Skytrak 6036 Service Manual Bedienungsanleitung Seite 250
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Stabil-TRAK™ System and Boom Interlock System
10-22
6036, 6042, 8042, 10042, 10054
10054 Stabil-TRAK™ Electrical Circuit
Boom Extend Mode 3
MODE 3
1.
Ignition “ON”
4.
PB Applied By Interlock Sys.
Conditions
2.
Boom Below 40°
5.
Trans. in Neutral By Interlock Sys.
3.
Boom Ext. Beyond 42 Foot Ext. Limit
6.
Outriggers Lowered
Right
Outrigger
UP
Solenoid
Right
Outrigger
DOWN
Solenoid
Left
Outrigger
UP
Solenoid
Left
Outrigger
DOWN
Solenoid
Extend
Circuit
Solenoid
Valve
Secondary
Function
Manifold
Park
Brake
Solenoids
152A1
45B
152B
51D
PB A
2K2
70A
45A
35
2B2
2B3
2B3
71B
50B
71A
65A
86
85
87A 87
30
86
85
87A 87
30
86
85
87A 87
30
E
86
85
87A 87
30
86
85
87A 87
30
E
86
85
87A 87
30
86
85
87A 87
30
86
85
87A 87
30
DE
C
86
85
87A 87
30
86
85
87A 87
30
23
2R
Lower
Transmission
Connectors
Upper
Transmission
Connectors
ZF Transmission WG 98
Y6 Y5 Y4
Y1 Y3 Y2
6
5
4
7
7
1
2
3
Y4Y5Y6
Y1 Y3 Y2
102B
2H
150B
101B
105B
104B
103B
2J
To
Back-Up
Alarm
31
150
103
102
104
105
101
150
103
104
102
105
101
150
103
104
2DD104A 150A
103A 102A
101A
10A
To
Fuel
Shutoff
+ +
40A
1
3C
7.5A
Park
Brake
Disengage
Relay
153A
45
Park
Brake
Switch
Ignition Switch
26A
51C
51
111
113A
113B
111
113
2CC
2AA
35
10A
7
39
SHIFTER
ZF
TRANSMISSION
9
8
7
6
5
4
3
2
1
FORWARD
NEUTRAL
REVERSE
GEAR
GEAR
GEAR
GEAR
B+
B+
153
105
101
150
103
104
102
112
113
102
45
114
112
114A
24
10A
34
2BB
2EE
153
102B
112
113
2D
CONSOLE/
ST
ABILIZER
& ENGINE
HARNESS
CONNECTORS
2HH
24A
To
Horn
114B
10
114A
FORWARD
REVERSE
F
N
R
Back-Up
Alarm
Relay
86
85
87A 87
30
PB B
48
SOL.
3
47
40B
Stabilizer
Lock
Relay
Boom
Switch
Relay
47
28
SOL.
4A
SOL.
4B
SOL.
12A
SOL.
12B
40
28B
47B
28A
47A
40
1
40A
2M
2L
2N
2P
2K
DE
DIODE PACKDIODE PACK
45
2T
7.5A
C
52
41B
45A2
107B
40
47
28
28
42A
102A
105
105A
101
7.5A
3B 3
3
3C
3A 3B
7.5A 7.5A
Right
Outrigger
Cylinder
Pressure
Switch
Left
Outrigger
Cylinder
Pressure
Switch
60A
2K1
51B
51A
Park
Brake
Interlock
Relay
Stabilizer
Interlock
Relay
Stabilizer
Lock-Up
Relay
2C1
2C2
70C
2E2D
2H
64
58
56A
56
7
Right
Outrigger
Switch
Left
Outrigger
Switch
60
60B 60E
64
62
71
50B
Boom
Extend
Interlock
Relay
71
66
Boom
Extend
Lockout
Relay
65A
50C
55
58
57
56
2G2F
62
61
Right
Outrigger
Lock
Relay
Outrigger
Lockout
Relay
63
Left
Outrigger
Lock
Relay
68
2A3
2A1
50C
2A2
2B2
56
70B
49
67
50A
LEGEND
=De-energized
= Energized
= Open
= Closed
= Active Circuit (Heavy Line)
=Inline Harness Connection
= Component/Bulkhead Connection
DE
E
O
C
1
152A3
152A
152A2
DE
DE
DE
O
E
E
E
E
DE
E
DE
E
E
E
DE
O
1
2
O
RELAY LOCATIONS
10
Light
Switch
Relay
Lights 1
Headlight
Switch
Rela
y
Park Br
ake
Disengage
Relay
Open Fuse
Transmission
Optional
Washer/Wiper
Stabilizer
Steer Select
Switch
Horn/Heater
Instrument
Panel
Main
7.5
Light Swtch
Relay
Neutral
Start
Relay
Stabilizer
Lock
Relay
Back-up
Alar
m
Relay
Boom
Switch
Relay
7.5
20
7.5
10
10
15
10
40
E
DE
E
DE
E
E
E
E
E
Stabilizer
Interlock
Relay
Park Brake
Interlock
Relay
Boom/Outrigger
Interlock
7.5
Boom/Outrigger
Interlock
7.5
Stabilizer
Lock Up
Relay
Boom
Extend
Lockout
Relay
Boom
Extend
Interlock
Relay
Right
Outrigger
Lock
Relay
Left
Outrigger
Lock
Relay
DE
DE
Stabilizer
Light
Park Brake
Light
Boom
Angle
Sensor
BLU
BRN
BLK
CBA
+
-
BLU
BRN
BLK
CBA
+
-
Boom
Extend
Interlock
Sensor
MH5881
- 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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