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Effectivity P
age
A
ugust, 1997 - 001 - Or
iginal Issue
F
ebruar
y 11, 2005 - B - Replaced all branding with JLG
.
Model 6036 S/N 9B0500 thru 14833
A
1
2
3
4
5
6
7
8
...
341
342
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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