Skytrak 6036 Service Manual Bedienungsanleitung PDF herunterladen (Seite 276)

Section 10. Electrical System

10-14

Model 6036/6036T S/N 9B0500 thru 14833

10. When the ignition key is released after start-

ing, it returns to a neutral position where it

directs current to circuit breakers which

distribute current for the operation of forklift

controls, gauges and equipment.

11. When the ignition key is turned to the OFF

position, contacts within the ignition switch are

opened and the fuel run solenoid valve closes,

blocking the flow of fuel to the fuel injection

pump.

10.5.1 Testing Starter in Forklift

General Starter Checks

If nothing happens when you turn the ignition key:

1. The 40 A circuit breaker may be open and

require replacement;

2. There may be a defect in the ignition switch,

ignition wiring, or starter solenoid;

3. Check the condition of the batteries as de-

scribed in paragraph 10.6.2. Clean the battery

posts and the connectors at each end of the

battery cables. Also check the ground cable

between the starter mounting bolt and the

frame.

4. Check for broken wires and damaged insula-

tion on the wires. Replace all broken or

damaged wiring.

5. Check all connections at the starter solenoid,

key switch, and wiring harness plugs. Clean

and tighten all connections.

6. If the starter still does not run after you do

these checks, check the starting circuit.

10.5 STARTING CIRCUIT

When you turn the ignition key to start the engine

with the transmission in neutral, the starting circuit

actuates a starter relay, a starter solenoid, a

starter and a fuel run solenoid. The fuel run

solenoid opens a valve which supplies fuel to the

injection pump.

PERKINS ONLY: When starting in a cold environ-

ment, turning the key to a position between run

and start for a few moments before starting, will

supply current to a thermo start plug in the intake

manifold. The plug ignites a fuel-air mixture in the

intake manifold to facilitate cold weather starting.

The starting circuit functions as follows:

1. Current from the batteries (1, Fig. 10.8) flows

through the positive battery cable (2) to the

starter solenoid.

2. It then flows to circuit breaker (3) and to

terminal “1” of the ignition switch (4).

3. When the key is turned to the START position,

current flows through contacts in the ignition

switch to the emergency brake switch (5).

4. If the emergency brake is set, current flows

through contacts in the brake switch to the

neutral start switch (6).

5. If the transmission select lever is in neutral,

current flows through contacts in the neutral

start switch to energize the coil of the starter

relay (7). The relay closes contacts which

allow current to energize the starter solenoid

and operate the starter.

6. When the solenoid and related mechanisms

cause the starter pinion to engage a gear on

the flywheel, the starter motor rotates the

gear, crankshaft and related components in

the engine.

7. When the ignition key was turned in step 3,

the fuel run solenoid opened a valve to supply

fuel to the fuel injection pump. As the starter

rotated the engine components, the fuel

injection pump and related lines and injectors

supplied fuel to the cylinders.

8. When the pistons compress this injected fuel,

ignition occurs, the engine runs and the starter

pinion retracts.

9. As the engine runs, it operates an alternator

which recharges the battery which was used

during the starting cycle.

Starter Circuit Checks

1. With the key turned to the RUN position, use a

jumper wire to try shorting the positive battery

cable to the solenoid starter connection. If the

starter now cranks, the problem is in the wiring

circuit. If the solenoid fails to “click” the starter

is probably defective.

2. If you hear a “whirring” noise but the engine

does not crank, the starter is spinning but is

not engaging the flywheel. The starter drive or

solenoid that pushes the drive forward to

engage the flywheel may be defective. Miss-

ing teeth on the flywheel can also prevent the

starter from cranking the engine.

3. If the starter only “clicks”, it might indicate

discharged batteries or a loose or corroded

battery cable connection(s). Check battery

charge and condition first.

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