Skytrak 6036 Service Manual Bedienungsanleitung Seite 153
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8-1
6036, 6042, 8042, 10042, 10054
Section 8
Hydraulic System
Contents
PARAGRAPH TITLE PAGE
8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.2 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.1 Hydraulic Oil Reservoir Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.3 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.4 Hydraulic Oil Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.6 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.6.1 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.7 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.2 Secondary Function Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.7.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.7.5 Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.7.6 Power Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.7.7 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.7.8 Unloader Valve (6036 & 6042 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.7.9 Outrigger Valve (10042 & 10054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.7.10 Extend Lockout Valve (10054 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
8.8 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.8.1 General Cylinder Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.8.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.8.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.8.4 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
- Service Manual 1
- EFFECTIVITY PAGE 3
- READ THIS FIRST 4
- SECTION CONTENTS 5
- Section Subject Page 6
- Section 1 9
- Safety Practices 9
- 1.1 INTRODUCTION 10
- 1.2 DISCLAIMER 10
- 1.4 DO NOT OPERATE TAGS 10
- 1.5 SAFETY INFORMATION 10
- 1.6 SAFETY INSTRUCTIONS 11
- 1.7 SAFETY DECALS 12
- Section 2 13
- 2.1 REPLACEMENT PARTS AND 14
- WARRANTY INFORMATION 14
- 2.2 THREAD LOCKING COMPOUND 14
- 2.3 TORQUE CHARTS 15
- SOCKET HEAD CAP SCREWS 19
- 2.4 SPECIFICATIONS 26
- 2.4.3 Electrical System 27
- 8042, 10042 & 10054 27
- 2.4.5 Tires 28
- 2.5 FLUID SPECIFICATIONS 29
- 2.7 SERVICE AND 32
- MAINTENANCE SCHEDULES 32
- 2.7.3 500 & 1000 Hour 34
- 2.7.4 2000 Hour 35
- 2.8 LUBRICATION SCHEDULES 36
- 6042 ONLY 39
- 2.8.3 1000 Hour 41
- Section 3 43
- 3.1 BOOM SYSTEM COMPONENT 45
- 3.2 SAFETY INFORMATION 46
- (498 cm) 54
- 3.4.8 Boom Installation 56
- 3.5.1 Boom System Operation 57
- 3.6.7 Third Boom Installation 66
- BOOM EXTEND AND RETRACT 70
- 3.7.2 Inspection Guidelines 71
- 3.7.4 Chain Lubrication 73
- Replacement (10054) 82
- 3.8 QUICK ATTACH ASSEMBLY 90
- 3.9 BOOM WEAR PADS 90
- 3.10 FORKS 91
- 3.11 TROUBLESHOOTING 92
- Section 4 95
- 4.1 OPERATOR CAB AND COVERS 96
- 4.2 OPERATOR CAB 97
- 4.3 CAB COMPONENTS 97
- 4.3.2 Service Brake Pedal 98
- 4.3.3 Throttle Pedal 99
- Cab and Covers 100
- 4.3.4 Joystick Assemblies 100
- 4.4 CAB REMOVAL 102
- 4.5 CAB INSTALLATION 104
- Section 5 107
- COMPONENT TERMINOLOGY (6036) 108
- COMPONENT TERMINOLOGY (6042) 109
- COMPONENT TERMINOLOGY (8042) 110
- COMPONENT TERMINOLOGY 111
- (10042 & 10054) 111
- 5.5 GENERAL INFORMATION 112
- 5.6 AXLE ASSEMBLIES 112
- 5.6.4 Axle Maintenance 113
- 5.6.6 Axle Replacement 115
- (8042, 10042 & 10054) 115
- Problem Cause Remedy 119
- TO TRANSMISSION 122
- 5.9 WHEELS AND TIRES 123
- 5.10 BRAKES 124
- FRONT OF 125
- 6036 & 6042 125
- 8042, 10042 & 10054 126
- Section 6 127
- Transmission 127
- 6.1 TRANSMISSION ASSEMBLY 128
- AND MAINTENANCE INFORMATION 129
- 6.4 TRANSMISSION REPLACEMENT 129
- Replacement 132
- 6.5 TRANSMISSION 133
- TROUBLESHOOTING 133
- Section 7 137
- 7.1 INTRODUCTION 138
- 7.2 ENGINE SERIAL NUMBER 138
- 7.3 SPECIFICATIONS AND 138
- MAINTENANCE INFORMATION 138
- IF EQUIPPED FOR ULS 140
- IF EQUIPPED FOR LS 140
- 7.5 ENGINE ELECTRICAL SYSTEM 141
- 7.6 FUEL SYSTEM 141
- VIEW FROM REAR OF MACHINE 145
- 7.8 AIR CLEANER ASSEMBLY 147
- 7.9 ENGINE REPLACEMENT 148
- 7.9.2 Engine Installation 149
- 7.10 ISOLATION COUPLER 150
- Section 8 153
- Hydraulic System 153
- 8.1 HYDRAULIC COMPONENT 154
- TERMINOLOGY 154
- 8.2 SAFETY INFORMATION 156
- 8.4 HYDRAULIC CIRCUITS 157
- 8.4.2 Hydraulic Schematics 164
- 8.5 HYDRAULIC RESERVOIR 172
- 8.6 HYDRAULIC SYSTEM PUMP 173
- REXROTH PUMP 174
- SAUER PUMP 174
- EATON PUMP 174
- 8.7 VALVES AND MANIFOLDS 175
- 6036 6042 178
- 8042, 10042, 10054 179
- 8.8 HYDRAULIC CYLINDERS 183
- AFTER the head gland 185
- AXLE CENTER SECTION 186
- STEERING CYLINDER 186
- Section 9 189
- Electrical System 189
- 9.1 ELECTRICAL COMPONENT 190
- 9.2 SPECIFICATIONS 191
- 9.3 SAFETY INFORMATION 191
- 9.4 FUSES AND RELAYS 191
- HARNESS, DASH/THROTTLE 193
- HARNESS, WIRING, OUTRIGGERS 199
- BOOM EXTEND 200
- HARNESS, LOGIC 200
- HARNESS, CAB/PWR DISTRIBUTION 201
- HARNESS, ENGINE/CHASSIS 202
- 9.7.1 Alternator 205
- 9.8 WINDOW WIPER/WASHER 206
- WINDSHIELD WIPER MOTOR 206
- 9.8.2 Skylight Wiper Motor 207
- 9.9 CAB HEATER AND FAN 208
- 9.10 SOLENOIDS, SENSORS AND 209
- 9.10.5 Service Brake Switch 212
- 9.10.6 Boom Angle Sensor 213
- (10054 only) 214
- (10054 Only) 215
- 9.11.1 Instrument Cluster 215
- 9.12 DASH SWITCHES 216
- 9.12.2 Dash Switches 217
- 9.13 TROUBLESHOOTING 218
- Section 10 229
- 10.1 STABIL-TRAK™ SYSTEM 231
- 10.2 BOOM EXTEND INTERLOCK 232
- SYSTEM COMPONENT 232
- TERMINOLOGY (10054 ONLY) 232
- 10.4 STABIL-TRAK™ OPERATION 234
- (SN 13198 through 17984) 235
- 10.4.4 Relay Testing 236
- 10.5 BOOM EXTEND INTERLOCK 237
- SYSTEM DESCRIPTION 237
- 10.6 BOOM EXTEND INTERLOCK 238
- SYSTEM OPERATION (10054 ONLY) 238
- Instructions 239
- 10.7.2 Stabil-TRAK™ System 239
- Test Procedures 239
- Electrical Circuit 243
- FREE PIVOT Mode 243
- SLOW PIVOT Mode 244
- LOCKED MODE 245
- TROUBLESHOOTING (10054) 246
- Boom Extend Mode 1 248
- Boom Extend Mode 2 249
- Boom Extend Mode 3 250
- SYSTEM TEST 251
- 10.11 STABIL-TRAK™ HYDRAULIC 253
- CIRCUIT OPERATION AND 253
- Pressure 256
- Load Sense 256
- LOCKED MODE, Frame Level Left 266
- 10.12 BOOM EXTEND SYSTEM 268
- HYDRAULIC CIRCUIT OPERATION 268
- AND TROUBLESHOOTING 268
- Extend Interlock Mode 270
- Outrigger Interlock Mode 272
- JLG Worldwide Locations 276
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