SkyTrak 3606 Service Manual - Manual (Page 275)

Hydraulic System
9-81
b. Auxiliary Function Manifold Disassembly,
Cleaning, Inspection and Reassembly
1. Secure the auxiliary function manifold (Fig. 9– 56) in a
suitable bench vise if possible.
2. Remove the pressure-reducing valve “PS” (Fig. 9–
56) set at 2500 psi (172 bar).
3. Remove the pressure-reducing valve “PB” set at 550
psi (38 bar).
4. Remove the pressure-relief valve set at 650 psi (45
bar).
5. Remove the check valve.
6. Remove the diagnostic nipples at “PPG” and PBG”.
7. Clean all components with a suitable cleaner before
inspection.
8. Inspect internal passageways of the auxiliary function
manifold and it component parts for wear, damage,
etc. If inner surfaces of the auxiliary function manifold
do not display an ultra-smooth, polished finish, or
components are damaged in any way, replace the
auxiliary function manifold or appropriate part. Most
often, dirty hydraulic fluid causes failure of internal
seals and damage to the polished surfaces within the
auxiliary function manifold.
Note: Always replace seals, O-rings, gaskets, etc. with
new parts to help ensure proper sealing and operation.
c. Auxiliary Function Manifold Installation
1. Align the auxiliary function manifold with its mount
holes on the hydraulic reservoir/engine mount near
the battery (Fig. 9– 55).
2. Align gaskets, bolt holes, etc. with component mount
holes. Secure the auxiliary function manifold with the
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.
6. 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.
7. Inspect the auxiliary function manifold 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.
8. Conduct a pressure check of the service brake and
steering hydraulic circuits.
9. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle, work area and tools.
9.9.4 Joystick Valve
The joystick valve (1, Fig. 9– 43) is part of the joystick
assembly. Refer to Section 4 Cab, Covers and Mirrors for
further information regarding replacement of the joystick
assembly.
Joystick commands are actuated both electrically and
hydraulically via a set of solenoid-operated control valves
mounted in an array at the pilot select manifold.
Verify the correct operation of the joystick switches and
circuit solenoids before considering replacement of the
joystick valve. The valve itself is not serviceable and must
be replaced in its entirety if replacement of electrical
parts does not solve the problem.
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