Skytrak 6036 Service Manual Bedienungsanleitung Seite 357
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9.5
Model 6036 Legacy
Electrical System
9.2 SERVICE WARNINGS
9.2.1 General
9.2.2 Battery
Always disconnect the negative (-) (Fig. 9-1, 1) or
positive (+) (2) (as required) battery cable from the
battery before working on the electrical system.
Figure 9-1 Disconnect the Negative (-) or Positive (+)
(as Required) Battery Cable Before Servicing Vehicle
9.3 SPECIFICATIONS
Electrical system specifications are listed in
Section 2,
General Information and Specifications Instructions
.
CAUTION: DO NOT disconnect any
wiring without first stopping the engine, turning
all electrical switches to the OFF position and
disconnecting the battery negative (-) cable
from the battery. Failure to remove the negative
(-) battery cable will result in damage to vehicle
electronic systems.
CAUTION: DO NOT cause a short circuit
by connecting leads to incorrect terminals.
Always identify a lead and its correct terminal.
A short circuit or wrong connection creating
reverse polarity will immediately and
permanently ruin internal components within
the electrical system.
CAUTION: DO NOT momentarily or
“flash” connect a terminal to check for current
flow. No matter how brief the contact, internal
components may be ruined.
WARNING: All lead-acid batteries
generate hydrogen gas, which is highly
flammable. If ignited by a spark or flame, the
gas may explode violently, causing spraying of
acid, fragmentation of the battery and possible
severe personal injuries, particularly to the
eyes. Wear safety glasses when working near
the battery.
WARNING: Avoid battery acid. Battery
acid can cause chemical burns or other
serious injury. In case of contact with battery
acid, flush area immediately with water.
WARNING: Charge the battery in a well-
ventilated area only. Always turn battery
chargers OFF before connecting to or
disconnecting from a battery.
CAUTION: DO NOT disconnect the
battery while the engine is running. This will
cause a voltage surge in the alternator
charging system that will immediately ruin
internal components.
CAUTION: DO NOT connect a battery
into the system without checking for correct
polarity and voltage.
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MA8410
1
2
- Service Manual 1
- EFFECTIVITY PAGE 3
- SECTION CONTENTS 5
- Section Subject Page 6
- Section 1 9
- 1.1 INTRODUCTION 10
- 1.2 OWNERS/OPERATORS MANUAL 10
- 1.3 TRAINING MECHANICS AS 11
- OPERATORS 11
- 1.4 SAFETY INFORMATION 11
- DANGER: 12
- WARNING: 12
- CAUTION: 12
- 1.6 SAFETY INSTRUCTIONS 13
- Safety Practices 14
- 1.6.3 General Hazards 14
- 1.6.4 Operational Hazards 14
- 1.8 HAZARD/EMERGENCY 15
- INFORMATION DECALS 15
- Domestic: 1-877-554-5438 15
- International: 1-717-485-5161 15
- Section 2 17
- 2.2 INTRODUCTION 20
- 2.3 TORQUES 21
- 2.4 METRIC CONVERSION FACTORS 22
- 2.4.2 Approximate Metric to 23
- American Conversions 23
- 2.5 SPECIFICATIONS 24
- 2.5.2 Vehicle Weights 26
- 2.5.3 Attachment Weights 27
- 2.5.6 Electrical System 28
- 2.5.9 Hydraulic System 31
- 2.5.10 Tires 31
- 4000 x 24 32
- 2.6.2 Axle Wheel Ends 33
- 2.6.3 Transmission 33
- 2.6.5 Hydraulic System 34
- 2.6.6 Engine 34
- 2.6.7 Drive Shaft Splines 35
- 2.6.8 General Anti-Corrosion 35
- 2.6.9 Electrical 35
- 2.7 CLEANING 36
- 2.8 REPLACEMENT 37
- 2.9 HOSES AND TUBES 37
- 2.10 BEARINGS 37
- 2.11 PRESSURE TESTING AND 38
- ADJUSTMENT 38
- 2.12.8 After Engine Service 40
- 2.12.9 After Boom Service 40
- 2.12.10 After Axle Service 40
- Section 3 41
- 3.1 BOOM SYSTEM COMPONENT 42
- 3.2 BOOM SYSTEM 43
- 3.3 BOOM ASSEMBLY MAINTENANCE 43
- Front Top Wear Pads 44
- Tilt Cylinder Hoses 45
- Hose Reel Side Plate 51
- Hose Reel Assembly 51
- Auxiliary Hydraulics Hoses 52
- Cylinder Rod End Pin 52
- Boom Rear Wear Pads 53
- Upper Rear Wear Pads 53
- 3.3.3 Outer Boom Removal 54
- Attachment Tilt Tubes 56
- Cylinder Pivot Pins 58
- Cylinder Base End Pin 59
- 3.3.4 Outer Boom Installation 60
- Slave Cylinder Bearings 61
- Tube Assemblies 67
- Lower Wear Pads 68
- Boom Front Wear Pads 72
- 3.3.6 Inner Boom Installation 73
- Inside the Inner Boom 74
- Boom Front Side Wear Pads 77
- Intermediate Boom Sections 79
- Hydraulic Coupler and Nipple 82
- Cylinder Base End Pivot Pin 82
- 3.3.7 Boom Chains 84
- Adjustment Locknuts 89
- Extend Chain Installation 92
- Retract Chain Removal 94
- 3.3.8 Boom Wear Pads 96
- Intermediate Boom 97
- Outer Boom 98
- 3.4 QUICK ATTACH ASSEMBLY 99
- 3.4.3 Quick Attach Removal 100
- 3.5 TROUBLESHOOTING 101
- Problem Cause Remedy 101
- Model 6036 Legacy 104
- Section 4 105
- Cab and Covers 105
- COMPONENT TERMINOLOGY 106
- 4.2 OPERATOR’S CAB 107
- 4.3 OPEN CAB COMPONENTS 108
- 4.3.4 Brake Pedal and Valve 114
- Assembly Replacement 119
- 4.3.8 Electrical Components 121
- 4.4 ENCLOSED CAB (OPTIONAL) 123
- COMPONENTS 123
- 4.4.5 Door and Latches 127
- 4.4.6 Windows 128
- 4.5 CAB REMOVAL 129
- 4.6 CAB INSTALLATION 133
- 4.7 ACCESS PANELS AND COVERS 136
- Section 5 137
- 5.2 GENERAL INFORMATION 139
- 5.3 AXLE ASSEMBLIES 139
- 5.3.4 Axle Specifications 140
- 5.3.5 Axle Maintenance 140
- 5.3.6 Axle Replacement 141
- Troubleshooting 150
- 5.4 DRIVE SHAFTS 151
- 5.4.2 Drive Shaft Maintenance 152
- 5.4.3 Drive Shaft Removal 152
- 5.4.4 Drive Shaft Disassembly 153
- 5.4.6 Drive Shaft Assembly 155
- Direction of Forward Travel 157
- WARNING: Damaged, modified 159
- Section 6 163
- Transmission: ZF 4 WG-98 TC 163
- 6.1 TRANSMISSION ASSEMBLY 164
- 6.2 TRANSMISSION DESCRIPTION 165
- 6.3 TRANSMISSION OPERATION 165
- 6.6 TRANSMISSION MAINTENANCE 166
- 6.7 TRANSMISSION REPLACEMENT 168
- 6.8 TOWING A DISABLED VEHICLE 175
- 6.9 TROUBLESHOOTING 176
- Section 7 179
- Engine: Cummins 4BT3.9 179
- 7.1 INTRODUCTION 180
- 7.2 SAFETY INFORMATION 182
- 7.3 ENGINE SERIAL NUMBER 184
- 7.4 SPECIFICATIONS AND 184
- MAINTENANCE INFORMATION 184
- 7.5 STANDARD PRACTICES 184
- 7.6 ENGINE COOLING SYSTEM 185
- Heater Replacement 188
- 7.7 ENGINE ELECTRICAL SYSTEM 192
- 7.8 FUEL SYSTEM 193
- 7.8.1 Diesel Fuel 194
- 7.9 ENGINE EXHAUST SYSTEM 201
- 7.10 AIR CLEANER ASSEMBLY 202
- 7.11 ENGINE REPLACEMENT 203
- 7.11.3 Engine Installation 208
- 7.12 ENGINE STORAGE 215
- 7.13 TROUBLESHOOTING 216
- Section 8 217
- Hydraulic System 217
- 8.1 HYDRAULIC COMPONENT 219
- TERMINOLOGY 219
- 8.2 SAFETY INFORMATION 220
- 8.3 SPECIFICATIONS 221
- 8.4 HYDRAULIC FLUID 221
- Replacement 222
- 8.7 HYDRAULIC SYSTEM TESTING 226
- 8.8 HYDRAULIC CIRCUITS AND 229
- TROUBLESHOOTING 229
- 3. Air in the lines 241
- Load Sense 262
- Pressure 262
- Description 268
- PROCEDURE 274
- 8.10 HYDRAULIC RESERVOIR 276
- 8.11 HYDRAULIC SYSTEM PUMP 277
- 8.11.2 Pump Replacement 278
- 8.12 VALVES AND MANIFOLDS 284
- 8.12.2 Main Control Valve 286
- 8.12.4 Service Brake Valve 305
- 8.12.5 Shuttle Valve 309
- 8.12.6 Power Steering Valve 310
- 8.12.7 Steer Select Valve 312
- 8.13 HYDRAULIC CYLINDERS 316
- 8.13.5 Slave Cylinders 321
- 8.13.7 Lift/Lower Cylinder 330
- 8.13.8 Frame Sway Cylinder 334
- 8.13.11 Steering Cylinders 351
- Section 9 353
- Electrical System 353
- 9.1 ELECTRICAL COMPONENT 355
- 9.2 SERVICE WARNINGS 357
- 9.3 SPECIFICATIONS 357
- 9.5 WIRING HARNESSES 358
- 9.5.3 Cleaning and Drying 359
- 9.5.4 Inspection and Repair 359
- 9.5.5 Installation 359
- 9.5.6 Wire Code and Color 359
- 9.6 FUSES AND RELAYS 360
- 9.7 ELECTRICAL SYSTEM 362
- 9.10 ENGINE START CIRCUIT 409
- 9.10.2 Starter 410
- 9.11 CHARGING CIRCUIT 411
- 9.11.2 Battery 414
- 9.12 ELECTRICAL SYSTEM 417
- 9.12.2 Back-Up Alarm 418
- 9.12.3 Instrument Cluster 419
- 9.13.2 Windshield Wiper Motor 422
- 9.13.3 Roof Wiper Switch 424
- 9.13.4 Roof Wiper Motor 424
- 9.14.1 Cab Heater Controls 427
- 9.15 SWITCHES AND SOLENOIDS 428
- 9.15.2 Fuel Shut-off Solenoid 430
- 9.15.4 Park Brake Switch 433
- 9.15.7 Steering 441
- 9.15.8 Steer Select Switches 443
- 9.15.9 Steer Select Valve 444
- 9.15.13 Engine Block Heater 448
- 9.15.15 Hourmeter 451
- Section 10 453
- Accident Prevention Tags 457
- 8990403 Origin 5/00 458
- JLG Worldwide Locations 460
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