Sky Trak published this 412-page service training manual for the 3606 rough-terrain material handler under factory document number 8990300; this Sky Trak 3606 service training PDF is that book. Hydraulics claim close to a third of it: pressure diagnosis, pump and reservoir service, valves and manifolds, cylinders, and circuit schematics that trace oil from pump through each circuit. Wiring harness diagrams, fuse and relay layouts, and the start and charging circuits fill nearly a quarter more, with separate chapters for the Clark-Hurth T 12000 transmission and the Perkins and Cummins engines. Set the inner boom to extend 2.25 to 2.75 in. (57 to 70 mm) beyond the intermediate section, then torque the retract chain locknut to 35 to 40 lb/ft. On site it is just you, the machine, and nobody to ask. Serial number locations for the machine, transmission and both engines help you order the right part the first time, and bookmarks take you straight to any chapter.
What's Inside This Sky Trak 3606 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-16 | Owners/Operators Manual, Accident Prevention Tags, Safety Instructions (Personal Hazards, Equipment Hazards, Operational Hazards), Safety Decals |
| General Information, Specifications, and Maintenance | 17-60 | Replacement Parts and Warranty Information, Serial Number Locations, Torque Values, Fluids, Lubricants and Capacities, Cleaning, Replacement, Hoses and Tubes |
| Boom | 61-86 | Boom Assembly, Quick-Attach Assembly, Specifications, Troubleshooting |
| Cab, Covers and Mirrors | 87-110 | Serial Number Decal, Cab Replacement, Cab Covers and Guards |
| Axles, Wheels and Tires | 111-124 | Axle Assemblies, Wheels and Tires |
| Transfer Case and Drive Shafts | 125-134 | Transfer Case, Drive Shafts, Specifications, Troubleshooting |
| Transmission: Clark-Hurth T 12000 | 135-146 | Transmission Serial Number, Transmission Specifications, Towing a Disabled Vehicle, Transmission Maintenance, Transmission Replacement, Transmission Troubleshooting |
| Engine: Perkins 1004 Series | 147-170 | Perkins Engine Serial Number, Perkins Specifications and Maintenance Information, Perkins Engine Standard Practices, Perkins Engine Cooling System, Perkins Engine Electrical System |
| Engine: Cummins 4BT3.9 | 171-194 | Cummins Engine Serial Number, Cummins Specifications and Maintenance Information, Cummins Engine Standard Practices, Cummins Engine Cooling System, Cummins Engine Electrical System |
| Hydraulic System | 195-318 | Hydraulic Pressure Diagnosis, Hydraulic Fluid, Hoses, Tube Lines, Fittings, Etc., Hydraulic Reservoir, Hydraulic System Pump |
| Electrical System | 319-412 | Service Warnings, Effective Ground Connections, Wiring Harnesses, Fuses and Relays, Engine Start Circuit, Charging Circuit, Electrical System Components |
Every system also includes introduction.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Retract chain locknut torque | 35-40 lb/ft (47,5 to 54,2 Nm) | p. 73 |
| Boom hoist/lower cylinder counterbalance valve rating | 4000 psi | p. 199 |
| Pop-off emergency relief valve port relief rating | 3750 psi | p. 199 |
| Retract chain anchor bolt torque | 31 lb/ft (42 Nm) | p. 75 |
| Inner to intermediate boom distance | 2.25"-2.75" (57-70 mm) | p. 73 |
| Front outer boom to intermediate boom top wear pad gap | 0.07"-0.13" (1,8mm-3,3mm) | p. 75 |
| Boom extension distance | 10 feet (9 m) | p. 83 |
| Hoist/lower cylinder rod locknut torque | 1550-1750 lb/ft (2102-2373 Nm) | p. 291 |
| Hoist/lower cylinder counterbalance valve torque | 45-50 lb/ft (61-68 Nm) | p. 291 |
| Attachment tilt cylinder hydraulic circuit pressure | 3200 psi ± 100 psi (220,6 ± 7 bar) | p. 284 |
| Wheel lug nut torque | 370 lb/ft (500 Nm) | p. 24 |
| Main system relief pressure | 3,500 +/- 100 psi (241,5 Bars) | p. 24 |
Sky Trak 3606 Common Problems This Manual Covers
Sky Trak 3606 boom wear pads wearing rapidly on telescoping sections with jerky boom functions
Measure boom wear pad thickness following page 76 and replace any pad under 0.375" (9,5 mm); a new flat pad is 0.625" (15,9 mm). Shim front pads to a 0.07"-0.13" (1,8-3,3 mm) gap per page 75, then apply #242 (blue) and torque mounting capscrews to 31 lb/ft (42 Nm).
Manual Section: Boom Troubleshooting p. 85Boom retract chain showing excessive chain wear during boom extend and retract cycles
Inspect the retract chain using the boom chart on page 85. Adjust until the inner boom extends 2.25"-2.75" (57-70 mm) beyond the intermediate boom, then tighten the locknut to 35-40 lb/ft (47,5 to 54,2 Nm) per page 73. Coat the anchor shoulder bolt with anti-seize and torque a new hex-lock nut to 31 lb/ft (42 Nm).
Manual Section: Boom p. 73Main relief valve issues suspected with hydraulic boom and attachment functions slow and jerky
Test main system relief pressure against 3,500 +/- 100 psi on page 201 before condemning the pump. Check unloader valve outlet pressure at 250 to 350 psi (17,25 to 24,15 bar) per page 259. If the relief valve assembly comes out, torque it back to 20 lb/ft (27 Nm) following page 258.
Manual Section: Hydraulic System Troubleshooting p. 311Boom hoist/lower cylinder drifting with a raised load or boom cannot lower the load
Inspect the hoist/lower cylinder counterbalance valve, rated 4000 psi on page 199, before tearing into the cylinder. Torque the replacement valve to 45-50 lb/ft (61-68 Nm) per page 291. If the cylinder comes apart, torque the rod locknut to 1550-1750 lb/ft (2102-2373 Nm) on reassembly.
Manual Section: Hydraulic System p. 291While maneuvering, power steering circuit feels spongy and soft at the steering wheel
Test steering relief pressure against 2,500 +/- 100 psi listed on page 201. Check hydraulic reservoir level next; the reservoir holds 32.2 gal (121,9 l) and the full system 59.5 gal (225,2 l) per page 26. Then work the spongy steering and cavitation checks in the hydraulic troubleshooting chart.
Manual Section: Hydraulic System Troubleshooting p. 311Clark-Hurth T 12000 transmission showing low clutch pressure, overheating, and lack of power under load
Check clutch pressure and converter pump output first, then work the overheating and noisy converter checks in the transmission troubleshooting chart. During transmission maintenance, install a new oil filter and torque it to 20-25 lb/ft (27-34 Nm) per page 143. If the transmission comes out, torque the main hydraulic pump-to-transmission capscrews to 75 lb/ft (102 Nm).
Manual Section: Transmission TroubleshootingFrequently Asked Questions
What are the torque specifications for the wheel lug nuts on the Sky Trak 3606?
The wheel lug nut torque for the Sky Trak 3606 is 370 lb/ft (500 Nm). p. 24
How do I reset the Engine Maintenance/Vehicle Lubrication indicator on the operators display panel?
After the engine is serviced, the indicator can be reset by pressing and holding the reset switch, 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. p. 367
What is the engine oil capacity for the Perkins engine with a filter change on the Sky Trak telehandler?
The engine oil capacity for the Perkins engine, including a filter change, is 9.0 quarts (8,5 liters). p. 39
What is the procedure for checking the hydraulic oil level?
To check the hydraulic oil level, fully retract all hydraulic cylinders, shut off the engine, and allow the oil to cool. The oil level should be visible at the lower end of the sight glass on the vertical wall of the hydraulic oil tank. p. 45
What is the torque specification for the transmission drive shaft yoke retaining bolts on the Sky Trak telehandler?
The M12 bolts for the drive shaft yoke retaining assembly must be tightened to 156 lb/ft (212 Nm). p. 32
What do I get after purchasing this Sky Trak 3606 manual?
Immediate download of the complete 412-page searchable Service Training. Access it on any device, from a laptop at your desk to a phone in the field.
Am I able to print pages from this Sky Trak 3606 manual?
Yes. Print the pages you need for the job in your own shop, and bin them when they get greasy.
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