rotate the alternator with the fan belt away from
(10) and position these parts in the mounting hole on the engine and tighten the upper hex-head capscrew
the front of the bracket (16). (1) and lower hex-head capscrew (10) securely.
4. Position the alternator (22) so that its front lower 8. Check for proper fan belt deflection (refer to Section
mount hole is aligned in the bracket (16), and begin 2.12.8 Engine Fan Belt).
to push the screw (10) through the front lower mount
9. At the ground stud on the back of the alternator,
hole. Position sleeve (12) so that the screw (10) goes
install the two alternator ground wires and secure
through it, through the alternator rear lower mount
with a hex nut.
hole, and out the rear of the bracket (16). Install the
washer (9) and self-locking nut (8) onto the screw 10. Connect the three-wire plug at the rear of the
(10) but DO NOT tighten at this time. alternator.
5. Install the spacer (7), lever (6), lockwasher (5), and 11. Connect the negative (-) battery cable (Fig. 10– 33) to
screw (4), and thread the screw (4) into the tapped the negative (-) battery terminal.
hole in the engine block.

10-44 Model 3606 • Origin 10/99

 Electrical System

7
2

6
1

1
4

5
3

MA6190
MA1881

1. Alternator 5. Lower Mounting Tab

2. Tensioner Bracket 6. Upper Mounting
3. Engine Fan Belt (“longer”) Capscrew Belt rides in
4. Lower Mounting 7. Upper Mounts pulley groove
Capscrew

Figure 10– 36. Cummins alternator mounting detail.

ratchet to lift the bracket and remove the engine fan
CUMMINS ENGINE belt (3).
3. Label and remove all wiring from the rear of the
a. Cummins Engine Bosch Alternator Removal alternator.
1. Disconnect the negative (-) battery cable (Fig. 10– 37) 4. Remove the lower mounting capscrew (4) securing
at the negative (-) battery terminal. the alternator to the lower mounting tab (5) on the
engine.
5. While supporting the alternator with one hand,
remove the upper ("longer") mounting capscrew (6)
from the upper alternator mounts (7). Remove the
alternator from the vehicle.

Negative (-) b. Cummins Engine Bosch Alternator Installation

Terminal 1. Position the alternator (1, Fig. 10– 36) between the
upper mounts (7) on the engine bracket. Align the
holes and insert the upper ("longer") mounting
capscrew (6) through the rear mount and alternator.
Thread the longer capscrew into the alternator front
mount. DO NOT tighten completely at this time.
OS1040 2. Align the lower alternator mount hole with the lower
mounting tab (5) on the engine and insert the lower
Figure 10– 37. Disconnect the negative (-) battery cable mounting capscrew (4). Tighten the lower capscrew
at the negative (-) battery terminal. (4) and upper capscrew (6) securely.
2. Install a 1/2" square drive ratchet into the square hole 3. At the rear of the alternator, reattach all wires to their
in the tensioner bracket (2, Fig. 10– 36). Turn the proper terminals.

Model 3606 • Origin 10/99 10-45

 Section 10

4. Use a 1/2" square drive ratchet to raise the tensioner The vents require keeping the battery in an upright posi-
bracket (2). Properly route the fan belt (3) onto the tion to help prevent electrolyte leakage. Tipping the bat-
alternator and engine pulleys. Check the tensioner tery beyond a 45° angle in any direction can allow a small
pulley to verify that it is pivoting freely to provide the amount of electrolyte to leak out the vent hole.
proper tension on the belt. Check for proper fan belt DO NOT exceed this 45° angle when carrying or install-
deflection (refer to Section 2.12.8 Engine Fan Belt). ing a battery.
5. Connect the negative (-) battery cable (Fig. 10– 37) to The battery has top-post terminals. Keep the terminals
the negative (-) battery terminal. clean, and securely tighten clean cable clamps onto the
posts. Grease or special spray sealers may be applied
10.7.2 Battery over the connections.
WARNING: All lead-acid batteries generate
b. Visual Inspection of the Battery
hydrogen gas, which is highly flammable. If
ignited by a spark or flame, the gas may Inspect for damage such as a cracked or broken case or
explode violently, causing spraying of acid, cover that could permit loss of electrolyte. If obvious
fragmentation of the battery, and possible physical damage is noted, replace the battery. Handle
severe personal injuries. Wear safety glasses the battery with care. Determine the cause of damage
when working near batteries. In case of contact and correct as needed before installing the new battery.
with acid, flush immediately with water.
c. Battery Load Test
A single, lead-acid type, 12-volt, negative (-) ground,
maintenance-free battery rated at 1000 cold-cranking 1. Disconnect both the negative (-) battery cable (first),
amps is used in this vehicle. Refer to Section 2.12.15 and the positive (+) battery cable from the battery.
Battery for general information. Make sure that the negative and positive battery
terminal posts are clean to help assure a good
a. Battery Description electrical connection.

The battery supplies power to the starter and ignition 2. Attach voltmeter and battery load tester clamps to
system to crank the engine, and provides extra power the battery terminal posts.
when the electrical load requirements of the vehicle 3. Remove the surface charge from any battery that has
exceed the supply from the charging system in the event just been charged (by a battery charger or by the
of an alternator or charging-system failure. The battery vehicle alternator). DO NOT remove the surface
also acts as a voltage stabilizer in the electrical system, charge from a battery that has been in storage. To
smoothing out or reducing temporarily high voltage. remove the surface charge, apply a 300-ampere load
across the terminals for 15 seconds. Then turn off
With the correct battery cables properly attached, and
the load and wait for 15 seconds to allow the battery
with the battery properly mounted, the battery does not
to recover and normalize.
require periodic maintenance.
4. Battery temperature should be estimated by touch
When starting the engine, allow the starter to crank for a
and also by the surrounding temperature it was
maximum of 15 seconds only, then wait a minimum of
exposed to during the preceding few hours before
two minutes to help avoid burning out the starter. Also,
testing. Select the nearest estimated temperature
DO NOT let the engine idle excessively, as low engine
from the chart below and determine the minimum
RPM can also lead to battery discharge.
voltage that must be maintained while the battery
Keep the battery from freezing by maintaining a full supplies a specified electrical load.
charge. A completely discharged battery will freeze at
18° F (8° C). 5. Apply a 260-ampere load test to check the charge
acceptance of the battery. Observe the voltage after
Due to the maintenance-free design, water never has to 15 seconds with the load connected, then turn off the
be added to the battery, so there are no filler caps. Each load.
battery is sealed, except for small vent holes in the cover.
6. If voltage is at or above the value determined in step
The vent holes allow gas and pressure produced in the
4, the battery is good and may be returned to service.
battery during charging to escape. The special chemical
composition inside the battery reduces gassing to a very 7. If voltage is below the value determined in step 4,
small amount at normal charging voltages. The special check the charge acceptance of the battery one more
chemistry also greatly reduces the possibility of over- time before discarding it. If the voltage continues to
charge damage. read below the value determined in step 4, replace
the battery.

10-46 Model 3606 • Origin 10/99

 Electrical System

Note: The accuracy of this test procedure depends on e. Battery Troubleshooting

closely following the load, time and temperature specifi-
If a battery has tested satisfactorily but then fails to per-
cations.
form satisfactorily for no apparent reason, the following
Relation of Battery Temperature to Minimum Voltage items are among the more popular factors that may help
TEMPERATURE MINIMUM VOLTAGE understand the cause:

70° F (21° C) and above 9.6 1. Vehicle accessories left on, causing battery
discharge.
50° F (10° C) 9.4
2. Charging system defect, such as slipping fan belt,
30° F (-1° C) 9.1 high wiring resistance, or faulty alternator.
15° F (-10° C) 8.8 3. A vehicle electrical load exceeds alternator output
0° F (-18° C) Below 0° F (-18° C) capacity (common with the addition of electrical
accessories such as radio equipment, lights, air
d. Battery Charging conditioning, or window defogging/de-misting
devices).
Charge rates between 3 and 50 amperes are generally
satisfactory as long as spewing of electrolyte does not 4. Electrical system defects, such as shorted wires.
occur, or the battery does not feel excessively hot [over 5. Extended slow speed driving with many accessories
125° F (52° C)]. Battery temperature can be estimated by on, and excessive engine idling (both cases do not
touching or feeling the battery case. If spewing of electro- allow engine RPM to reach a sufficient speed to
lyte occurs or temperature exceeds 125° F (52° C), com- enable alternator output to sufficiently charge the
monly referred to as "boiling" the battery, the charging battery).
rate must be reduced or temporarily halted to permit
6. Loose or poor battery cable-to-post connections,
cooling. Failure to do so will destroy the battery.
previous improper charging of a run-down battery, or
When charging a battery, keep this point in mind: loose battery hold-down hardware.
• Battery charging consists of a charge current in 7. High resistance connections or defects in the starting
amperes for a period of time in hours. Thus, a 25- system.
ampere charging rate for 2 hours would result in a
8. Failure to disconnect the battery before long periods
50-ampere hour charge to the battery.
of vehicle storage. Small current drains of vehicle
The time required for a charge will vary due to the follow- accessories that are connected all the time can also
ing conditions: discharge the battery in a six- to eight-week period. A
• Size of battery: For example, a completely battery left in a discharged condition for a prolonged
discharged, large, heavy-duty battery requires more period of time is subject to freezing and can become
than twice the recharging as a completely discharged difficult to recharge.
small passenger car battery.
f. Jump Starting with
• Temperature: For example, more time will be
an Auxiliary (“ booster” ) Battery
required to charge a battery at 0° F than at 80° F.
When a fast charger is connected to a cold battery, Note: Use this information in addition to that found
the current accepted by the battery will be very low at under C. Jump Starting in Section 2.12.15 Battery.
first, then in time the battery will accept a higher rate
Both the auxiliary or “booster” battery and the discharged
as the battery warms.
battery should be treated carefully when using jumper
• State of Charge: A completely discharged battery cables. Follow the following procedure exactly, and DO
requires more than twice as much charge as a half- NOT cause sparks to occur:
charged battery. Because the electrolyte is nearly
1. Engage the park lock of the booster vehicle and
pure water and therefore a poor conductor in a
place its transmission in NEUTRAL (N). DO NOT
completely discharged battery, the current accepted
allow both vehicles to touch each other in any
is very low at first. Later, as the charging current
manner, as this could establish a ground connection
causes the electrolyte acid content to increase, the
and counteract the jump-starting process.
charging current will likewise increase.
• Charger Capacity: A charger that can only supply
5 amperes will require a much longer period of
charging than a charger that can supply 30 amperes
or more.

Model 3606 • Origin 10/99 10-47

 Section 10

i. Battery Inspection, Cleaning and Drying

WARNING: Any other procedure than that out- 1. Periodically inspect the battery for accumulation of
lined in these instructions could result in: dirt or corrosion on the battery, terminals, cable ends,
• Personal injury caused by electrolyte spewing and battery retaining hardware. Also check that the
out of the top vent holes on the battery. battery case and cover is not cracked or leaking, and
• Personal injury or property damage due to that the terminal posts are not broken or loose.
battery explosion; 2. Prepare a mixture of baking soda and water and
• Damage to the starting systems of both vehi- obtain a non-metallic scrub brush. Dip the brush in
cles. the mixture and scrub the battery and cable
terminals. Also clean the battery mounting area on
2. Continue with the jump starting instructions found the vehicle frame before replacing the battery.
under C. Jump Starting in Section 2.12.15 Battery.
3. Dry the battery with a clean, lint-free cloth.
g. Battery Removal
j. Battery Installation
1. Disconnect the negative (-) battery cable from the
battery (Fig. 10–38). Disconnect the positive (+) 1. Carefully place the battery (Fig. 10–38) in the battery
battery cable from the battery. compartment.

2. Remove the battery retaining (“hold-down”) strap 2. Install the battery retaining (“hold-down”) strap and
hardware and the retaining strap (Fig. 10–38). the retaining strap hardware. Attach the strap
properly to help prevent the battery from shifting,
3. Carefully remove the battery from the vehicle. moving and vibrating. Vibration is harmful to a
Note: The best time to clean the battery compartment is battery. DO NOT overtighten the fasteners.
when the battery is removed from the vehicle. 3. Install the rear engine cover (Fig. 10–39).
4. Connect the positive (+) cable to the positive battery
terminal post.
5. Connect the negative (-) cable to the negative battery
Positive (+) terminal post.
Terminal
Retaining
Strap Auxiliary Function
Negative (-)
Manifold
Terminal

Battery

OS1040 Battery
Figure 10–38. Disconnect the negative (-)
and positive (+) battery terminals.
Rear engine cover
h. Battery Removal MS2100

1. Disconnect the negative (-) battery cable from the Figure 10–39. The rear engine cover is located
battery (Fig. 10–38). Disconnect the positive (+) to the rear of the battery.
battery cable from the battery.
2. Remove the rear engine cover (Fig. 10–39), the
battery retaining (“hold-down”) strap hardware, the
retaining strap (Fig. 10–38) and the battery.
Note: The best time to clean the battery compartment is
when the battery is removed from the vehicle.

10-48 Model 3606 • Origin 10/99

 Electrical System

10.8 ELECTRICAL SYSTEM COMPONENTS b. Warning Indicator Lights

(in operators display panel)
Electrical components include warning devices such as
the indicators in the operators display panel, horn, back- 2 3
up alarm, and other components such as the joystick,
logic panel, various solenoids and all accessories. 1 4
Examine the appropriate wiring diagrams and 1 2 3 4
schematics earlier in this section to help understand the
F
wiring circuits involved.
D N
R
10.8.1 Warning Devices
Vehicle warning devices include the horn, instrument
8 7 6 5 OS0531
panel warning lights, and the back-up alarm.
Figure 10– 41. Typical operators display panel
a. Horn warning indicator lights.
The horn (Fig. 10– 40) is mounted forward of the cab on There are eight subdued or "hidden" warning indicator
the vehicle frame. lights (described below) present in the operators display
The horn sounds when the momentary-contact horn but- panel (Fig. 10– 41). These warning indicators illuminate
ton on the center of the steering wheel is pressed. during critical circumstances.
Removal of the horn button is discussed in Section 4.2.4 IMPORTANT: All eight warning indicator lights demand
Controls of this manual. immediate attention and vehicle service. In many cases,
the vehicle should be shut down as soon as practical to
help prevent serious mechanical failure. Appropriate ser-
vice procedures for each circuit, as applicable, appear
elsewhere in this section of the manual.
1. Engine Maintenance/Vehicle Lubrication Indicator
This light (item 1, Fig. 10– 41) illuminates every 250 hours
of engine operation to remind the operator that important
maintenance operations are required. After the engine is
serviced (engine oil and engine oil filter changed), the
Horn indicator can be reset by pressing and holding the reset
switch (Fig. 10– 42), then turning the ignition switch to the
RUN position. The indicator light will illuminate during
power-up and will cease to illuminate when it is reset.
The reset switch can then be released. Should there be a
problem with the indicator and it does not cease to illumi-
nate after servicing the engine and conducting the reset
MS1830
steps above, check the involved circuit and the reset
Figure 10– 40. Horn location. switch itself for continuity and shorts. Replace a defective
switch. If the problem is determined to exist in the opera-
The horn sound is produced by a solenoid-actuated dia- tors display panel, replace the panel with a new unit.
phragm in the horn that develops a resonating air column
Reset Switch
in the horn trumpet, which is shaped to project the sound.
If the horn doesn't sound when the horn button is
pressed, check that the fuse is not blown.
Check for corrosion on the horn mounting that may be
preventing a solid ground, and check for a loose horn
wire. Test the horn switch for continuity when the horn
button is pressed.
If the problem is still not located, remove the horn from
the frame and test it using short, heavy-gauge wires con-
nected to a fused or otherwise protected 6-amp minimum OS0251
output, 12-volt DC power supply. Figure 10– 42. Typical maintenance reset switch.

Model 3606 • Origin 10/99 10-49

 Section 10

2. Engine Coolant Temperature Warning Indicator c. Back-Up Alarm

This indicator (item 2, Fig. 10– 41) is illuminated when the The back-up alarm (Fig. 10– 43) is located at the rear of
engine coolant temperature is above 210° F (85° C). An the vehicle, under the rear cover, mounted on the top left
audible alarm will sound, and the engine must be shut side of the frame.
down as soon as practical to help avoid engine damage.
Back-up
3. Transmission Temperature Warning Indicator Alarm
This indicator (item 3, Fig. 10– 41) illuminates when the
transmission fluid temperature exceeds 250° F (107° C).
An audible alarm will also sound, and the vehicle should
be stopped and the engine allowed to idle at high idle for Mounting
five minutes. If the light and alarm do not cease after five Hardware
minutes, the engine must be shut down to help avoid
transmission damage.
4. Hydraulic Oil Temperature Warning Indicator
This warning light (item 4, Fig. 10– 41) will activate when
the hydraulic oil temperature is above 195° F (76° C).
The vehicle should be stopped and the engine allowed to
idle at high idle for five minutes. If the light continues to
illuminate after five minutes, the engine must be shut
MS1800
down to help avoid damage in the hydraulic system.
Figure 10– 43. Back-up alarm location.
5. Hydraulic Oil Filter Restriction Warning Indicator
When the transmission shift control switch (travel select
This warning light (item 5, Fig. 10– 41) will activate when
lever) is shifted to the reverse position, the back-up alarm
a restricted hydraulic oil system filter is detected. The
will automatically sound. Place the travel select lever in
vehicle should be stopped and the engine allowed to idle
reverse to test the back-up alarm. The back-up alarm
at high idle for five minutes. If the light remains illumi-
must not sound when the travel select lever is in
nated or begins to flicker on and off at high idle, replace
NEUTRAL (N) or FORWARD (F). Also, with the ignition
the hydraulic oil filter (see Section 9 Hydraulic System for
key switch in the RUN position, the back-up alarm will
further information).
sound when the travel select lever is shifted into the
6. Engine Air Filter Restriction Warning Indicator REVERSE (R) position.
This warning light (item 6, Fig. 10– 41) will activate when The back-up alarm is energized via current from the
a restricted engine air filter is detected. The vehicle transmission shift control switch, part of the travel select
should be stopped and the engine allowed to idle at high lever mounted within the steering column. See the appro-
idle for five minutes. If the light remains illuminated or priate wiring schematic and diagram in this section to
begins to flicker on and off at high idle, replace the help understand the back-up alarm circuit. See Section
engine air filter (see Section 8A Perkins Engine or Sec- 4.2.4 Controls for information on removing and replacing
tion 8B Cummins Engine for information on replacing the the transmission shift control switch.
air filter).
7. Alternator Charging Warning Indicator
This light (item 7, Fig. 10– 41) illuminates when the charg-
ing system is not working properly. Check and service the
alternator and battery as required.
8. Engine Oil Pressure Warning Indicator
This indicator (item 8, Fig. 10– 41) illuminates and an
audible alarm sounds after 15 seconds if the engine is
not started. This is normal. When the ignition key switch
is turned to the OFF position, the indicator is reset.
Should the light and alarm begin during engine opera-
tion, the engine oil pressure is too low. The engine must
be shut down as soon as practical to help avoid engine
damage.

10-50 Model 3606 • Origin 10/99

 Electrical System

Back-up Alarm Removal 10.8.2 Operators Display Panel

1. Disconnect the negative (-) battery cable at the There are two types of operators display panels in exist-
negative battery terminal (Fig. 10– 44). ence (Fig. 10– 45) at the time this manual was published.

1 2 3 4

F P
D N
R
Negative (-)
Terminal
Early Production Operators Display Panel

OS1040

Figure 10– 44. Disconnect the negative (-) battery cable

at the negative (-) battery terminal.
OS0222
2. Label and disconnect the wiring from the back-up Current Production Operators Display Panel
alarm.
3. Two nuts and lockwashers secure the back-up alarm Figure 10– 45. There are two types of
operators display panels.
to weldstuds on the vehicle frame. Remove the nuts
and washers and remove the alarm from the vehicle. The information under this heading deals mainly with the
description and function of each indicator in the opera-
Disassembly tors display panel. Appropriate service procedures for
each circuit, as applicable, appear elsewhere in this sec-
DO NOT disassemble the back-up alarm. Replace a
tion of the manual.
defective or faulty alarm with a new one.
The operators display panel is of solid-state, printed cir-
Inspection and Replacement cuit design and contains five wiring terminals or plugs,
two printed-circuit boards mounted piggy-back style with
Inspect the wiring harness connector and alarm termi- standoffs, and a display panel that provides overall moni-
nals for continuity and shorting. Replace a defective or toring of vehicle functions and status. Due to the complex
faulty alarm with a new one. design and solid-state circuitry, the panel is non-service-
able. Electro-static discharge and moisture are two of the
Installation and Testing main reasons for malfunction. Prevent the panel from
1. Position the back-up alarm (Fig. 10– 43) on its coming into contact with static or other electrical sources.
mounting studs and secure with two 1/4-20 hex-lock When washing the vehicle, keep spray away from the
elastic nuts and 1/4” lockwashers. operators display panel. Replace a defective, malfunc-
tioning or faulty panel with a new unit.
2. Connect the wiring harness connector lead to the
back-up alarm. The operators display panel provides important informa-
tion in a “user friendly” design with easily-recognizable
3. Connect the negative (-) battery cable to its battery
graphic and alpha-numeric indicators. The panel pro-
terminal (Fig. 10– 44).
vides information the operator needs on vehicle and
4. Test the alarm by turning the ignition key switch to the engine functions.
RUN position and shifting the travel select lever into
When testing circuits connected to the dash, disconnect
the reverse position.
the harness connector and test the harness side only.

Model 3606 • Origin 10/99 10-51

 Section 10

a. Power-Up Lights C. Steering Mode Indicators

When the ignition key switch is turned to power up the The steering mode indicators (Fig. 10– 46) illuminate to
vehicle, all lights in the display panel will illuminate for show which of the steering modes (front-wheel, crab, or
three seconds as a test function. During this time, an four-wheel steering) is presently engaged.
audible alarm will also sound.
The Fasten Seat Belt and Read Manual symbols (Fig. D. Attachment Tilt Mode Indicator
10– 46) will remain illuminated for five to seven seconds One of the two attachment tilt mode indicators will illumi-
(repeated whenever the seat belt switch senses that nate to show which mode (extend/retract or raise/lower)
pressure is removed from the seat), reminding the opera- is presently engaged.
tor to fasten the seat belt and to review the Owners/Oper-
ators Manual if there are any questions about safe and Function Indicator Lights
proper operation of the vehicle (a manual should be kept
C B
in the storage compartment beneath the seat at all A
times).
1 2 3 4
Normal Operating Lights F P

After the engine starts, the operators display panel (Fig. N

R
10– 46) provides information via the following indicators:
Fasten Seat Belt
Early Production Operators Display
Fuel Level Read
Indicator B Gear Select
Manual B
Bars Indicators A
C
A C 1 2 3 4
1 2 3 4 F P
F D N
N R
R
OS0492
Current Production Operators Display
OS0211
Fuel D
Indicator Travel Select Figure 10– 47. Function indicator lights.
Symbol Indicators There are three subdued or "hidden" function indicator
Figure 10– 46. The operators display panel indicators lights (Fig. 10– 47) in the display panel that illuminate only
illuminate when the vehicle is started. when a specific function is activated. They are:

A. Fuel Level Indicator Bars A. Engine Preheat Indicator (Perkins engines only)
Each of the fuel level indicator bars (Fig. 10– 46) repre- This light flashes when the ignition key is held in the
sents approximately 1/4 tank. The vehicle must be PREHEAT position (Fig. 10– 48). After 30 seconds, the
parked on a firm, level surface to ensure an accurate fuel light will glow steadily, indicating the engine is warm
level reading. The fuel level indicator bars will be illumi- enough to start.
nated with a low-light green hue, easily apparent for night OFF RUN
visibility and in low-light conditions. When approximately
1/8 tank is reached, the last fuel level indicator bar will
PREHEAT
stop illuminating, and the fuel level indicator symbol, a
graphic of a fuel dispensing pump, will change from
green to orange. When the fuel level indicator symbol
changes from green to orange, refuel the tank. START

B. Travel and Gear Select Indicators

These illuminate to show the direction the travel select OF0390

lever is in (F for FORWARD, N for NEUTRAL, and R for Figure 10– 48. Ignition key switch positions.
REVERSE) and the gear presently engaged.

10-52 Model 3606 • Origin 10/99

 Electrical System

B. Parking Brake Indicator

This illuminates any time the parking brake switch is Display Internal-hex
applied and the ignition switch is in the RUN position. Panel Fastener

C. Stabil-TRAK Indicator
This light illuminates when the Stabil-TRAK system is
activated.

b. Operators Display Panel Removal

IMPORTANT: Static electricity can cause damage to the
operators display panel. Avoid any manner of touching Five-plug
(hands, tools, etc.) the printed circuit boards and termi- Dash Console Connector
nals. Disconnect the negative (-) battery cable at its bat- (ref.)
MS1680
tery terminal before beginning this procedure. Failure to
comply can result in damage to the operators display Figure 10– 50. The operators display panel connects to the
panel and malfunction of the instruments and indicator cab wiring harness via five plug terminals.
lights.
1. Disconnect the negative (-) battery cable at its c. Installation
battery terminal (Fig. 10– 49). 1. Connect the five quick-disconnect plug terminals at
the rear of the operators display panel (Fig. 10– 50).
Install the panel by positioning it into the dashboard
housing and aligning the four fastener mounting
holes.
2. Install the four internal-hex fasteners securing the
operators display panel to the dashboard housing.
Negative (-)
Terminal 3. Connect the negative (-) battery cable to the negative
battery terminal (Fig. 10– 49).
4. Turn the ignition switch key to the RUN position
(Fig. 10– 51) and observe that all operators display
panel functions are operative per the following
diagnostic test:

OS1040

Figure 10– 49. Disconnect the negative (-) battery cable

at the negative (-) battery terminal.
2. Remove the four internal-hex fasteners (Fig. 10– 50)
securing the operators display panel to the
dashboard housing.
3. Disengage the five quick-disconnect plug terminals at
the rear of the operators display panel. Remove the
panel from the vehicle.

Model 3606 • Origin 10/99 10-53

 Section 10

Operators Display Panel Test 10.8.3 Switches and Solenoids

Check the following as the key is switched into the "RUN"
a. Ignition Key Switch
position (Fig. 10– 51):
The ignition key switch (Fig. 10– 52) is located on the
lower left side of the dash. It is a key-operated switch
OFF RUN
used to start the engine and to run the vehicle. Only on
Perkins engines equipped with the optional cold start fea-
PREHEAT ture (refer to Thermo-Start Plug in this section), the igni-
tion switch preheat function will allow the thermo-start
plug to ignite the air/fuel mixture in the intake manifold,
START making the engine easier to start in cold weather.
Ignition
Key Switch
OF0390

Figure 10– 51. Ignition key switch positions.

1. All lights must illuminate for a minimum of 3 seconds.
2. An audible alarm must sound for a minimum of 3
seconds.
3. "Seat belt" light and “Read Manual” light and must
remain on for 5 to 7 seconds, with operator seated.
4. "Seat belt" light and "Read manual" light must
OS0091
illuminate when operator is removed from seat.
5. Warning lights and alarm must be OFF for an Figure 10– 52. Ignition key switch location.
additional 15 to 20 seconds.
When the key is inserted into the ignition key switch, the
6. Engine oil pressure light and alarm will turn ON in 15 switch can be turned clockwise from the OFF position
seconds if engine is not running. (Fig. 10– 51) to the RUN, PREHEAT (Perkins-only
7. One of three travel direction lights (F, N, or R) must option), and START positions. The PREHEAT and the
always remain ON. START positions are spring-loaded to return the switch to
8. 1 of 4 gear selection lights must always remain ON the RUN position; these two switch positions must be
"1, 2, 3, 4" (4-speed transmission only). manually held in place for cold-weather starting (Perkins-
OR only option) and for normal starting.
1 of 3 gear selection lights must always remain on
"1, 2, 3" (3-speed transmission only). OFF Position
9. 1 of 3 steering mode lights must always remain ON. The entire electrical system is shut down, with power at
the ignition switch and the starter solenoid only.
10. The appropriate fuel level indicator lights must always
remain ON.
RUN Position
Note: 4 green bars = a full tank; 1 green bar = 1/4 tank,
All controls and indicators are operable.
and at 1/8 tank, no green bars illuminate and the fuel dis-
pensing pump symbol illuminates in orange. PREHEAT position (Perkins-only option)
Preheats air in the induction manifold for cold-weather
starting (refer to Thermo-Start Plug in this section).
When starting in cold weather, momentarily hold the key
in the PREHEAT position before turning it to the START
position.

START Position
When the park brake switch is ON and the transmission
is in NEUTRAL (N), turning the ignition switch to the
START position engages the starter to start the engine.

10-54 Model 3606 • Origin 10/99

 Electrical System

If the key binds in the switch, check the key for defects Refer to the SWITCH POSITION table below. Using an
and the switch for foreign objects. Clean or remove for- ohmmeter or a continuity tester, check for continuity.
eign material from the key as required. Check that the Replace the switch if it fails to test according to the table.
key is not bent or excessively worn; replace a bent or
worn key with a new key. Apply powdered graphite to the SWITCH POSITION
key and insert and withdraw the key from the switch sev-
eral times to distribute the graphite into the switch lock Switch Terminals OFF RUN PREHEAT START
mechanism. 1. BAT X X X
During freezing temperatures, if the ignition switch fails to
2. IGN X X X
turn, or does not allow the key to be inserted, warm the
switch with a heat gun (blow dryer), or use liquid lock 3. START X
deicer to help evaporate frozen moisture from within the
switch. 4. ACC X

IMPORTANT: Only use graphite or a liquid lock deicer 5. PREHEAT X X

within the switch. Replace a defective switch.
Ignition Switch Installation
Ignition Switch Removal
1. Connect the wires according to the labels applied
1. Disconnect the negative (-) battery cable at the during removal. Follow the ignition key switch wiring
negative battery terminal (Fig. 10– 49). diagram (Fig. 10– 53) as required.
2. Remove the hex nut securing the ignition switch to
IGNITION ORN
the dash. SWITCH 6 To MAIN Fuse

3. Reach up and under the dash to work the ignition To 7.5-Amp Fuse DK GRN
15 3
1
2 5
YEL/RED To Switched Grid
(fuse panel bus)
switch and wiring out of the mounting hole. 4 5

PUR
4. Label the wires on the ignition switch. Disconnect the To Positive (+) Grid BRN
7
77 To 15-Amp Fuse
wires from the switch and remove the switch from the (fuse panel bus)
MS2430
vehicle.
Figure 10– 53. Ignition key switch wiring diagram.
Disassembly 2. Reach up and under the dash to work the ignition
DO NOT disassemble the ignition switch. Replace a switch and wiring into the ignition switch-mounting
defective switch with a new one. hole on the left side of the dash (Fig. 10– 52).
3. Align the ignition switch so that when it is in the OFF
Inspection and Replacement position (Fig. 10– 54), the key slot is positioned
The key should insert and turn freely in the switch. If the vertically (straight up and down). Install the hex nut
key binds in the switch, check the key for defects and the securing the ignition switch to the dash. DO NOT
switch for foreign objects. Clean or remove foreign mate- overtighten.
rial from the key as required. Check that the key is not OFF RUN
bent or excessively worn; replace a bent or worn key with
a new key. Apply powdered graphite to the key and insert PREHEAT
and withdraw the key from the switch several times to dis-
tribute the graphite into the switch lock mechanism.
IMPORTANT: Only use graphite or a liquid lock deicer START
within the switch. Replace a defective switch.

OF0390

Figure 10– 54. Ignition key switch positions.

Model 3606 • Origin 10/99 10-55

 Section 10

4. Connect the negative (-) battery cable at the negative 10.8.4 Thermo-Start Plug
battery terminal (Fig. 10– 55). (optional for Perkins engines only)
The thermo-start plug (Fig. 10– 56) is located in the Per-
kins engine intake manifold, plumbed into the fuel line.
1

Negative (-)
Terminal
3
1
2

MA1071
1. Thermo-start Plug 3. Electrical Terminal
OS1040 2. Intake Manifold 4. Fuel Line Fitting

Figure 10– 55. Connect the negative (-) battery cable Figure 10– 56. The thermo-start plug is located in the
to the negative (-) battery terminal. Perkins engine intake manifold.
The thermo-start plug is activated by the PREHEAT igni-
b. Transmission Neutral Start Feature tion key switch position (Fig. 10– 54). The PREHEAT cold-
The transmission neutral start feature is a safety feature starting aid should be used when the temperature is
designed to prevent the engine from starting with the below 32° F (0° C), but not below 10 ° F (-12° C) if 10W30
transmission in FORWARD (F) or REVERSE (R). engine oil is used in the crankcase. Consult the appropri-
ate Perkins engine manual for other variables.
Shifting into NEUTRAL (N) activates the neutral relay (in
the relay and fuse panel). When the travel select lever is When the ignition key switch (Fig. 10– 54) is turned to the
in NEUTRAL (N), electrical power flows to the starter PREHEAT position, an air/fuel mixture in the intake mani-
relay, allowing the starter to engage and start the engine. fold is ignited to help make cold-weather starting easier.
Test the transmission neutral start circuit as follows: For specific cold starting instructions, see the Owners/
• The starter MUST NOT operate with the Operators Manual for this vehicle.
travel select lever in FORWARD or REVERSE WARNING: Ether, starting fluid, or high-energy
• The starter MUST NOT operate when the fuels should not be used with the PREHEAT
park lock is OFF (disengaged) system. An explosion may cause serious injury
or engine damage.
• The starter MUST operate with the travel select
lever in NEUTRAL The engine is fitted with an efficient cold-starting aid and
If the starter fails to turn the engine with the travel select no responsibility can be accepted for any damage
lever in NEUTRAL (N) and the ignition switch in the caused by unauthorized starting aids.
START position, refer to Section 10.9 Electrical System If the engine is difficult to start or fails to start and the
Troubleshooting. The neutral position contacts in the shift thermo-start plug is suspected, check the electrical con-
switch are non-repairable. Replace the switch if defective. nection at the plug. If the electrical connection is not sus-
pect, check that fuel is indeed reaching the thermo-start
plug by unscrewing the fuel line fitting at the plug. If fuel
is present, the plug itself may not be working correctly.
This can be checked by removing the air cleaner and
watching the cold starting aid while the equipment is
used. When the ignition key switch is turned to the PRE-
HEAT position, the element should become red hot, and
when the ignition key switch is placed in the START posi-
tion and the starter engages the engine, ignition of the
fuel should occur.

10-56 Model 3606 • Origin 10/99

 Electrical System

a. Thermo-Start Plug Removal 10.8.5 Fuel Run Solenoid

1. Label and disconnect the thermo-start wiring lead at The fuel run solenoids a valve that lets fuel enter the
the thermo-start plug electrical connector. injection pump when the ignition switch is turned to the
2. Disconnect the fuel line. START or RUN positions. The fuel run solenoid is located
as follows:
3. Remove the thermo-start plug by unthreading it from
the intake manifold. PERKINS ENGINE

On the side of the fuel injection pump (2, Fig. 10– 57).
b. Disassembly
DO NOT disassemble the thermo-start plug. Replace a
defective plug with a new one.

c. Cleaning and Drying

DO NOT submerge the thermo-start plug. Clean the 1
exterior of the plug in an approved solvent. Dry the plug
with a clean, lint-free cloth. 2

d. Inspection and replacement

Examine the fuel line and the thermo-start plug mounting
bore in the intake manifold for any contamination and
MS2450
clean as required.
1. Fuel Injector Pump
Test the thermo-start plug coil using short, heavy-gauge 2. Fuel-run Solenoid
wires connected to a fused or otherwise protected 6-amp
minimum output, 12-volt DC power supply. If the coil fails Figure 10– 57. Perkins engine fuel-run solenoid.
to heat, replace the thermo-start plug with a new one.

e. Thermo-start Plug Installation CUMMINS ENGINE

1. Thread the thermo-start plug (Fig. 10– 56) into its On the rear of the fuel injection pump, connected to
mounting bore in the intake manifold. mechanical linkage (2, Fig. 10– 58).
2. Connect the fuel line to the thermo-start plug.
3. Connect the wiring lead to the thermo-start plug 1
terminal.

MS1690
1. Fuel Injector Pump
2. Fuel-run Solenoid

Figure 10– 58. Cummins engine fuel-run solenoid.

Model 3606 • Origin 10/99 10-57

 Section 10

a. Fuel Run Solenoid Removal 3. Connect the wiring connector at the fuel run solenoid
lead.
1. Disconnect the negative (-) battery cable at the
negative battery terminal (Fig. 10– 59). 4. Connect the negative (-) battery cable to the negative
battery terminal (Fig. 10– 59).
5. Clear personnel and any obstructions from the area
around the vehicle.
6. Start the engine.
7. If the engine starts, the fuel run solenoid is
functioning.
Negative (-)
Terminal 8. If the engine fails to start, the fuel run solenoid may
have a poor ground connection. Visually check the
wiring at the fuel run solenoid leads and/or check for
continuity with a voltmeter as required.
9. Check for fuel and/or oil leakage around the solenoid.

OS1040 10.8.6 Hydraulic Oil Filter Pressure Switch

The hydraulic oil filter pressure switch (Fig. 10– 60) is
Figure 10– 59. Disconnect the negative (-) battery cable threaded into a fitting welded at the top rear of the
at the negative (-) battery terminal.
hydraulic oil reservoir.
2. Disconnect the wiring connector at the fuel run
solenoid lead, then remove the fuel run solenoid from
the fuel injector pump. Pressure Switch

3. For Perkins engines: Use a wrench to remove the Temperature Switch

solenoid.
For Cummins engines: Remove the two bolts
securing the solenoid to the mounting plate. Remove
the nut holding the linkage to the arm on the fuel
injection pump. Save the hardware for later re-use. Sight Glass

b. Fuel Run Solenoid Disassembly

DO NOT disassemble a fuel run solenoid. Replace a
defective fuel run solenoid with a new one.

c. Fuel Run Solenoid Inspection and Replacement

Use a 12-volt DC source and ground to test the solenoid.
Energize the solenoid and watch for the plunger to
retract. If the plunger does not retract, replace the fuel MS1700
run solenoid with a new one.
Figure 10– 60. Location of the hydraulic oil filter
pressure switch, hydraulic temperature switch,
d. Fuel Run Solenoid Installation
and hydraulic oil sight glass.
1. Clean the exterior of the fuel injector pump.
The switch is connected to the wiring harness and to the
2. For Perkins engines: Install a new O-ring on the fuel hydraulic oil temperature switch. When the 25 psi
run solenoid (2, Fig. 10– 57). Install the fuel run (1,7 kPa) hydraulic oil system filter is clogged or
solenoid onto the fuel injector pump (1). Use a restricted and the internal pressure of the filter rises to 25
wrench to install the solenoid. DO NOT overtighten. psi (1,7 kPa), the switch closes and the hydraulic oil filter
restriction indicator illuminates on the operators display
For Cummins engines: Using the hardware removed panel. The vehicle should be stopped and the engine
earlier, install the nut holding the linkage to the arm revved at high idle for five minutes. If the light remains
on the fuel injection pump (2, Fig. 10– 58). Install the illuminated or begins to flicker on and off at high idle, shut
two bolts to secure the solenoid to the mounting down the engine and inspect the hydraulic system.
plate.

10-58 Model 3606 • Origin 10/99

 Electrical System

Examine the fluid in the hydraulic oil sight glass c. Cleaning and Drying
(Fig. 10– 61) to check whether there is a sufficient
DO NOT submerge the hydraulic oil filter pressure switch.
amount of fluid in the system (the oil level should be at
Clean only with an approved solvent and dry with a
the bottom of the sight glass with all hydraulic cylinders
clean, lint-free cloth.
retracted) and whether the fluid is contaminated. Replace
the hydraulic oil filter as required.
d. Inspection and Replacement
Inspect switch wiring for continuity and shorting. Replace
a defective or faulty switch with a new one.

e. Installation and Testing

Sight Glass 1. Thread the hydraulic oil filter pressure switch into its
welded fitting on the hydraulic reservoir. Tighten
securely.
2. Connect the switch wiring connector leads for the
wiring harness and for the hydraulic oil temperature
OS1590
switch.
Figure 10– 61. Examine the fluid in the 3. Connect the negative (-) battery cable to its battery
hydraulic oil sight glass. terminal (Fig. 10– 62).

a. Hydraulic Oil Filter Pressure Switch Removal 4. Clear the area around the vehicle of personnel and
any obstructions to vehicle travel.
1. Disconnect the negative (-) battery cable at the
5. Start the engine, check for hydraulic fluid leaking at
negative battery terminal (Fig. 10– 62).
the hydraulic oil filter pressure switch, and allow the
hydraulic fluid to reach operating temperature.
6. Cycle the boom several times and check whether the
hydraulic oil filter restriction indicator illuminates on
the operators display panel.
Auxiliary
Function 10.8.7 Hydraulic Oil Temperature Switch
Manifold
The hydraulic oil temperature switch (Fig. 10– 60) is
Park Brake threaded into a welded fitting at the top rear of the
Solenoids hydraulic oil reservoir, inboard from the hydraulic oil filter
pressure switch. The hydraulic oil temperature switch is
Negative (-) connected to the hydraulic oil filter pressure switch, and
Terminal through it to the wiring harness and operators display
panel. When the hydraulic oil temperature is above
OS1040
195° F (76° C), the hydraulic oil temperature warning
Figure 10– 62. Disconnect the negative (-) battery cable indicator on the operators display panel illuminates. The
at the negative (-) battery terminal. vehicle should be stopped and the engine allowed to idle
at high idle for five minutes. If the warning indicator con-
tinues to illuminate after five minutes, the engine must be
2. Label and disconnect the hydraulic oil filter pressure shut down to help avoid damage in the hydraulic system.
switch wiring connectors. Examine the fluid in the hydraulic oil sight glass (Fig. 10–
3. Unthread the switch from the hydraulic reservoir. 61) to check whether there is a sufficient amount of fluid
in the system (the oil level should be at the bottom of the
b. Disassembly sight glass with all hydraulic cylinders retracted) and
whether the fluid is contaminated. Replace the hydraulic
DO NOT disassemble the hydraulic oil filter pressure
oil filter as required. Explore other causes for excessive
switch. Replace a defective or faulty switch with a new
temperature, such as high air temperature, plugged oil
one.
cooler or lines, loose fan belt, plugged radiator, etc.

Model 3606 • Origin 10/99 10-59

 Section 10

a. Hydraulic Oil Temperature Switch Removal 10.8.8 Parking Brake Switch

1. Disconnect the negative (-) battery cable at the The parking brake switch (Fig. 10– 63) is located on the
negative battery terminal (Fig. 10– 62). dash to the left of the steering column and is pressed or
2. Label and disconnect the switch wiring connector "snapped" into a rectangular switch bezel. The parking
from the hydraulic oil filter pressure switch lead. brake switch is a two-position toggle switch; the two posi-
tions are engaged and disengaged (Fig. 10– 64). The
3. Unthread the switch from the hydraulic reservoir. parking brake switch must be ENGAGED to permit
engine starting. The parking brake may be used to stop
b. Hydraulic Oil Temperature Switch Disassembly in an EMERGENCY situation; however, notify the opera-
DO NOT disassemble the hydraulic oil temperature tor to use caution as the stop will be abrupt and the oper-
switch. Replace a defective or faulty switch with a new ator and the load may be jolted forward unexpectedly.
one.

c. Hydraulic Oil Temperature Switch

Cleaning and Drying
DO NOT submerge the hydraulic oil temperature switch.
Clean only with an approved solvent and dry with a
clean, lint-free cloth.

d. Hydraulic Oil Temperature Switch Inspection and Parking Brake

Replacement Switch
Inspect switch wiring for continuity and shorting. Replace
a defective or faulty switch with a new one.
OS0402

e. Installation and Testing

Figure 10– 63. Location of various operational controls.
1. Thread the switch (Fig. 10– 60) into its welded fitting
When engaged, the parking brake switch completes the
on the hydraulic reservoir. Tighten securely.
parking brake circuit. The park brake solenoids on the
2. Connect the switch wiring connector lead for the auxiliary function valve (Fig. 10– 62) are normally de-
hydraulic oil pressure switch. energized, allowing the park brake to engage. When the
3. Connect the negative (-) battery cable to its battery park brake solenoids are energized, the park brake is dis-
terminal (Fig. 10– 62). engaged. The system is designed so that, when electri-
cal power is OFF the park brake is engaged.
4. Clear the area around the vehicle of personnel and
any obstructions to vehicle travel.
5. Start the engine, check for hydraulic fluid leaking at P To engage, toggle downward
OS0120
the hydraulic oil temperature switch, and allow the
hydraulic fluid to reach operating temperature. Cycle
the boom several times and check whether the P To disengage, toggle upward
OS1322
hydraulic oil temperature warning indicator
illuminates on the operators display panel. Figure 10– 64. The parking brake switch has two positions,
engaged and disengaged.

10-60 Model 3606 • Origin 10/99

 Electrical System

a. Parking Brake Switch Removal 6. To test for proper parking brake switch
disengagement, firmly depress the service brake
1. Disconnect the negative (-) battery cable at the
pedal, disengage the park lock switch, place the
negative battery terminal (Fig. 10– 62).
travel select lever in either forward or reverse and in
2. Carefully pry the parking brake switch and wiring out first gear, and slowly press the throttle pedal while
of the mounting hole in the switch bezel (Fig. 10– 63). releasing the service brake pedal. The park brake
3. Label and disconnect the wiring from the parking should release and the vehicle should travel freely.
brake switch. Remove the switch from the vehicle. Note: The park brake indicator on the operators display
panel must illuminate when the park brake switch is
b. Parking Brake Switch Disassembly engaged, and not illuminate when the park brake switch
DO NOT disassemble the parking brake switch. Replace is disengaged.
a defective or faulty switch with a new one.
10.8.9 Service Brake Switch
c. Parking Brake Switch The service brake switch (Fig. 10– 66) is located above
Inspection and Replacement the service brake pedal, inserted through a mount hole in
Inspect the switch terminals for continuity and shorting in the cab crossmember weldment and connected to a wir-
both the engaged and disengaged positions. Replace a ing harness lead. A nut threads onto the service brake
defective or faulty switch with a new one. switch to secure it to the crossmember.

d. Parking Brake Switch Installation and Testing

1. Route the wiring from the dash through the bezel,
then connect the wiring to the parking brake switch
as labeled during switch removal.
Service
2. Properly position the "P" on the switch, then press or Brake
"snap" the switch into place in the bezel. Plunger Switch
3. Connect the negative (-) battery cable to its battery Depressed at
terminal (Fig. 10– 65). least 1/4”
(6,35 mm)
4. Clear the area around the vehicle of personnel and
MS1810
any obstructions to vehicle travel.
5. Start the engine, engage the park lock switch, place Figure 10– 66. The service brake switch is located
the travel select lever in FORWARD (F) or REVERSE above the service brake pedal.
(R) and second gear and apply full throttle. The
The service brake switch is a spring-loaded switch that
vehicle should remain motionless in both FORWARD
senses movement along the service brake pedal arm.
and REVERSE positions.
When the brake pedal is pressed and the brake pedal
arm begins to move through its arc, the spring within the
switch allows internal contacts to close an electrical con-
nection. The service brake switch circuit is also spliced
into the park brake and Stabil-TRAK circuits.
Auxiliary
Function Service Brake Switch Replacement
Manifold
If the service brake switch (Fig. 10– 66) is suspect,
remove the switch. Remove the jam nut, then dislodge
Park Brake
Solenoids the switch from the crossmember and unplug the har-
ness connector. Remove the switch from the vehicle and
Negative (-) test the switch for continuity and shorting. Replace a
Terminal defective or faulty switch with a new one.
OS1040
When installing a switch, make sure that the brake pedal
does not actuate the brakes, and that the rubber cap on
Figure 10– 65. Connect the negative (-) battery cable the switch is securely threaded onto the mounting stem.
at the negative (-) battery terminal.
Adjust the jam nut so that the switch plunger is pushed
up into the switch is at least 1/4” (6,35 mm).

Model 3606 • Origin 10/99 10-61

 Section 10

Service Brake Switch Adjustment Gear Select Lever (switch)

The service brake switch may be adjusted as required by The gear select lever (Fig. 10– 68) is part of the transmis-
loosening the jam nut and positioning the switch so that sion shift control switch (travel select lever). The lever has
the brake switch does not activate until the pedal arm a twist-grip handle with four positions, although only
moves a minimum of 1/8” (3,2mm). Tighten the jam nut three may be used, depending on the engine the vehicle
after adjusting the position of the switch in relation to is equipped with and on the direction the transmission
pedal travel. shift lever (gear select lever) has engaged.

10.8.10 Transmission Shift Control Switch

(Travel Select Lever) Gear Select
Lever
The transmission shift control switch (travel select lever) 2
1

3
is located on the left side of the steering column. The
switch has three positions (Fig. 10– 67): FORWARD (F, all
the way up), NEUTRAL (N, center position), and
REVERSE (R, all the way down). The switch or lever
OS0140
must be in the NEUTRAL (N) position to permit engine
starting. Figure 10– 68. The gear select lever permits transmission
gear selection (shifting).
Vehicles equipped with the Perkins naturally aspirated
(non-turbo) engine have three (3) forward gears and
three (3) reverse gears. Placing the gear select lever into
Travel
the fourth position when in forward will have no effect on
Select vehicle speed.
Lever Vehicles equipped with either the Perkins turbo-charged
engine or Cummins turbo-charged engine have four (4)
forward gears and three (3) reverse gears.
First gear is used for the highest torque and pulling
power, and the higher-numbered gears are for increasing
vehicle travel speed.
Refer to Section 4.2.5 Transmission Shift Control Switch
Removal and Transmission Shift Control Switch Installa-
OS0130 tion for removal and installation instructions.
Figure 10– 67. The travel select lever has three positions. Refer to the Owners/Operators Manual for this vehicle for
information on how travel direction and gear select con-
Moving the lever opens and closes electrical contacts in
trol should be indicated on the operators display panel.
the switch, allowing electricity to flow to the appropriate
relays and on to the transmission shift solenoids.
Travel selections are changed by grasping the lever, pull-
ing it toward the steering wheel, then UP or DOWN to the
desired selection, FORWARD (F) or REVERSE (R).
When the switch is shifted to the REVERSE (R) position,
the back-up alarm will automatically sound.
Refer to Section 4.2.5 Transmission Shift Control Switch
Removal and Transmission Shift Control Switch Installa-
tion for removal and installation instructions.

10-62 Model 3606 • Origin 10/99

 Electrical System

10.8.11 Transmission Solenoid Valves a. Transmission Solenoid Valve Removal

The transmission is shifted via spool-type solenoid car- 1. Disconnect the negative (-) battery cable at the
tridge assemblies (Fig. 10– 69) or valves. While each 12- negative battery terminal (Fig. 10– 70).
volt solenoid coil at the transmission is the same, the wir-
ing to the solenoids is different and connected so that the
various transmission clutches can be actuated via input
from the transmission shift control switch (travel select
lever) and gear select switch.

Negative (-)
Terminal

OS1040
10 1
11 2
98 Figure 10– 70. Disconnect the negative (-) battery cable
Reverse 7 3 at the negative (-) battery terminal.
5
Forward 6 2. Remove the cover screws (3, Fig. 10– 69),
5
First Second 4 lockwashers (2) and protective cover (1) secured
Shuttle* MS1720 over the transmission solenoid cartridge valves (7).
(*not on Perkins naturally-aspirated 3-speed)
3. Remove the valve cartridge retainer nut (4) securing
1. Protective Cover 7. Cartridge Valve the 12-volt solenoid coil (6) to the transmission.
2. Lockwasher 8. O-ring 4. Remove the 12-volt solenoid coil (6). An O-ring (5) is
3. Screw 9. O-ring on each side of the 12-volt solenoid coil. Remove
4. Retainer Nut 10. O-ring both O-rings. Always replace used O-rings with new
5. Coil O-ring 11. O-ring O-rings. Label the connections if removing more than
6. Solenoid Coil one solenoid valve.
5. Carefully withdraw the 4-way cartridge valve
Figure 10– 69. Transmission shift solenoids assembly and count to make sure all four O-rings (8,
are easily replaced. 9, 10, and 11) come with it.
So that the solenoids can be properly connected, the Note: Always replace used O-rings with new O-rings.
transmission solenoid valve wiring is identified by color-
coded plastic bands as described in the chart below. 6. Inspect the cartridge valve for nicks, cut O-rings, and
debris or foreign material.
Solenoid Color Code Indicator
2nd Clutch GREEN b. Transmission Solenoid Valve Disassembly
Reverse Clutch BROWN DO NOT further disassemble the transmission solenoid.
Forward Clutch BLUE Replace a defective or faulty unit with a new one.
Shuttle Clutch LIGHT BROWN
c. Transmission Solenoid Valve Inspection, Testing
1st Clutch YELLOW and Replacement
Note: Replacement solenoids will not have colored Inspect the solenoid wiring and connector plug. Test for
bands. continuity and shorting. The solenoid should have 7.5 to
If the transmission is not shifting properly and a faulty or 10 ohms of resistance when testing with an ohm/volt
defective transmission shift solenoid is suspected, meter. Replace a defective or faulty solenoid valve.
remove and test the solenoid. Replace a defective or
faulty unit with a new one.

Model 3606 • Origin 10/99 10-63

 Section 10

d. Transmission Solenoid Valve Installation For further transmission information, refer to Section 7
Transmission and to the Clark-Hurth T 12000 transmis-
1. Carefully install the four-way cartridge valve
sion service manual.
assembly with four new O-rings (8, 9, 10 and 11, Fig.
10– 69) into the transmission. Always replace used O-
rings with new O-rings.
2. Install an O-ring (5) on each side of the 12-volt
solenoid coil (6). Always replace used O-rings with
new O-rings. Install the 12-volt solenoid coil onto the
cartridge valve (7).
Negative (-)
3. Install the valve cartridge retainer nut (4) securing the Terminal
12-volt solenoid coil to the transmission.
4. Install the protective cover (1), lockwashers (2) and
cover screws (3) over the transmission solenoid
valves.
5. Refer to the chart listed earlier under 10.8.11
Transmission Solenoid Valves. Connect the OS1040

transmission solenoid valve(s) with the proper wiring

connector(s). Figure 10– 71. Disconnect the negative (-) battery cable
at the negative (-) battery terminal.
6. Connect the negative (-) battery cable to the negative
battery terminal (Fig. 10– 70).
7. Test the operation of the transmission. Put the
transmission through its entire range of gears
(speeds) in both FORWARD (F) and REVERSE (R)
and check that the transmission also shifts into
NEUTRAL (N).
8. Verify that each function works properly, that the
transmission does not engage when in NEUTRAL
(N) and that the proper indicators illuminate on the
operators display panel.

10-64 Model 3606 • Origin 10/99

 Electrical System

10.8.12 Attachment Tilt Mode Switch d. Attachment Tilt Mode Switch

Installation and Testing
The attachment tilt mode switch (Fig. 10– 72) is located
on the dash to the right of the steering column. 1. Route the wiring through the dash and switch bezel
(Fig. 10– 73), then connect the wiring to the
attachment tilt mode switch as labeled during switch
removal.
138 GRN / BLU
Top of Switch
138A GRN / BLU

137 LT BLU / ORN

139 ORN / GRY

NOTE: 138 and 138A

are double-terminated. 2PP BLK

Attachment Tilt Top of Switch

Mode Switch Attachment
Attachment Tilt Switch Tilt Mode
OS0402 Switch
Right button depressed;
see owners/operators manual display panel symbol
Figure 10– 72. Switch location.
for explanation of operation/functions Attachment Tilt with
The switch is pressed or "snapped" into a rectangular Extend & Retract
switch bezel. The attachment tilt mode switch is a two- MS2470
position switch that allows the operator to chose between
the boom lift/lower function and the extend/retract func- Figure 10– 73. Attachment tilt mode switch wiring
tion accompanying the attachment tilt capability. For and installation position.
detailed information, see 10.8.14 Joystick and the Own- 2. Properly position the "top" of the switch (Fig. 10– 73),
ers/Operators Manual for this vehicle. then press or "snap" the switch into place in the
bezel.
a. Attachment Tilt Mode Switch Removal
3. Connect the negative (-) battery cable to its battery
1. Disconnect the negative (-) battery cable at the terminal (Fig. 10– 71).
negative battery terminal (Fig. 10– 71). 4. Clear the area around the vehicle of personnel and
2. Carefully pry the attachment tilt mode (Fig. 10– 72) any obstructions to vehicle travel.
switch and wiring out of the mounting hole in the 5. Start the engine, and check the operation of the
switch bezel. attachment tilt mode switch functions with the switch
3. Label and disconnect the wiring from the attachment in both positions.
tilt mode switch. Note and mark the "top" of the
switch in relation to the switch wiring terminals, and
remove the switch from the vehicle.

b. Attachment Tilt Mode Switch Disassembly

DO NOT disassemble the attachment tilt mode switch.
Replace a defective or faulty switch with a new one.

c. Attachment Tilt Mode Switch Inspection and

Replacement
Inspect the switch terminals for continuity and shorting in
all three switch positions. Replace a defective or faulty
switch with a new one.

Model 3606 • Origin 10/99 10-65

 Section 10

10.8.13 Joystick
The multi-function joystick (Fig. 10– 74) controls boom
movement, attachment tilt, vehicle frame tilt, and optional
auxiliary hydraulics.
Logic Panel Screw
(one of four)
Multi-function
Joystick

Logic Panel

OS0151

Figure 10– 74. Joystick and logic panel locations.

The joystick is equipped with several momentary
switches (“buttons”) that enable the joystick to operate in
four specific modes. The mode available per selection is
displayed on a logic panel located just forward of the joy-
stick. The logic panel will illuminate an indicator for the
specific mode that corresponds with the movement of the
joystick and the button(s) selected.
Two functions can be accomplished at the same time by
moving the joystick in between quadrants. For example,
moving the stick forward will lower the boom, and moving
the stick to the left will retract the boom; moving the joy-
stick forward and to the left will both lower and retract the
boom at the same time.
The speed of movement relates to the amount of joystick
movement away from the center position. The overall
speed of movement also depends directly on engine rpm.
IMPORTANT: When the joystick is in an off-center posi-
tion, the mode will change immediately upon releasing
any button.
Joystick mode operation can be checked according to the
joystick operation instructions found in the Owners/Oper-
ators Manual for this vehicle. Operational checks will indi-
cate whether the system is working properly. If a
designated function does not occur as described, check
both the electrical and hydraulic circuit involved to deter-
mine the cause.

10-66 Model 3606 • Origin 10/99

 Electrical System

7.5 A

BULKHEAD
TOP TOP
246 FRONT RIGHT LEFT MIDDLE
BUTTON BUTTON BUTTON BUTTON

139 137 COMMON

ORN/GRY LT BLU/ORN BUTTON 43
16 16 GRY/BRN
16
• 12V RED BLUE WHITE GREEN YELLOW
+6 2
2/A 6/A 6/C 6/B 6/D 6/E 6/F 7/A
ATTACH.
TILT HYDRAULIC
MODE JOYSTICK
SWITCH LOGIC
-7
3

2PP
BLK 138
16 GRN/BLU ATUP ATDN LFT LWR EXT RET ATR ATL AUP ADN AXM AXF
16 2/B

G18
7/D 7/E 7/G 7/C 7/F 3/C 7/B
138A
GRN/BLU 40 36 37 38 39 41
16 RED/YEL ORN/GRN WHT/RED LT BLU/WHT DK GRN/RED GRN/WHT
16 16 16 16 16 16

ATTACH.
81 TILT LIFT EXTEND FRAME ATTACH. AUX.
FORE/AFT SOL. SOL. TILT SOL. TILT SOL. HYD. SOL.
TO DASH SOLENOID
INPUT

SUPP. SUPP. SUPP. SUPP. SUPP. SUPP.

DIODE DIODE DIODE DIODE DIODE DIODE

2J 2J 2J 2J 2J 2J 2E
BLK BLK BLK BLK BLK BLK BLK
16 16 16 16 16 16 16

G35 G3 G4 G5 G6 G7 G8

159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174
BOOM FUNCTIONS
MS2520

Figure 10– 75. Logic panel and joystick wiring schematic.

Model 3606 • Origin 10/99 10-67

 Section 10

a. Joystick Button Testing b. Joystick Function Solenoid Valves

1. Remove the four button-head capscrews (Fig. 10– 76) Joystick commands are actuated both electrically and
securing the logic panel to the side console. hydraulically via a set of solenoid-operated control valves
mounted in an array at the pilot select manifold
Button-head (Fig. 10– 78). The pilot select manifold is located inside
Capscrew the rear cover on the left side of the frame.
As the solenoid coils are energized/de-energized, the
cartridge valves work to open and close oil passages
(Fig. 10– 79), thereby directing hydraulic fluid flow to the
proper hydraulic circuit for the function selected.
Logic Panel
SS1210

Figure 10– 76. Logic panel mounting detail.

2. Carefully pry the panel up away from the console and
locate the six-wire connector that comes from the
joystick (Fig. 10– 77).
Six-wire
Connector

Logic Panel

Solenoid Coil
MS2540

Figure 10– 77. Logic panel to joystick wire connector. Cartridge Valve
Pilot Select
3. Inspect the wiring and connector plug for obvious
Manifold MS2440
signs of shorts, damage, etc.
4. Disconnect the harness half. Test only the joystick Figure 10– 78. Pilot select manifold.
half.
5. Using an ohm/volt meter, test for continuity in the
joystick button switches when they are depressed. Solenoid Coil and Cartridge Valve Replacement
The wiring should have zero (0) ohms of resistance If a solenoid coil (Fig. 10– 79) is suspected of malfunc-
when testing with an ohm/volt meter. Using the chart tioning, disconnect the coil wiring lead and test the coil.
below and the wiring schematic in Fig. 10– 75, test Also inspect the valve cartridge, O-rings, and the other
each joystick button switch for proper functioning. hydraulic and electrical components in the circuit to accu-
Joystick Wire Color / Function Chart rately determine the cause of the problem.

YELLOW Common Wire Pilot Select

Manifold
GREEN Middle Button
WHITE Top Left
BLUE Top Right Button
FRONT
RED Front Button
Battery positive (+) is accessed via wire 43, the fused Solenoid Coil
GRY/BRN 16-gauge wire. The ground wire, 2E, is a black
(BLK) 16-gauge wire.
Cartridge Valve
MS2480

Figure 10– 79. Solenoid and cartridge valve detail.

10-68 Model 3606 • Origin 10/99

 Electrical System

10.8.14 Logic Board Panel 10.8.15 Boom Sensor (Proximity Switch)

The logic board or side console panel (Fig. 10–80; see The boom sensor (Fig. 10–81) is a proximity switch
also Fig. 10–76 and Fig. 10–77) is secured to the right located inside the rear cover on the top left of the frame.
side dash panel, in front of the joystick. The panel con- When energized, the sensor creates a magnetic field and
sists of a solid-state printed circuit board and various detects the presence of the boom, as the boom is raised
indicators that illuminate per joystick, attachment tilt, and or lowered past the sensor. Depending on conditions
auxiliary hydraulics selections. (including boom raised above or below 40 degrees, park
or service brakes ON or OFF, Stabil-TRAK engaged or
not, etc.), the boom sensor and its electrical circuitry will
Multi-function
either allow or disallow certain hydraulic functions.
Joystick

Proximity Switch

Logic Panel

OS0151
Sensor-to- Outer
Figure 10–80. Joystick and logic panel locations. Boom Gap
1/4” to 3/8”
The logic board panel is of solid-state, printed circuit (6,4 to 9,5mm)
design and contains a wiring terminal or plug (Fig. 10–76 (see text)
and Fig. 10–77), a printed-circuit board and a display
panel that provides monitoring of joystick, attachment tilt
and auxiliary hydraulics functions and status.
Due to the complex design and solid-state circuitry, the
MS2420
panel is non-serviceable. Electro-static discharge is one
of the main reasons for panel malfunction. Prevent the Figure 10–81. Boom proximity switch location.
panel from coming into contact with static or other electri-
cal sources. When washing the vehicle, keep spray away Boom Sensor Replacement and Adjustment
from the logic board panel. Replace a defective, malfunc- The sensor is easily removed by disconnecting the wire
tioning or faulty panel with a new unit. lead from the wiring harness connector, removing the
The logic board panel provides important information in a sensor mounting nut, and removing the sensor from the
“user-friendly” design with easily-recognizable graphic vehicle.
and arrow indicators. The panel provides information the To install and adjust a boom sensor:
operator needs on joystick, attachment tilt and auxiliary
1. Place the sensor into the mounting bracket as shown
hydraulics functions at any given time.
in Fig. 10–81.
The panel (Fig. 10–76 and Fig. 10–77) is mounted with
2. Adjust the sensor to achieve a 1/4” to 3/8” (6,4 to 9,5
four button-head capscrews and well nuts for easy
mm) gap between the sensor and the boom.
replacement.
3. Connect the wiring harness lead, then tighten the
sensor mounting nut to 36-inch pounds (4 Nm).
4. Operate the boom through its full range of motion;
the boom must NEVER touch the sensor.
5. Check the function of the Stabil-TRAK system as
described in Section 10.8.16 Stabil-TRAK System.

Model 3606 • Origin 10/99 10-69

 Section 10

10.8.16 Stabil-TRAK System With the boom below 40° , the Stabil-TRAK system is in
the free pivot mode and the rear axle is allowed to pivot
The patented Stabil-TRAK system works to stabilize the
freely. The frame sway control will function normally.
vehicle under various conditions. The Owners/Operators
Manual for this vehicle contains basic Stabil-TRAK infor- Locked Mode
mation; a copy of the Owners/Operators Manual should (Fig. 10– 83)
always be in the storage compartment beneath the oper-
With the boom above 40° and by activating one or more
ators seat.
of the following functions listed below, the Stabil-TRAK
The operators display panel Stabil-TRAK indicator (C, system is in the locked mode and the rear axle is locked
Fig. 10– 47, page 10-48) goes ON when the Stabil-TRAK so it is rigid with the frame.
system is activated.
• engaging the parking brake switch
The stabilizing system operates via interface among the
• placing the travel select lever in NEUTRAL (N)
boom proximity switch, the park, service brake and travel
select lever switches, and five solenoid-operated valves • depressing and holding the service brake pedal
on the Stabil-TRAK cylinder manifold. The frame sway control will function slower than normal
The front axle frame tilt cylinder is also involved in the in this mode.
Stabil-TRAK system, but only in a passive role as hydrau-
lic fluid is cycled to accommodate Stabil-TRAK system
operation. Above
40° LOCKED
In general, if there is a problem with the Stabil-TRAK sys- MODE
tem beyond common electrical troubles, the involved
electrical and hydraulic circuits should each be checked
and the exact source of the problem diagnosed before
any parts are replaced. Refer to Section 9 Hydraulic Sys- Stabil-TRAK
tem in this manual for more information. Light
"ON"
The Stabil-TRAK or rear axle lock system can only be
activated when the boom angle is greater than forty OS1481

degrees (40° ). Any one, any two or all three of the follow-
Figure 10– 83. Stabil-TRAK system locked mode.
ing selections will activate the system:
Final Positioning Mode
• Engaging the parking brake switch
(Fig. 10– 84)
• Placing the travel select lever in NEUTRAL (N)
• Depressing and holding the service brake With the boom above 40° , the Stabil-TRAK system is
now in the final positioning mode. In this mode the rear
a. Understanding the Stabil-TRAK system axle is unlocked and is allowed to pivot, but will respond
SLOWLY to changes in terrain.
The following describes the three basic modes of the pat-
The frame sway control function will function normally in
ented Stabil-TRAK system. The vehicle may operate in
this mode.
any one of these three modes.
IMPORTANT: Regularly check that this system is func-
Free Pivot Mode tioning properly. Refer to the Stabil-Trak System Test Pro-
(Fig. 10– 82) cedures.

Below Above
40° SLOW
40°
PIVOT
MODE

FREE
PIVOT Stabil-TRAK
Stabil-TRAK
MODE Light
Light
"OFF" "OFF"

OS0191 OS1491

Figure 10– 82. Stabil-TRAK system free pivot mode. Figure 10– 84. Stabil-TRAK system final positioning mode.

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 Electrical System

Stabil-TRAK System Test Stabil-TRAK System Test Procedures

IMPORTANT: The operator must know that the Stabil- 1. Fasten seat belt and place the vehicle on a level
TRAK system is active and functioning properly. surface with 0° sway, no load on the forks, boom fully
retracted and horizontal. Check to be sure the Stabil-
TRAK light is OFF. See Fig. 10– 47 on page 10-48 for
DANGER: Vehicle tipover can result in death the location of the light in the display panel.
or serious injury. DO NOT use the vehicle if the 2. Locate an 8 inch (203,2 cm) wood or cement block in
Stabil-TRAK system is not functioning properly. front of the left front tire and drive the vehicle up on
the block. Use the frame sway control to level the
vehicle back to 0° .
To test the function of the Stabil-TRAK system, read the
3. With the service brake pedal depressed, the parking
Stabil-TRAK system test instructions and follow steps 1
brake switch OFF, move the travel select lever to the
through 9 of the Stabil-TRAK system test procedure.
NEUTRAL (N) position and raise the boom to exactly
Stabil-TRAK System Test Instructions 60° . The Stabil-TRAK light should come ON when
• Test the Stabil-TRAK system with the vehicle on a the boom angle is at about 40° and remain ON.
level surface. IMPORTANT: Perform steps 4 through 9 with the engine
• Remove any attachment from the quick attach rpm at idle.
before performing the test. 4. While the service brake pedal is depressed, move
• Perform the test with the boom fully retracted. DO the travel select lever to the REVERSE (R) position.
NOT extend the boom at any time during the test. Ease your foot off the service brake pedal and
increase the engine RPM slightly if necessary just
• DO NOT raise the boom above 60° for steps 3
enough to back the vehicle off the block, while
through 6.
keeping the service brake pedal partially depressed
• DO NOT raise the boom above 45° for steps 7 so the Stabil-TRAK light remains ON. The rear axle
through 9. should remain locked while backing off the block and
• Follow steps 1 through 9 of the Stabil-TRAK system the left front tire should remain off the ground.
test procedure exactly as written. 5. While keeping the service brake pedal depressed,
IMPORTANT: If the Stabil-TRAK light goes OFF and the move the travel select lever to the NEUTRAL (N)
front left tire lowers to the ground at any time during steps position and take your foot off the service brake
4 through 7, the test was not performed properly or the pedal. The rear axle should remain locked, the Stabil-
Stabil-TRAK system is not functioning properly. Carefully TRAK light should remain ON, and the left front tire
repeat the steps starting with step 1. If the Stabil-TRAK should remain off the ground.
light goes OFF and the front left tire lowers to the ground 6. With the travel select lever in the NEUTRAL (N)
consistently during steps 4 through 7, the Stabil-TRAK position, engage the parking brake switch and move
system is not functioning properly and the test should be the travel select lever to the FORWARD position. The
stopped immediately. DO NOT use the vehicle if the Sta- rear axle should remain locked, the Stabil-TRAK light
bil-TRAK system is not functioning properly. Repair the should remain ON, and the left front tire should
system immediately. remain off the ground.
7. With the parking brake switch ON, move the travel
select lever to the NEUTRAL (N) position, and lower
WARNING: DO NOT operate this vehicle the boom to exactly 45° . Use the frame sway control
unless you are in the seat with the seat belt fas- to tilt the vehicle no more than 5° to the left and then
tened around you. Death or serious injury could no more than 5° to the right. The vehicle should sway
result if the belt is not securely fastened. slowly to the left and then to the right. The Stabil-
TRAK light should remain ON, and the left front tire
should remain off the ground. The left front tire
should not raise or lower when swaying. Leave the
vehicle swayed to the right 1° to 2° .

Model 3606 • Origin 10/99 10-71

 Section 10

8. Depress the service brake pedal. Disengage the b. Stabil-TRAK Solenoid Valves
parking brake switch and move the travel select lever
There are five Stabil-TRAK solenoid valves (Fig. 10– 85)
to the REVERSE (R) position. Release the service
attached to the Stabil-TRAK cylinder manifold, anchored
brake pedal to deactivate the Stabil-TRAK system
at the left side of the rear axle. Individual solenoid valves
and the Stabil-TRAK light should go OFF. The left
may be replaced as required.
front tire should return to the ground while the vehicle
travels in reverse. Depress the service brake pedal to Stabil-TRAK Solenoid Coil 5
FT
R
stop the vehicle. Manifold
Valve
9. With the service brake pedal depressed, boom angle
(under retainer)
at exactly 45° , move the range select lever to third (3)
and the travel select lever to FORWARD (F). Release
the service brake pedal to deactivate the Stabil-
TRAK system and the Stabil-TRAK light should go Solenoid
OFF. Slowly drive the vehicle forward against the Solenoid Coil 2
block to stop the vehicle from moving forward. With Coil 1
the left front tire against the block, frame sway the
vehicle no more than 5° in both directions (left and
right) while checking that the front tires remain on the
ground. It is normal for the left front tire to raise
slightly when swaying to the left and for the right front
tire to raise slightly when swaying to the right, but the Solenoid Coil 4
tires should immediately lower when the frame sway Solenoid Coil 3 MS1730
function is stopped. The tires should not come
completely off the ground during this step. Frame Figure 10– 85. Stabil-TRAK manifold.
sway the vehicle back to 0° . Depress the service Stabil-TRAK Solenoid Valve Replacement
brake pedal, shift the travel select lever to NEUTRAL
(N) and lower the boom. If a solenoid valve (Fig. 10– 85) is suspected of malfunc-
tioning, disconnect the coil wiring lead and test the coil.
If steps 1 through 9 prove positive, the Stabil-TRAK sys- Also inspect the valve cartridge, O-rings, and the other
tem is functioning properly and the vehicle can be hydraulic and electrical components in the circuit to accu-
returned to service. if any of these steps indicate that the rately determine the cause of the problem.
Stabil-TRAK system is not functioning properly, repair the
system immediately.

10-72 Model 3606 • Origin 10/99

 Electrical System

10.8.17 Steering
Travel and Gear Steering Selection
Certain steering functions are dependent upon electrical Indicators
Select Lever
operations, described below. Consult the Owners/Opera-
tors Manual for further information related to steering.

Four Wheel Steer Indexing Bezel

If the vehicle does not drive “straight,” the steering could

not be synchronized or “out of phase.” Perform the Four Bezel Joystick
Wheel Steer Indexing procedure to synchronize the
steering.
Parking Brake
Four Wheel Steer Indexing Procedure Switch
1. With the steering select switch (Fig. 10– 87) in the Attachment Tilt
four wheel steer position, turn the steering wheel fully Mode Switch
left. OS0402
Steering Select
2. While holding the steering wheel fully left, toggle the Switch
steer select switch to the front wheel steer position.
3. Steer the front wheels back to center. Figure 10– 86. Location of various operational controls.

4. Toggle the steer select switch back to four wheel

steer position. STEERING
FOUR SELECTION
5. Turn the steering wheel fully left.
WHEEL INDICATORS
6. Toggle the steering select switch back to the front STEERING
wheel steering position.
7. Steer the front wheels fully left.
FRONT
8. Toggle the switch to the four wheel steer position and WHEEL
return to center. STEERING
The vehicle should now be properly indexed in four wheel
steering. If the steering is still not synchronized, repeat
the procedure. CRAB STEERING OS1411
STEERING SELECT
a. Steering Select Switch
SWITCH
The steering select switch (Fig. 10– 86 and Fig. 10– 87) is Figure 10– 87. Steering select switch.
located on the right console to the rear of the joystick
below the armrest. It is a three-position switch that is This three-position switch is a single-pole, double throw
pressed or “snapped” into a rectangular switch bezel. toggle switch that has three positions (Fig. 10– 87 and
Fig. 10– 88). It has a multiple-connector plug on its under-
side that connects to the cab wiring harness. Wiring from
the plug connects the switch with power from the fuse
panel bus bar, and to the operators display panel and the
steering select solenoids on the vehicle.

Model 3606 • Origin 10/99 10-73

 Section 10

• Two-wheel steer mode: (Fig. 10– 90) With the steering

FOUR FRONT select switch in the centered position, the following condi-
WHEEL WHEEL CRAB tions must be met:
STEERING STEERING STEERING

OS0290

Figure 10– 90. Two wheel steering.

1. Front-wheel steer mode light (only) must be
OS0640 illuminated on the operators display panel
Figure 10– 88. The steer select switch has three positions. (Fig. 10– 86).
2. Front wheels must steer in the direction that the
Steering select indicators on the right side of the opera-
steering wheel is turned.
tors display panel illuminate per the switch selected
mode, and the steering select solenoids are energized or 3. Rear wheels must remain in a fixed forward position
de-energized accordingly to provide the type of steering and not move.
selected. The switch allows four-wheel steering (the rear • Crab-steer mode: (Fig. 10– 91) With the steering select
wheels turn opposite the front wheels), two-wheel steer- switch in the rear most position, the following conditions
ing (the front wheels only), or crab steering (the rear must be met:
wheels turn in the same direction as the front wheels).

b. Steering modes and conditions:

• Four-wheel steer mode: (Fig. 10– 89) With the steering
select switch in the forward most position, the following
conditions must be met:
OS0310
1. Four-wheel steer mode light (only) must be
illuminated on the operators display panel Figure 10– 91. Crab steering.
(Fig. 10– 86).
1. Crab-steer mode light (only) must be illuminated on
the operators display panel (Fig. 10– 86).
2. Front wheels must steer in the direction that the
steering wheel is turned.
3. Rear wheels must steer in the direction that the
steering wheel is turned.

OS0280

Figure 10– 89. Four wheel steering.

2. Front wheels must steer in the direction that the
steering wheel is turned.
3. Rear wheels must steer in the opposite direction from
which the steering wheel is turned.

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 Electrical System

c. Steering Select Switch Removal e. Steering Select Switch Installation and Testing
1. Disconnect the negative (-) battery cable at the 1. Route the wiring through the dash and switch bezel,
negative battery terminal (Fig. 10– 92). then connect the wiring (Fig. 10– 94) to the switch as
labeled during switch removal (the eight-pin
connector only goes on one way).
2. Properly position the “front” and top of the switch as
noted during removal, then press or “snap” the switch
into place in the bezel.

53 DK BLU / ORG 2F BLK

Negative (-)
Terminal 18 GRY / GRN
Top of Switch
18A GRY / GRN

19 YEL / BLK
19A YEL / BLK
17 PNK / WHT
NOTE: 18 and 18A, plus 19 and 19A
are double-terminated.
OS1040
Top of Switch
Steering
Select
Figure 10– 92. The negative (-) battery terminal. Steering Select Switch Switch
Set for Front Wheel Steering;
1. Carefully pry the switch (Fig. 10– 93) and wiring out of see owners/operators manual display panel symbol
the mounting hole in the switch bezel. for explanation of operation/functions Steering
Modes
STEERING
FOUR SELECTION MS2490
WHEEL INDICATORS Figure 10– 94. Steering select switch wiring
STEERING and installation position.
3. Connect the negative (-) battery cable to its battery
FRONT terminal (Fig. 10– 92).
WHEEL 4. Clear the area around the vehicle of personnel and
STEERING any obstructions to vehicle travel.
5. Start the engine, and check the operation of the
steering select switch functions with the switch in all
CRAB STEERING three positions.
OS1411
STEERING SELECT
SWITCH
Figure 10– 93. Steering select switch.
2. Label and disconnect the wiring from the switch. Note
and mark the "front" or top of the switch in relation to
the switch wiring terminals, and remove the switch
from the vehicle.

d. Steering Select Switch Disassembly,

Inspection and Replacement
DO NOT disassemble the switch. Replace a defective or
faulty switch with a new one. Inspect the switch and the
wiring harness connector terminals for continuity and
shorting in all three switch positions. Inspect the switch
terminals for continuity in the "up" and "down" positions
and for shorting in the "middle" position. Replace a
defective or faulty switch with a new one.

Model 3606 • Origin 10/99 10-75

 Section 10

10.8.18 Steer Select Valve

The steer select valve (Fig. 10– 95), is secured to the 1
steer select manifold and frame with four capscrews and
O-rings near the hydraulic fluid reservoir.
It contains two solenoids that direct hydraulic fluid
through hoses and ultimately help operate the steering. 8
The valve is a direct dual-solenoid operated, spool-type
directional control valve. The steer select valve controls
the start, stop and direction of hydraulic fluid flow to the
steering cylinders mounted on each axle.The valve con- 4
sists of a housing (2, Fig. 10– 96), two solenoids (3), a 3
3 2
control spool (4), and two return springs (5). 7 5 6 7
6 5
In the de-energized state, the spool (4) is held by the
return springs (5) in the center position. The spool is
shifted through the action of the two wet-pin type
solenoids (3).
The force of an acting solenoid works against the push
MS2060
pin (6) on the end of the spool (4). The spool is shifted
from its normal position to the end position for selected 1. O-rings 5. Return Springs
flow. The selected flow pattern is covered in Section 9 2. Housing 6. Push Pin
Hydraulic System. 3. Solenoids (2) 7. Manual Override
4. Control Spool 8. Solenoid-operated Valve
Steer Select
Solenoid Valve Figure 10– 96. Steer select valve detail.
When the solenoid is de-energized, the control spool (4,
Fig. 10– 96) is returned to its normal condition by the cen-
Capscrew tering springs (5).
Check the steer select valve solenoids for proper opera-
tion and check the wiring for continuity or shorts. When
Capscrew energized/de-energized, the solenoid should move and/
or an audible “click” should be heard; check for the pres-
Hydraulic Hose ence of voltage with a voltmeter. Replace a defective or
faulty steer select valve with a new unit. Refer to Section
10.9 Electrical System Troubleshooting.

MS1740

Figure 10– 95. Steer select valve location and mounting.

10-76 Model 3606 • Origin 10/99

 Electrical System

10.8.19 Engine Low Oil Pressure Sender

The engine oil pressure sender is located on the engine PERKINS ENGINE
block (Cummins, Fig. 10– 97, and Perkins, Fig. 10– 98)
and is connected via the engine wiring harness, bulk- Engine Oil
head connector and cab wiring harness to the operators Pressure Sender
display panel (Fig. 10– 99).

CUMMINS ENGINE

Transmission
Temperature
Sender

Engine Oil
Pressure Sender

MS1770

Figure 10– 98. Perkins engine/transmission senders.

The operators display panel indicator (E, Fig. 10– 99) illu-
minates when engine oil pressure is too low to properly
lubricate the engine. The warning indicator illuminates
when oil pressure is below 8.7 psi (0,6 bar) and an audi-
ble alarm will also sound. When the engine has attained
normal oil pressure, the sender opens and the operators
Transmission display panel indicator and alarm turn OFF.
Temperature Sender
B C

A D

1 2 3 4

F
D N
R

OS0531
E F G H
Figure 10– 99. Operators display panel indicators.

MS1760 a. Engine Oil Pressure Sender Removal

Figure 10– 97. Cummins engine/transmission senders. 1. Disconnect the negative (-) battery cable at the
negative battery terminal (Fig. 10– 100).
2. Unplug the wiring harness connector from the
sender.
3. The sender is threaded into the engine block.
Remove the sender.

Model 3606 • Origin 10/99 10-77

 Section 10

c. Engine Oil Pressure Sender Inspection and

Replacement
Inspect the sender and the wiring harness connector ter-
minals for continuity. Replace a defective or faulty sender
with a new one.

d. Engine Oil Pressure Sender Installation and

Negative (-) Testing
Terminal
1. Thread the sender (Cummins, Fig. 10– 101 or
Perkins, Fig. 10– 98) into the engine block snugly,
then connect the wiring harness connector lead to
the sender.
2. Connect the negative (-) battery cable to its battery
OS1040
terminal (Fig. 10– 100).
3. Start the engine, allow it to reach operating
Figure 10– 100. Disconnect the negative (-) battery cable temperature, and observe the operators display
at the negative (-) battery terminal. panel for sender indication. If the sender is not
defective, the problem could be elsewhere; possibly
b. Engine Oil Pressure Sender Disassembly in a shorted wire, improper-running engine, defective
DO NOT disassemble the sender. Replace a defective or display, etc.
faulty sender with a new one.

10-78 Model 3606 • Origin 10/99

 Electrical System

10.8.20 Transmission High Temperature Sender 10.8.21 Engine Coolant

The transmission high temperature sender (Cummins,
High Temperature Sender
Fig. 10– 101 or Perkins, Fig. 10– 98) is threaded into the The engine coolant high temperature sender (Cummins,
transmission housing and is connected via the engine Fig. 10– 101 or Perkins, Fig. 10– 98) is threaded into the
wiring harness, bulkhead connector and cab wiring har- engine block and is connected via the engine wiring har-
ness to the operators display panel (Fig. 10– 99). ness, bulkhead connector and cab wiring harness to the
When the transmission fluid temperature rises above operators display panel.
250° F (107° C), the sender heats up, closing contacts CUMMINS ENGINE Engine Coolant
within the sending unit. The operators display panel indi- Temperature Sender
cator (C, Fig. 10– 99) illuminates and an audible alarm will
sound. When the transmission temperature is below 250°
F (107° C), the contacts within the sending unit open and
the operators display panel indicator and alarm turn OFF.

a. Transmission High Temperature Sender Removal Transmission

1. Disconnect the negative (-) battery cable at the Temperature Sender
negative battery terminal (Fig. 10– 100).
2. Unplug the wiring harness connector from the sender
(Cummins, Fig. 10– 101 or Perkins, Fig. 10– 98).
3. The sender is threaded into the transmission housing
or case. Remove the sender.

b. Transmission High Temperature Sender

Disassembly
DO NOT disassemble the sender. Replace a defective or
faulty sender with a new one.
MS1760

c. Transmission High Temperature Sender Figure 10– 101. Cummins engine/transmission senders.
Inspection and Replacement
When the engine coolant temperature exceeds normal
Inspect the sender and the wiring harness connector ter- limits and rises above 210° F (85° C), the sender heats
minals for continuity. Replace a defective or faulty sender up, closing contacts within the sending unit. The opera-
with a new one. tors display panel indicator (B, Fig. 10– 103) illuminates
and an audible alarm will sound. When the engine cool-
d. Transmission High Temperature Sender ant temperature is below 210° F (85° C), the contacts
Installation and Testing within the sending unit open and the operators display
1. Thread the sender (Cummins, Fig. 10– 101 or panel indicator and alarm turn OFF.
Perkins, Fig. 10– 98) into the transmission housing
snugly, then connect the wiring harness connector
lead to the sender.
2. Connect the negative (-) battery cable to its battery
terminal (Fig. 10– 100).
3. Start the engine, allow all systems to reach operating
temperature, and observe the operators display
panel for sender indication. If the sender is not
defective, the problem could be elsewhere; possibly
in a shorted wire, clogged or defective transmission
cooler, defective display, etc.

Model 3606 • Origin 10/99 10-79

 Section 10

PERKINS ENGINE

Engine Coolant
Temperature Sender

Negative (-)
Terminal

Transmission
Temperature
Sender OS1040

Figure 10– 104. Disconnect the negative (-) battery cable

at the negative (-) battery terminal.

c. Engine Coolant High Temperature Sender

Inspection and Replacement
Inspect the sender and the wiring harness connector ter-
MS1770 minals for continuity. Replace a defective or faulty sender
with a new one.
Figure 10– 102. Perkins engine/transmission senders.

d. Engine Coolant High Temperature Sender

B C Installation and Testing
1. Thread the sender (Fig. 10– 101 or 10– 102) into the
A D
engine block snugly, then connect the wiring harness
1 2 3 4 connector lead to the sender.
F 2. Connect the negative (-) battery cable to the negative
D N (-) battery terminal (Fig. 10– 104).
R
3. Start the engine, allow it to reach operating
OS0531
temperature, and observe the operators display
E F G H panel for sender indication. If the sender is not
defective, the problem could be elsewhere; possibly
Figure 10– 103. Operators display panel indicators.
in a shorted wire, improper-running engine, improper
coolant, obstructed or faulty radiator, water pump,
a. Engine Coolant High Temperature Sender
loose fan belt, defective display etc.
Removal
1. Disconnect the negative (-) battery cable at the
negative battery terminal (Fig. 10– 104).
2. Unplug the wiring harness connector from the sender
(Fig. 10– 101 or 10– 102).
3. The sender is threaded into the engine block.
Remove the sender.

b. Engine Coolant High Temperature Sender

Disassembly
DO NOT disassemble the sender. Replace a defective or
faulty sender with a new one.

10-80 Model 3606 • Origin 10/99

 Electrical System

10.8.22 Engine Block Heater (option) 10.8.23 Fuel Level Indicator

Some engines are equipped with an optional engine
and Fuel Level Sender
block heater (Fig. 10– 105) that can be plugged into a The fuel level indicators on the left side of the operators
standard 110/120V ac grounded outlet to heat the engine display panel (Fig. 10– 106) work in conjunction with the
coolant. When temperatures are below 10° F (-12° C), fuel level sender (Fig. 10– 107, next page).
the block heater should be used. The submerged, coil-type fuel sender is secured to the
fuel tank beneath the cab and is connected via the
CUMMINS ENGINE engine wiring harness, bulkhead connector and cab wir-
ing harness to the operators display panel.
Fasten Seat Belt
Fuel Level Read
Indicator B Gear Select
Manual
Bars Indicators

A C
1 2 3 4

F
N
R

Fuel D
Indicator Travel Select
Engine Block Symbol Indicators
Heater OS0211

Figure 10– 106. Operators display panel indicators.

PERKINS ENGINE The operators display panel fuel level indicator bars on
the left of the operators display panel illuminate to show
Engine Block
the approximate fuel level in 1/4 tank increments. The
Heater
fuel level indicator bars will be illuminated with a low-light
green hue, easily apparent for night visibility and in low-
light conditions. When approximately 1/8 tank is reached,
the last fuel level indicator bar will stop illuminating, and
the fuel level indicator symbol will change from green to
orange. When the fuel level indicator symbol changes
from green to orange, refuel the tank.

The fuel level sender wiring harness connector can be

accessed from beneath the cab without removing the
cab. The cab must be removed to access the fuel tank
and fuel sender. See Section 4 Cab, Covers and Mirrors
in this manual for cab and fuel tank removal instructions.
MS2500

Figure 10– 105. Some engines are equipped with an

optional engine block heater.
For further information, consult the appropriate engine
manual or the nearest engine distributor.

Model 3606 • Origin 10/99 10-81

 Section 10

The fuel level sender (Fig. 10– 107) consists of a resis- a. Fuel Level Indicator Testing
tance, float-type fuel level sender mounted in the top of
1. With approximately eight gallons (30,4 liters) of fuel
the fuel tank, and the wiring connecting it with the fuel
in the fuel tank (Fig. 10– 107), the bottom fuel level
indicators in the operators display panel.
indicator bar should illuminate, indicating
approximately 1/4 tank of fuel.
2. The fuel level sender wiring harness connector can
Fuel Level
be accessed from beneath the cab without removing
Sender the cab. Beneath the cab, disconnect the fuel level
sender wiring harness connector. Connect a jumper
wire across the two wires in the harness connector.
Fuel Tank 3. From the operators position, turn the ignition key
switch to the RUN position (Fig. 10– 108). DO NOT
start the engine. Observe the fuel level indicator bars
on the operators display panel. The reading must be
Vehicle Frame (ref.) at the FULL mark, with all four bars illuminated after
the engine start-up bulb test is completed.
OFF RUN

PREHEAT

START

MS1790

OF0390
Figure 10– 107. Fuel level sender.
Figure 10– 108. Ignition key switch positions.
The resistance of the fuel sender is 33.5 ohms for a full
tank of fuel and 240 ohms for an empty tank. The fuel 4. Turn the ignition key switch to the OFF position. The
level indicator bars in the operators display panel receive bars should turn OFF.
a signal sensed within the electronic circuitry of the oper- The cab must be partially removed to access the fuel
ators display panel. Examine the fuel level sender circuit tank and fuel sender. See Section 4 Cab, Covers and
in the appropriate wiring diagram and schematic earlier Mirrors in this manual for cab and fuel tank removal
in this section. instructions.
Battery voltage is applied to the circuit and the circuit
divides at the fuel level indicator bars. One path contin- b. Fuel Level Circuit Tests
ues to ground through the operators display panel and
If the fuel level indicators are suspected of giving a false
fuel level indicator connector plug. Another electrical path
reading, perform the following checks:
goes to ground through the variable resistor of the fuel
level sender. 1. Check for loose or defective wiring, faulty ground
connections, and corrosion on the fuel tank sender
When the fuel level reaches approximately 1/8 of a tank,
and wiring lead.
the resistance of the sender increases. This in turn
changes the operators display panel, causing the green 2. If the fuel level indicator bars do not illuminate after
fuel level indicator bars to turn OFF, and resulting in the the engine start-up bulb test is completed and when
orange fuel indicator symbol (shaped like a standard fuel the ignition key switch is turned to the RUN position,
pump) to turn ON. use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level
When the tank is more than 1/8 full, the sender resis-
indicator wiring connector behind the operators
tance is lower. On the operators display panel, the green
display panel (the panel can be unfastened and
fuel level indicator bars illuminate according to the
raised slightly to do this).
amount of resistance supplied.
3. If the fuel level indicator bars do not illuminate, check
the fuel tank for fuel.

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 Electrical System

4. If the fuel level indicators do not illuminate, and a Hourmeter

faulty or defective fuel sender in the fuel tank has
been ruled out, and wiring and connectors have been
checked and ruled out, the operators display panel is
defective and must be replaced in its entirety.
5. Check that the ignition terminal has current, and that
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
wiring at the operators display panel, fuse and relay
panel, ignition key switch, and from the fuel sender
OS0750
on the fuel tank through the wiring in the cab. Figure 10– 109. The hourmeter is located on
7. Check the fuel level sender. The resistance of the the left outside edge of the dash console.
fuel sender is 33.5 ohms for a full tank of fuel and
240 ohms for an empty tank. A defective fuel level a. Hourmeter Removal
sender in the fuel tank may also prevent the fuel level Note: For vehicles with the optional closed cab, the front
indicator bars from illuminating. console must be removed (see Section 4 Cab, Covers
Excessive fuel level indicator bar “fluctuation” may be and Mirrors) to access the hourmeter.
caused by loose wire connections or a defective fuel
1. Disconnect the negative (-) battery cable at the
sender in the fuel tank.
battery (Fig. 10– 110).
A full tank reading at all times may occur if the wiring to
2. Remove the two screws securing the hourmeter to
the fuel sender in the tank is broken, if the sender is not
the dash console (Fig. 10– 109). Gently begin
properly grounded, or if the sender is defective.
removing the hourmeter from the dashboard until the
If the fuel level indicator bars indicate inaccurately, the two wires are visible. Note or label the wires
fuel sender in the tank may be defective or there may be respective of their colors and locations. Disconnect
low voltage at the fuel level indicator connector to the (unplug) both wire terminals at the rear of the
operators display panel. hourmeter.
If the fuel level indicator bars fluctuate when other electri-
cal items are used, there may be a defective, corroded or b. Hourmeter Installation
improper ground. Check the cab harness ground stud 1. Attach both wire terminals at the rear of the meter.
under the dash, the engine to chassis ground, and the The black wire attaches to the forward terminal; the
negative (-) battery cable and ground stud cable near the green wire attaches to the rear terminal.
hydraulic reservoir fill cap under the engine cover.
2. Insert the meter into the opening in the left side of the
The cab must be partially removed to access the fuel dash console (Fig. 10– 109). Secure with two screws.
tank. See Section 4 Cab, Covers and Mirrors in this man-
ual for cab and fuel tank removal instructions. 3. Reconnect the negative (-) battery cable (Fig. 10–
110). Start the engine. Observe the hourmeter for
function with the engine running to verify operation.
10.8.24 Hourmeter
Time the hourmeter for six minutes to verify that a
The hourmeter (Fig. 10– 109) is a non-repairable instru- tenth of an hour has been recorded.
ment that records hours of vehicle engine operation in
tenth of an hour increments and is located on the left out-
side edge of the dash console. The hourmeter is an ana-
log device, similar to an odometer, and will display
99,999.9 hours before resetting to zero.If trouble is sus-
pected, time the hourmeter for six minutes to verify that a Negative (-)
tenth of an hour has been recorded. The meter is Terminal
secured to the dashboard with two screws; there are two
wires at the rear of the meter; one is connected to a sen-
sor on the engine, the other provides grounding.

OS1040

Figure 10– 110. The negative (-) battery terminal.

Model 3606 • Origin 10/99 10-83

 Section 10

10.9 ELECTRICAL SYSTEM This section provides an easy reference guide covering
TROUBLESHOOTING the most common problems that occur in the electrical
system.
Electrical System Troubleshooting

Problem Possible Cause Remedy

1. HORN doesn’t sound when 1. No voltage at horn; broken wire or 1. Replace wiring and fuse as
horn button is pressed. blown fuse. required.
2. Corroded electrical ground at horn 2. Repair electrical ground.
mounting.
3. Loose or broken wiring. 3. Repair or replace wiring.
4. Defective horn switch. 4. Test horn switch for continuity
with horn button pressed; replace
switch if open.
5. Defective horn. 5. Remove horn from vehicle and
test horn using short, heavy-
gauge wires connected to a
fused or otherwise protected 6-
amp, 12-volt DC power supply
2. Horn sounds continuously 1. Stuck horn button. 1. Free horn button; inspect and
although horn button is not eliminate cause of sticking.
being pressed. 2. Defective horn switch 2. Test horn switch for continuity
without pressing horn button;
replace switch if closed.
3. Short circuit in wiring. 3. Determine and repair cause of
short circuit
3. BACKUP ALARM doesn't 1. No voltage at backup alarm; 1. Check for voltage at backup
sound with travel select broken wire. alarm wire leads; determine and
lever in REVERSE (R). repair cause of broken wiring as
required.
2. Short circuit in wiring. 2. Determine and repair cause of
short circuit.
3. Defective travel select switch. 3. Test travel select switch for
continuity; replace as required.
4. Backup alarm sounds with 1. Short circuit in wiring. 1. Determine and repair cause of
travel select lever in short circuit.
NEUTRAL (N) and/or 2. Defective travel select switch. 2. Test travel select switch for
FORWARD (F). continuity; replace as required.
5. OPERATORS DISPLAY 1. No voltage at panel; loose or 1. Replace wiring and fuse as
PANEL warning indicator broken wiring or blown fuse. required.
lights do not illuminate. 2. Defective operators display panel. 2. Replace operators display panel.
• During lamp test?
• During operation?
6. Operators display panel 1. Short circuit in wiring. 1. Determine and repair the cause
indicators illuminate contin- of the short circuit.
uously with ignition key 2. Defective operators display panel 2. Replace operators display panel
switch in the RUN position
(after lamp test).

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 Electrical System

Electrical System Troubleshooting

Problem Possible Cause Remedy

7. LOSS OF ELECTRICAL 1. No voltage at these circuits, 1. Repair wiring, switch and fuse as
POWER for some but not all caused by a broken wire or switch, required.
vehicle operations. or a blown fuse.
8. FUSE continuously blows. 1. Check the system for shorts, loose 1. Repair or replace as required.
grounds, defective or corroded
electrical components.
9. Overheating and burnout of 1. Incorrect fuse for circuit or fuse is 1. Use correct fuse. Correct the
wiring and electrical com- bypassed with a jumper. cause of the overload and
ponents. IMPORTANT: NEVER connect a replace damaged wiring,
jumper between fuse terminals with- components and fuses as
out providing an equivalent protective required.
device in the jumper.
10. Starting System/GENERAL 1. Transmission is in FORWARD (F) 1. Shift travel select lever into
or REVERSE (R). NEUTRAL (N).
Engine will not crank and 2. Battery is discharged. 2. Check battery and charge or
starter relay or starter sole- replace battery.
noid does not engage.
3. Inoperative ignition switch, relay or 3. Check circuitry and repair or
Note: Refer to the Perkins or solenoid. replace faulty components.
Cummins engine troubleshooting
information in Section 8A or 4. Starting circuit is open or has high 4. Check circuit connections and
Section 8B. resistance. repair or replace faulty wiring.
5. Neutral relay is open or shorted. 5. Check and replace as necessary.
11. Starter relay closes and 1. Battery is discharged. 1. Check battery and charge or
solenoid engages but replace.
engine will not crank. 2. Defective starter motor 2. Check, clean and tighten
connections or loose battery connections.
connections.
3. Starter motor is faulty. 3. Inspect, repair or replace.
4. Relay or solenoid contacts are 4. Replace relay or solenoid.
burned.
5. Engine is seized, crankshaft 5. Repair or replace engine or
cannot rotate. transmission as required.
12. Starting motor turns but 1. Defective starter solenoid or 1. Inspect and repair or replace.
does not crank engine. pinion.
2. Defective solenoid or pinion drive. 2. Inspect and repair or replace.
3. Defective flywheel ring gear. 3. Inspect and replace.
13. Engine cranks slowly. 1. Battery output is low. 1. Check battery and charge or
replace.
2. Excessive resistance in the 2. Check circuit connections and
starting circuit. repair or replace faulty wiring.
3. Defective starter motor. 3. Inspect and repair or renew.

Model 3606 • Origin 10/99 10-85

 Section 10

Electrical System Troubleshooting

Problem Possible Cause Remedy

14. Engine turns over but does 1. Fuel tank is empty. 1. Fill fuel tank.
not start. 2. Faulty injection pump or fuel run 2. Test for fuel at injection pump.
Note: Refer to the Perkins or solenoid. Test the electrical circuit and the
Cummins engine trouble- solenoid. Check that 12 volts are
shooting information in present at the fuel run solenoid.
Section 8A or Section 8B. Check wiring for defects and
repair as required.
15. Starter doesn't operate or 1. Discharged battery. 1. See corrections for problem of
doesn't operate correctly. discharged battery.
2. Bad connections, wires, cables or 2. See troubleshooting the starting
other components in the start system/GENERAL.
circuit.
3. Wrong engine oil (viscosity too 3. Refer to appropriate engine
thick) for cold weather operation. section and see lubrication
instructions in Section 2 General
Information, Specifications and
Maintenance of this manual.
4. Worn teeth on the starter drive 4. Remove the starter to check the
pinion or the flywheel ring gear. teeth. Repair or replace as
necessary.
5. Starter fasteners are loose. 5. Tighten the fasteners.
16. STARTER MOTOR RELAY 1. Starter relay is not energized due 1. Replace wiring or fuse.
No voltage at the starter to broken wiring or a blown fuse.
solenoid when the ignition
key switch is in the START
position.
17. Starter operates continu- 1. Starter relay is stuck in the closed 1. Replace the starter relay.
ously without ignition key position.
switch in the START posi-
tion.
18. THERMO-START 1. Discharged battery. 1. Charge battery only if electrolyte
Intake manifold remains is not frozen. If electrolyte is
cold after ignition key frozen, remove the battery from
switch is momentarily the vehicle, completely thaw it
turned to the PREHEAT and then attempt to charge the
position. battery.
2. Broken wiring or blown fuse. 2. Replace switch, wiring or fuse.
3. Loose connections. 3. Tighten connections.
4. Clogged or bent fuel line to the 4. Clean or replace the fuel line.
thermo-start plug.
5. Defective thermo-start plug. 5. Replace the thermo-start plug.
6. Defective ignition switch. 6. Remove and test the ignition key
switch in all positions. Replace a
faulty switch.

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 Electrical System

Electrical System Troubleshooting

Problem Possible Cause Remedy

19. Intake manifold remains 1. Thermo-start plug is ON 1. Remove and test the ignition key
abnormally hot during continuously due to a defective switch in all positions. Replace a
normal engine operation. ignition switch or a short circuit in defective switch.
the wiring.
2. Thermo-start plug leaks fuel into 2. Replace thermo-start plug.
intake manifold.
20. Charging System/GENERAL 1. Check for loose or corroded 1. Repair as required.
VISUAL CHECK connections.
2. Check the condition and 2. Install a new belt if necessary.
adjustment of the alternator belt.
3. Check the condition of the battery. 3. Refer to Section 10.7.2 Battery.
21. ALTERNATOR 1. Damaged or worn drive belt. 1. Install new drive belt.
Noisy Alternator. 2. Worn alternator bearings or shaft. 2. Install new alternator.
22. BATTERY 1. Damaged or defective battery. 1. Test battery; refer to Section
Battery doesn't perform sat- 10.7.2 Battery.
isfactorily.
23. Discharged battery. 1. Short circuit in battery cell(s). 1. Conduct battery load test.
2. Loose or dirty battery cable 2. Clean and tighten connections.
connections.
3. Electrical draw on battery. 3. Test and correct draw on battery.
4. Dirty battery top. 4. Clean the top of the battery.
5. Low output or no output from 5. Test the alternator.
alternator.
6. High resistance in the positive (+) 6. Check the positive cable.
battery cable.
7. High resistance in the negative (-) 7. Check the negative cable.
battery cable.
24. Switches and Solenoids 1. Sticky, dirty, or bent key. 1. Clean, remove sticky substance
IGNITION KEY SWITCH or dirt, burrs, etc. from key and
Key binds in switch. sprinkle powdered graphite on
key. Insert, turn and withdraw
several times from ignition switch.
IMPORTANT: Use only graphite or a
liquid lock deicer within the lock.
25. Key cannot enter switch or 1. Defective switch. 1. Replace the switch.
be turned once inside. 2. Ice has formed in switch. 2. Warm the switch with warm air or
use liquid lock deicer to thaw the
lock.
26. Ignition switch fails to func- 1. Loose or broken wiring or blown 1. Replace wiring and fuse.
tion in one or more posi- fuse.
tions. 2. Trouble in the starting circuit. 2. Refer to starting circuit
troubleshooting.
3. Defective ignition key switch. 3. Test and repair or replace the
ignition key switch.

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 Section 10

Electrical System Troubleshooting

Problem Possible Cause Remedy

27. With key in the START posi- 1. Travel select lever is in forward (F) 1. Move the travel select lever to
tion, engine does not crank. or reverse (R). NEUTRAL (N).
28. Engine runs momentarily 1. Defective fuel run solenoid. 1. Refer to Step 30, Fuel Run
then stops. Solenoid troubleshooting.
Note: Refer to the Perkins or 2. Fuel tank is empty. 2. Fill fuel tank.
Cummins engine trouble- 3. Defective fuel injection pump. 3. Check that pump operates
shooting information in properly per the appropriate
Section 8A or Section 8B. engine section of this manual.
4. Clogged or dirty fuel filter. 4. Replace fuel filter.
5. Excessive water in fuel. 5. Drain water separator or replace
water filter.
29. NEUTRAL START SWITCH 1. Check for problems in the 1. Check the transmission shift
Starter fails to crank engine transmission shift switch or wiring. switch wiring and fuse.
with travel select lever in 2. Check transmission shift switch for 2. Replace a defective switch or
NEUTRAL (N), parking proper operation, continuity, relay.
brake switch engaged and shorts, etc.
ignition key switch in
START position.
30. FUEL RUN SOLENOID 1. Fuel run solenoid. 1. Test for voltage at fuel run
Ignition switch cranks solenoid with ignition key switch
engine in START position in RUN position.
but engine doesn't operate 2. Fuel tank is empty. 2. Fill fuel tank.
when key returns to RUN
position. 3. Defective injection pump. 3. Replace pump. See the
appropriate engine
troubleshooting section.
31. PARKING BRAKE SWITCH 1. Blown fuse. 1. Replace fuse.
When switched to disen- 2. Defective park brake solenoid. 2. Test solenoids and circuits; test
gaged position, park brake for continuity with park brake
switch fails to disengage switch in both positions; check
park brake. park brake solenoid operation.
Repair circuits or replace switch
and/or solenoids as required.
3. Defective park brake switch. 3. Replace.
4. Hydraulic problem. 4. Refer to Section 9 Hydraulic
System.
32. BACK-UP ALARM 1. No voltage at backup alarm; 1. Test alarm and ground circuit;
Backup alarm doesn't broken wiring or blown fuse. check for voltage at alarm. Repair
sound with travel select wiring or replace fuse as
lever in REVERSE (R). required.
2. Defective alarm. 2. Test alarm and ground circuit.
3. Defective travel select lever. 3. Test travel select lever for
continuity and circuit for shorts.
Replace travel select lever if
defective.

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 Electrical System

Electrical System Troubleshooting

Problem Possible Cause Remedy

33. Backup alarm sounds with 1. Short circuit in wiring. 1. Determine and repair cause of
travel select in NEUTRAL short circuit.
(N) and FORWARD (F). 2. Defective travel select lever. 2. Test travel select lever for
continuity and circuit for shorts.
Replace travel select lever if
defective.
34. STEER SELECT SWITCH 1. Blown fuse. 1. Replace fuse. Check circuit for
Steer select switch fails to cause of blown fuse.
select mode or selects 2. Short circuit or broken wire. 2. Repair short, repair or replace
incorrect steering mode. wire.
3. Defective steer select switch. 3. Remove steer select switch and
check for continuity in each
position. Replace switch if
defective.
4. Defective steer select solenoid. 4. Test for correct operation.
Replace if defective.
35. HOURMETER 1. No voltage at meter terminals. 1. Check for proper voltage at
Hourmeter doesn't operate. hourmeter terminals with engine
running. Required voltage is 9 to
36-volts DC. If voltage is present,
replace hourmeter.
2. Defective wiring and/or ground. 2. Repair wiring and repair ground.
36. WARNING INDICATORS 1. Defective sender switch(es). 1. Test sender and/or circuit.
(on operators display panel) Replace sender switch(es).
Indicators fail to illuminate 2. Defective operators display panel. 2. Replace panel.
after engine start up lamp
test.
37. All warning indicators on 1. Short circuit in wiring. 1. Determine and repair the short.
the operators display panel 2. Defective panel. 2. Test panel ground circuit.
illuminate continuously
when the ignition key
switch is in the RUN posi-
tion after engine start up
lamp test.
38. ENGINE OIL PRESSURE 1. If the oil level and oil pressure are 1. If there are no shorts to ground,
SWITCH sufficient, check for shorts to install a new engine oil pressure
Oil pressure indicator con- ground between the operators switch.
tinuously illuminates when display terminal and the engine oil
engine is running. pressure sender switch on the
engine block.
39. Oil pressure indicator does 1. Wiring broken or disconnected. 1. Check wiring and circuit
not illuminate after lamp continuity. Repair break(s) in
test, engine not running for circuit as required.
twenty seconds. 2. Defective oil sender switch (switch 2. Install a new engine oil pressure
is closed when engine is not sender switch.
running).

Model 3606 • Origin 10/99 10-89

 Section 10

Electrical System Troubleshooting

Problem Possible Cause Remedy

40. ENGINECOOLANT TEM- 1. Defective engine coolant 1. Check and test sender. Test
PERATURE SWITCH temperature sender. electrical circuit to sender.
Engine coolant tempera-
ture warning indicator on 2. Defective wiring. 2. Test circuit for continuity and
operators display panel repair as required.
fails to illuminate when
engine is overheated.
41. Engine coolant temperature 1. Short circuit in wiring. 1. Disconnect the wiring harness
warning indicator illumi- connector at the engine coolant
nates when engine is not temperature sender switch on the
overheated (indicator lights engine block. If the indicator goes
during lamp test on engine out, install a new engine coolant
start up for five seconds; if temperature sender switch on the
sender wiring is discon- engine block.
nected, operators display 2. Defective engine coolant 2. If the indicator continues to
indicator will light). temperature sender. illuminate, check the wire lead at
the display panel and at the
ignition switch for a short to
ground. Repair a short circuit or
replace the sender.
42. BATTERY/ALTERNATOR 1. Defective alternator or wiring. 1. Test and/or replace alternator
CHARGING and wiring
WARNING INDICATOR
Charging indicator fails to
illuminate when alternator
is not producing voltage
(but does illuminate during
engine start-up lamp test).
43. TRANSMISSION 1. Circuit wiring is disconnected or 1. Check wiring, test circuit and
Temperature Warning defective. repair as required.
Indicator 2. Transmission temperature sender 2. Replace switch.
Transmission temperature switch on transmission is
warning indicator fails to defective.
illuminate when transmis-
sion is overheated.

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 Electrical System

Electrical System Troubleshooting

Problem Possible Cause Remedy

44. Transmission temperature 1. Wiring is shorting to ground. 1. If the indicator continues to
warning indicator illumi- illuminate, check the wiring from
nates during vehicle opera- the operators display panel to the
tion when transmission is ignition key switch, fuse panel
not overheated (indicator and sender for a short to ground.
illuminates normally during If a short is detected, test the
engine start-up lamp test). circuit and repair the short.
2. Defective transmission 2. Disconnect wiring connector at
temperature sender. the transmission temperature
sender switch on the
transmission. If the wiring checks
out o.k. and the transmission
temperature warning indicator
continues to illuminate, install a
new transmission temperature
sender switch. If the problem
persists, replace the operators
display panel. Test and replace
the sender as required.
45. FUEL LEVEL INDICATOR 1. No current in circuit because of 1. Check wiring and repair or
BARS broken or disconnected lead. replace as required. Follow wiring
No indication. from sender on fuel tank beneath
cab to fuse panel, ignition key
switch and operators display
panel terminal for fuel level
indicator bars.
2. Bad ground connection. 2. Repair ground.
3. Defective fuel level sender at fuel 3. Check for proper resistance; see
tank. Section 10.8.25 Fuel Level
Indicator and Fuel Level Sender.
4. Defective operators display panel. 4. Replace panel.
46. Excessive fuel level indica- 1. Loose wire connections. 1. Tighten connections at fuel level
tor bar fluctuation (not sender.
caused by frame tilt func- 2. Defective fuel level sender at fuel 2. Test. If bad, replace sender.
tion, travel over rough ter- tank.
rain, etc.).
47. FULL reading at all times. 1. Wire #27 BRN/GRN to sender is 1. Repair short.
shorted to ground.
2. Defective fuel level sender at fuel 2. Test. Replace if defective.
tank.
48. Fuel level indicator bars 1. Defective fuel level sender in tank. 1. Replace fuel level sender in tank.
indicate inaccurately. 2. Low voltage at fuel level sender 2. Check ohm reading. Determine
(should read 33.5 ohms for a full and correct cause of low voltage.
tank of fuel and 240 ohms for an
empty tank).

Model 3606 • Origin 10/99 10-91

 Section 10

10-92 Model 3606 • Origin 10/99

 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Phone: (61) 2 65 811111 England Fax: (49) 421 693 5035
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711

JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025

JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
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