Skytrak 6036 Service Manual Bedienungsanleitung Seite 107
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Section 8A Perkins Engine
Model 6036/6036T S/N 9B0500 thru 14833
8A-15
Do not mix gasoline or alcohol with diesel fuel.
This mixture can cause an explosion.
8A.12 ENGINE ELECTRICAL
SYSTEM
The engine electrical system is described in
Section 10, Electrical System. These instructions
describe warning devices, wiring harnesses, circuit
breakers, the starting and charging circuits,
switches and solenoids, gauges and indicator
lights, and electrical troubleshooting.
IMPORTANT: Due to the precise tolerances of
diesel injection systems, it is extremely important
that the fuel be kept clean and free of dirt or water.
Dirt or water in the system can cause severe
damage to both the injection pump and the
injection nozzles.
Use ASTM No. 2 D Fuel with a minimum Cetane
number of 40. No. 2 diesel fuel gives the best
economy and performance under most operating
conditions. Cetane number indicates ignition
performance. Fuel with a low cetane number can
cause cold start problems and affect combustion.
At operating temperatures below 32 °F (0 °C), use
a blend of No. 1 D and No. 2 D fuels, also known
as “winterized” No. 2 D.
NOTE: No. 1 D fuel can be used, however, fuel
economy will suffer.
Use low sulfur content fuel having a cloud point
that is at least 10 degrees below the lowest
expected fuel temperature. Cloud point is the
temperature at which wax crystals begin to form in
diesel fuel.
The viscosity of the fuel must be kept above 1.3
centistrokes to provide adequate fuel system
lubrication.
NOTE: When using diesel fuel with a sulfur
content below 1.3 percent, the oil filter change
interval must be reduced by 75 hours. The use of
fuel with a sulfur content above 1.3 percent is not
recommended.
8A.13.2 Fuel Tank
The fuel tank (1, Fig. 8A.26) is located directly
behind the front axle.
a. Removal
1. Have a dry chemical (Class B) fire extin-
guisher near the work area.
2. Disconnect the negative (–) battery cable.
3. Using a hand operated pump, when available,
pump as much fuel as possible through the fill
cap or fuel level sensor openings in the fuel
tank. Pump the fuel oil into a marked and
approved receptacle for fuel oil.
8A.13 ENGINE FUEL SYSTEM
The engine fuel system includes a fuel tank (1,
Fig. 8A.26), a fuel level sender (2) and gauge, a
fuel pre-filter (3), a fuel lift pump, Fig. 8A.28, a fuel
filter (21, Fig. 8A.26), and fuel lines to and from
the fuel injection pump, and fuel lines from the fuel
injection pump to and from the fuel injectors back
to the fuel filter and fuel tank. A separate line runs
from the fuel filter to the Thermo Start plug, Fig.
8A.16, in the intake manifold.
The threaded fuel fill opening in the top of the fuel
tank has a filler cap with a tether (3, Fig. 8A.26).
The fuel level sender (2) and gauge are described
in Section 10, Electrical System.
A fuel supply hose carries fuel from the bottom of
the tank to the fuel pre-filter (20). The fuel then
flows through a fuel filter tube, a hose and a fuel
pump tube to the fuel lift pump, Fig. 8A.28, which
is located on the left side of the engine.
A tube carries fuel under pressure from the fuel lift
pump to fuel filter (21, Fig. 8A.26). Fuel which has
been filtered by the fuel filter is directed through
tubes to the fuel injection pump and to the Thermo
Start plug, Fig. 8A.17 in the intake manifold.
A tube from the fuel injectors returns surplus fuel
from the injectors to the fuel filter (21, Fig. 8A.26)
and into a line and hose which returns it to the fuel
tank.
8A.13.1 Type of Diesel Fuel to Use
Fuel represents a major portion of your forklift
operating costs; therefore, it is important to use it
efficiently. Don’t let cost tempt you to use inferior
diesel fuel. The initial savings is a false economy
when you consider the damage poor fuel can do to
your forklift engine.
NOTE: Use only diesel fuel designed for diesel
engines. Some heating fuels contain harmful
chemicals which can seriously affect engine
efficiency and performance.
Warning
- Service Manual 1
- Effectivity Page 3
- SECTION CONTENTS 5
- SECTION 1 7
- SAFETY PRACTICES 7
- 1.3 PERSONAL CONSIDERATIONS 8
- 1.4 EQUIPMENT CONSIDERATIONS 8
- 1.5 GENERAL CONSIDERATIONS 9
- 1.7 FINAL WORD 10
- SECTION 2 11
- GENERAL INSTRUCTIONS 11
- 2.1 INTRODUCTION 12
- 2.2 CLEANING 12
- 2.3 REPLACEMENT 12
- 2.4 HOSES AND TUBES 12
- 2.7 TORQUES 13
- 2.5 BEARINGS 13
- 2.6 PRESSURE TESTING 13
- AND ADJUSTMENT 13
- 2.8 PAINTING 14
- 2.9 AFTER SERVICE 15
- STARTUP AND CHECKS 15
- 2.10 FLUID LEVELS 16
- AND LUBRICATION 16
- SECTION 3 19
- Fig. 3.3) 20
- Section 3 Boom 21
- OUTER BOOM 21
- 3.1.3 Outer Boom Replacement 23
- 3.1.4 Chain Replacement 27
- 3.1.5 Chain Lubrication 28
- 3.1.6 Chain Tension Check 28
- 3.1.8 Wear Pad Replacement 29
- 3.1.9 Hose Tensioning 30
- 3.2 EMERGENCY BOOM 32
- LOWERING 32
- 3.2.2 Hydraulic Line Failure 33
- 3.3 QUICK ATTACH 34
- ASSEMBLY 34
- Excessive 35
- 3.5 SPECIFICATIONS 36
- SECTION 4 37
- OPERATOR'S CAB 37
- 4.2.2 Travel Select 38
- Section 4 Operator's Cab 39
- 4.2.3 Boom Control and Grille 40
- 4.3 ELECTRONIC 41
- JOYSTICK 41
- (without TLC) 42
- Replacement without TLC 45
- 4.4 MECHANICAL FOOT 46
- CONTROLS 46
- FUEL PUMP 48
- 4.5 REAR VIEW MIRRORS 49
- SECTION 5 51
- 5.1 WHEEL ASSEMBLY 52
- AND TIRE 52
- Tube within Tire 54
- 5.1.2 Demounting Tire 55
- 5.1.4 Demounting Tire from 55
- Three Piece Wheel 55
- (S/N OF1191 & Before) 55
- 5.1.11 Mounting Tire 58
- 5.2 AXLE ASSEMBLY 61
- 5.2.1 Axle 62
- ALWAYS replace with new ones 64
- 5.2.4 Axle Steering Joints 67
- 5.2.6 Park Lock Unit 71
- 5.2.7 Carrier Assembly 73
- 5.3 AXLE LUBRICATION 76
- 5.3.3 Wheel End Brake Oil 77
- 5.4 SPECIFICATIONS 78
- 5.5 TROUBLESHOOTING 78
- SECTION 6 79
- DRIVE SHAFTS AND DROP BOX 79
- 6.2 DROP GEAR BOX FOR 81
- S/N 9N0941 AND BEFORE 81
- 6.2.2 Oil Seals 82
- 6.3 DROP GEAR BOX FOR 83
- S/N 9N0942 AND AFTER 83
- 6.4 SPECIFICATIONS 85
- SECTION 7 87
- 7.2 HOW TO TOW 88
- THE FORKLIFT 88
- Section 7 Transmission 89
- 7.9 TROUBLESHOOTING 90
- 7.10 SPECIFICATIONS 91
- SECTION 8A 93
- 8A.4.2 Maintenance Intervals 95
- 8A.5.1 Inspect the Engine 95
- 8A.6 ENGINE MAINTENANCE 98
- Every 250 Hours 98
- 8A.7 ENGINE MAINTENANCE 99
- Every 500 Hours 99
- 8A.7.2 Clean Sediment Chamber 100
- 8A.8 ENGINE MAINTENANCE 101
- Every 1,000 Hours 101
- 8A.8.2 Replace Air Filter 102
- Primary Element 102
- 8A.9 ENGINE MAINTENANCE 103
- Every 2,500 Hours 103
- 8A.10 ENGINE OIL 104
- SPECIFICATIONS 104
- 8A.11 ENGINE COOLING 104
- 8A.11.2 Radiator Pressure Cap 105
- Section 8A Perkins Engine 106
- 8A.12 ENGINE ELECTRICAL 107
- 8A.13 ENGINE FUEL SYSTEM 107
- 8A.13.4 Fuel Pre-Filter 109
- 8A.13.5 Fuel Lift Pump 109
- 8A.13.6 Fuel Filter 110
- 8A.13.7 Fuel Injection Pump 111
- 8A.13.8 Fuel Injectors 111
- 8A.14 ENGINE EXHAUST 112
- 8A.15 HOW TO REMOVE 113
- ENGINE FROM FORKLIFT 113
- 8A.16 HOW TO OVERHAUL 115
- THE ENGINE 115
- 8A.17 HOW TO INSTALL THE 115
- ENGINE IN FORKLIFT 115
- 8A.18 HOW TO TORQUE 117
- CYLINDER HEAD 117
- SCREWS AND NUTS 117
- 8A.19 ENGINE STORAGE 118
- 8A.20 TROUBLESHOOTING 119
- SECTION 8B 121
- Section 8B Cummins Engine 122
- 8B.3.2 Maintenance Intervals 123
- 8B.4.1 Inspect the Engine 123
- 8B.5 ENGINE MAINTENANCE 126
- EVERY 250 HOURS 126
- OR 3 MONTHS 126
- 8B.6 ENGINE MAINTENANCE 128
- EVERY 500 HOURS 128
- OR 6 MONTHS 128
- 8B.7 ENGINE MAINTENANCE 130
- EVERY 1,000 HOURS OR 130
- ANNUALLY 130
- 8B.7.2 Tensioner Bearing 131
- 8B.7.3 Fan Hub 131
- 8B.7.4 Check Valve Stem 131
- 8B.7.5 Drain Cooling System 132
- 8B.7.8 Replace Air Filter 133
- 8B.8 ENGINE OIL 134
- 8B.9 ENGINE COOLING 134
- 8B.9.2 Radiator Pressure Cap 135
- 8B.10 ENGINE ELECTRICAL 136
- 8B.11 ENGINE FUEL SYSTEM 136
- 8B.11.2 Fuel Tank 138
- 8B.11.7 Fuel Injectors 139
- 8B.11.5 Dual Head Fuel Filter 139
- 8B.12 ENGINE EXHAUST 141
- 8B.13 HOW TO REMOVE 143
- 8B.14 HOW TO OVERHAUL 144
- 8B.15 HOW TO INSTALL THE 144
- 8B.16 ENGINE STORAGE 147
- 8B.17 TROUBLESHOOTING 149
- SECTION 9 151
- HYDRAULIC SYSTEM 151
- 9.1 SYSTEM OPERATION 152
- 9.2 MAIN CONTROL VALVE 152
- OPERATION 152
- CABLE CONTROL 152
- Section 9 Hydraulic System 153
- 9.3 MAIN CONTROL VALVE 160
- ELECTRONIC CONTROL 160
- 9.4 SECONDARY CONTROL 166
- VALVE OPERATION 166
- Example: 167
- 9.4.3 Frame Tilt Circuit 171
- 9.4.4 Brake Circuits 174
- (S/N 9B0500 thru OE1179 – 174
- Without Trans. De-Clutch) 174
- 9.4.5 Brake Circuits 176
- (S/N OE1180 and After – 176
- With Trans. De-Clutch) 176
- 9.4.6 Power Steering Circuit 179
- 9.5 CYLINDERS 185
- Refer to paragraph 9.5.a 187
- 9.5.4 Boom Extend Cylinder 192
- 9.5.7 Slave Cylinder 197
- 9.5.8 Grille Tilt Cylinder 200
- 9.5.9 Frame Tilt Cylinder 203
- 9.5.10 Steering Cylinder 206
- (S/N 3101 & Before) 206
- 9.5.11 Steering Cylinder 209
- (S/N 3102 & After) 209
- (Optional) 212
- 9.6 VALVES 218
- Electronic Control 222
- SUPPLY PORT 224
- RETURN PORT 224
- EXT. RAISE 224
- 9.6.3 Brake Valve 232
- 9B0500 thru OE1179) 237
- 9.6.7 Steer Select Valve 239
- 9.6.8 Priority Valve 240
- 9.7 PUMPS 241
- Threadlocker 242 246
- IMPORTANT 247
- DO NOT operate any boom or 247
- 9.8 TROUBLESHOOTING 248
- HYDRAULIC DIAGRAM 258
- (Cable Controlled with 258
- Transmission De-Clutch) 258
- Hydraulic Pump Flow Test 259
- HYDRAULIC TESTING 259
- 9.9 SPECIFICATIONS 260
- 9.9 SPECIFICATIONS (cont.) 261
- SECTION 10 263
- ELECTRICAL SYSTEM 263
- Warning ! 264
- 10.2 WARNING DEVICES 265
- EMERGENCY 266
- 10.3 WIRING HARNESSES 267
- 10.4 CIRCUIT BREAKERS 267
- AND/OR FUSES 267
- Section 10. Electrical System 268
- S/N 1883 and After 269
- 10.5 STARTING CIRCUIT 276
- 10.5.2 Starter 278
- 10.5.3 Starting Motor Relay 279
- Weather Starting - Perkins 281
- 10.6 CHARGING CIRCUIT 282
- Size of Battery 286
- Temperature 286
- State-of-Charge 286
- Charger Capacity 286
- 10.7 SWITCHES 288
- AND SOLENOIDS 288
- 10.7.2 Neutral Start Switch 289
- 10.7.3 Fuel Run Solenoid 290
- 10.7.4 Park Lock Switch 292
- 10.7.6 Steering Select Switch 293
- 10.7.5 Reverse Switch 293
- 10.8 GAUGES AND INDICATOR 294
- 10.8.3 Hourmeter 295
- 10.8.5 Engine 297
- Low Oil Pressure Sender 297
- 10.8.6 Engine Coolant 298
- High Temperature Sender 298
- 10.8.8 Transmission 298
- 10.8.9 Fuel Gauge 299
- 10.9 OPTIONAL 305
- LIGHTING SYSTEM 305
- 10.9.2 Momentary Brake Light 307
- (Stop Light) 307
- Reservoir (Enclosed Cab Only) 309
- (Enclosed Cab Only) 311
- 10.10.5 Roof Washer Motor and 313
- Reservoir - Later Models 313
- (Enclosed Cab Only) - Later 313
- Cab Only) - Later Models 314
- 10.11 FAN SWITCH AND FAN 315
- MOTOR (OPTIONAL) 315
- 10.12 CAB HEATER 315
- (ENCLOSED CAB ONLY) 315
- 10.14 TROUBLESHOOTING 318
- CONTENTS 318
- Important: Never jumper a 320
- IMPORTANT: Use only 325
- 10.15 SPECIFICATIONS 337
- JLG Worldwide Locations 342
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