Skytrak 6036 Service Manual Bedienungsanleitung Seite 264
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Section 10. Electrical System
10-2
Model 6036/6036T S/N 9B0500 thru 14833
10.1.1 Service Warnings
and Recommendations
• DO NOT disconnect the battery while the
engine is running. This will cause a voltage
surge in the alternator charging system that
will immediately ruin the diodes or transistors.
• DO NOT disconnect any wiring without first
stopping the engine, turning all electrical
switches to the OFF position and disconnect-
ing the battery ground cable from the battery.
• DO NOT cause a short circuit by connecting
leads to incorrect terminals. Always identify
a lead to its correct terminal. A short circuit
or wrong connection giving reverse polarity
will immediately and permanently ruin
transistors and diodes.
• DO NOT connect a battery into the system
without checking for correct polarity and
voltage.
• DO NOT “flash” connections to check for
current flow. No matter how brief the contact
the transistors may be ruined.
• Wear safety glasses when working near
batteries.
• All lead-acid batteries generate hydrogen gas
which is highly flammable. If ignited by a
spark or flame, the gas may explode violently
causing spraying of acid, fragmentation of the
battery, and possible severe personal
injuries, particularly to the eyes.
• Avoid battery acid. In case of contact with
acid, flush immediately with water.
• Charge batteries only in a well-ventilated
area. Always be sure battery chargers are
OFF when connecting to or disconnecting
from batteries.
• See Delco Remy Service Bulletin 1B115 and
1B-116 for additional safety information and
procedures.
These instructions assume that all wires are
connected and routed as designed. Take into
account any disconnected and rerouted wires
before you begin any diagnosis. By referring to
the wiring diagrams, you can test circuits for
continuity or shorts by using a conventional test
light, ohmmeter, multimeter or low reading voltme-
ter.
Warning !
A. The area around the base of the stud (the outside
diameter of lock washer (5)) shall be free of paint.
B. Stud, bolt, or capscrew
1. Hex nut or lock nut
2. Tooth or slot type lock washer
3. Flat washer
4. Electrical ground or grounds
5. Tooth type lock washer
Fig. 10.1 Recommended Sequence of Parts for
Electrical Wire Grounding
10.1 SYSTEM COMPONENTS
The electrical system produces, stores, distributes
and uses electricity in the operation of the forklift.
Electricity is produced by an engine-driven alterna-
tor which has a solid state voltage regulator.
Current from the alternator charges the battery
and powers components.
The battery provides power for starting the engine
and supplements the output of the alternator
during periods of peak demand.
Other electrically powered components include a
horn, neutral start switch, steer select valve; park
lock release valve, reverse switch and backup
alarm; an hourmeter, a fuel level sender and
gauge, and a cluster of warning lights.
A forklift may have the following electrical options:
• a lighting system with headlights, tail lights,
directional signals, emergency flashers, rear
work lights and boom light;
• an enclosed cab with air circulating and
heater fans and a windshield washer and
wiper
A
B
2
1
4
3
5
MA0871
- 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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