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Service Manual

1. NS ET 26 s MA1331 1 Wiring Harness 2 Headlight 3 3 Turn Signal Light 2 4 Front Bracket 2 5 Hose Clamp 5 16 6 Locknut 3 8 NC 2 7 Capscrew hex hd 3 8 NC x 1 2 8 Grommet not shown 9 Momentary Brake Light Switch 10 Capscrew hex hd 3 8 NC x 1 3 4 11 Actuator Plate a 3 3 ya g 7 of Pa i I I l me ON SAN SS 22 23 24 25 12 Flasher Mount Ko 15 26 13 Flasher ye a 16 27 14 Machine Screw rd hd 10 24 x 3 4 2 oe Pd 28 15 Locknut 10 24 2 a 29 16 Flat Washer 10 2 30 17 Turn Signal Switch 31 18 Conduit 1 2 ID x 12 not shown 32 19 Head Light Switch 33 20 Terminal female 1 4 spade 7 34 21 Hose Clamp 3 8 2 35 Fig 10 53 Schematic of Lighting System Model 6036 S N 9B0499 and Before Section 10 Electrical System 8 IS A GROMMET NOT SHOWN 24 IDENTIFIES FOUR PLASTIC TIES NOT SHOWN MA1332 Tail Light Bracket 2 Stop and Tail Light 2 Plastic Tie 4 diameter not shown Terminal male 1 4 spade Wire As
2. RIGHT BOOM HOIST CYLINDER i DE BOOM HOIST RELIEF VALVE HOIST CYLINDER PRESSURE GAUGE COUNTERBALANCE VALVES MA0421 0 4000 psi _ MAIN CONTROL VALVE DIRECTIONAL CONTROL VALVE POSITIONS RAISE LOWER ABC ABC ABC CERI s DEF DEF DEF CENTER MAIN RELIEF VALVE RESERVOIR aaa eG OT STRAINER RETURN FILTER Fig 9 1 Boom Hoist Circuit port relief valve Fig 9 2 will open allowing hydraulic oil to return to the reservoir Return oil from the top end of the boom hoist cylinder piston is directed back to the directional control valve through ports B to D Fig 9 1 to the return filter and reservoir If the filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar Lower Position When the joystick is placed in the lower position the directional control valve spool is shifted so that supply pressure is directed through ports E to B Fig 9 1 to the rod top end of both left and right boom hoist cylinder pistons This supply pressure also pilots open the counterbalance valve Fig 9 1 The open counterbalance valve allows return Model 6036 S N 9B0499 and Before oil from the base end of the cylinder to return through ports A to D Fig 9 1 of the directional control valve to the return filter and
3. CAPSCREW 3 CAPSCREW 3 MA0091 Fig 3 9 Front Wear Pads Attached to Outer Boom Rear Wear Pads are Attached to Intermediate Boom 3 Install the capscrews and lock washers locking the boom pivot pins to the outer boom 4 Rest the front of the boom on cribbing so it is not solely supported by the hoist 5 Install the grille tilt cylinder tubing in clamps on the bottom of the outer boom Fig 3 8 and connect each tube extend tubes and bulkhead fittings to fittings at the support plate Connect main valve hoses Tighten the tube clamps 6 Refer to Fig 3 8 and connect the grille tilt cylinder hoses to the tubing Route the hoses around hose guide bracket and into the outer boom Continue pushing the hoses until they come out the rear boom cover opening 7 Install the base end of the boom extend retract cylinder on the outer boom with a pivot pin Fig 3 7 and retaining rings Coat the pin with anti seize compound 8 Reattach tubes to extend cylinder ports 9 Attach the rod end of the slave cylinder to the outer boom with a pivot pin and lock the pin in place with a capscrew and locknut Model 6036 S N 9B0499 and Before 10 Attach the rod end of each hoist cylinder to the outer boom with a pivot pin and lock the pin in place with a capscrew and locknut SHIM HERE TO MAINTAIN 0 07 TO 0 13 1 8 TO 3 3 mm GAP USING 10 AND OR 14 GA WASHER SPACERS CAPSCREW AND LOCK NUT
4. 2 A 1 MA1401 Torque from 18 to 22 Ib inch 2 03 to 2 49 Nm Screw 3 Cover Spacing Washers Cable Securing Bracket Parking Switch Assembly Cable Assembly Gear and Shaft Assembly Spacing Washer Automatic Wiper Parking Adjustment Stud Wiper Motor Fig 10 63 Wiper Motor Disassembly 10 55 Section 10 Electrical System c Disassembly 1 To facilitate reassembly place parts ona clean bench or in a clean pan in the order in which they are removed 2 Remove cover fastening screws 1 Fig 10 63 cover 2 spacing washers 3 and cable securing bracket 4 from the gear housing 3 Remove parking switch assembly 5 If the parking switch is to be replaced unsolder all leads from the plate 4 Remove cable assembly 6 if replacement is necessary 5 Remove gear and shaft assembly 7 and spacing washer 8 from the drive shaft NOTE If drive gear housing or motor housing is damaged beyond repair replace motor assembly d Cleaning and Drying 1 Clean the gear and shaft assembly 7 and the armature shaft worm with Varsol or equivalent cleaning fluid IMPORTANT Bearing equipped parts must not be immersed in the cleaning fluid These parts should be cleaned with a brush dipped in the cleaning fluid making certain that the cleaning fluid does not contact the bearings 2 Thoroughly dry all parts that have been in contact with the cleaning fluid 3 Clean the parking switch u
5. TIE ROD by x L BALL JOINT KNUCKLE OA0192 Fig 5 17 Axle Grease Points 5 3 AXLE LUBRICATION A Warning 5 3 1 Grease Lubricate the following axle points Fig 5 17 after Do not attempt carrier and differential removal overhaul or at 50 hour intervals using multi purpose and installation and differential and pinion lithium based grease disassembly and assembly without thor e pivot pins 4 points e Pa nan e TA Lubricate the following axle points Fig 5 17 after aie to your forklift P overhaul or at 250 hour intervals using multi i purpose lithium based grease e steering knuckles 8 points e tie rod ball joints 4 points e steer cylinder ball joints 8 points If it becomes necessary to disassemble any parts inside the carrier it is suggested that the entire axle be removed from the forklift and held tight in a stand or rack with carrier 5 3 2 Differential Housing Oil pinion positioned up Level Check 250 hour intervals When removing axle assembly make sure forklift is properly supported an improperly 1 Clean the area around the axle and remove the supported vehicle can cause serious injury or fill and level plug Fig 5 18 from the axle death housing If axle assembly is still in the forklift be sure Check the oil level carrier differential and pinion assemblies are 3 Add gear oil meeting military specification MIL securely supported before they are separated L2105C API classific
6. FRAME BEARING FRAME OUTER BOOM Q BOOM PIVOT PIN DO NOT SHIM HERE GREASE FITTING MA0101 Fig 3 10 Boom Pivot Pin Shimming 3 7 Section 3 Boom 11 12 13 14 15 16 3 8 SHOULDER SCREW AND LOCKNUT YOKE oe CLEVIS SHOULDER SCREW AND LOCKNUT PIN AND RETAINING RING EXTEND CHAIN LOCKNUT AND EXTEND CHAIN FLAT WASHER BLOCK sul q erer OUTER BOOM Fa ay e A G E EEA E A E A E E E E EA INNER BOOM M PEELLLLL te INTERMEDIATE BOOM in ren TT INNER BOOM A RETRACT RETRACT OAN ee OUTER BOOM ere CRAIN a RETRACT CHAIN Rae LOCKNUT AND LOCKNUT AND a FLAT WASHER FLAT WASHER MAO111 Jf Fig 3 11 Chain Replacement pads and the intermediate boom The gap Attach the two extend chains at the chain yoke Fig 3 11 on top of the boom Allow the remaining ends of the chains to hang free until should be 0 07 to 0 13 1 8 to 3 3 mm and equal on all sides Remove or install shims as required the intermediate boom has been installed IMPORTANT The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert the ends must range from flush to 0 19 5 mm recessed in the wear pad insert refer to Fig 3 3 17 Install the wear pads by applying Loctite 242 to the capscrews and
7. If the forklift is equipped with lighting switch on the lights If not connect a 0 20 Vdc voltmeter across the battery terminals before proceeding Disconnect the wire from the fuel shut off solenoid at the fuel injection pump Turn the ignition switch to START and watch for the following symptoms e The lamps dim or the voltmeter reading drops to about 6 volts and the starter motor does not crank the engine Check the batteries must be at least half charged and battery lugs clean and with a good ground connection e Ifthe lamps do not dim or the voltmeter reading remains steady at about 12 volts and the starter does not crank the engine connect voltmeter between the BAT 10 11 Section 10 Electrical System solenoid terminal and the starter yoke Operate the starter 2 If no volts are indicated check for e poor lug connections at battery e bad ground connection e broken starter lead batteries to starter 3 If full voltage 12 to 14 V is indicated check for e Faulty solenoid switch e Open circuit in starter check brushes 4 Reconnect the wire from the fuel shut off solenoid at the fuel injection pump REMOTE START 1 I I i SWITCH I BUTTON i I I BATTERY TERMINAL MA0921 Fig 10 9 Measuring Voltage Loss in Complete Starting Circuit 10 5 2 How to Check Voltage Loss in the Starting Circuit e The starter remains on the engine for these tests e Do not operate
8. PAD INSERT 2 LOCK WASHER 6 INTERMEDIATE FLAT WASHER 6 BOOM 3 8 16 X 7 8 CAPSCREW 2 3 8 16 X 1 3 4 CAPSCREW 4 cana Fig 3 5 Front Wear Pads Attached to Intermediate Boom 3 4 Inspect hoses and replace if damaged Inspect and replace wear pads as described in paragraph 3 1 8 c Installation 1 Refer to Fig 3 6 and install the rear bottom wear pad Fig 3 6 on the intermediate boom Install a new pad if it is excessively worn refer to paragraph 3 1 8 Apply Loctite Removable Threadlocker 242 to the capscrews and torque them to 31 Ib ft 42N m 2 Using a sling and a suitable hoist slide the repaired or new intermediate boom into the outer boom 3 Working through the rear boom cover opening refer to Fig 3 6 and temporarily install the rear top and side wear pads on the intermediate boom Replace pads that are excessively worn Use the same amount of shimming as used when the pads were removed IMPORTANT The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert the ends must range from flush to 0 19 5 mm recessed in the wear pad insert refer to Fig 3 3 4 Refer to paragraph 3 1 1 c and install the inner boom 5 Connect the extend chains at the front of the outer boom 6 On the front of the intermediate boom check the gap between the intermediate boom side and top wear pads and the inner boom Fig 3 5 The gap should be 0 07 to 0 13 inches 1
9. 1 Lower carriage to ground shut off engine and engage park lock 2 Unlock and open the left rear engine access door 3 Inspect the fan belt Replace a cracked or frayed belt 4 Check fan belt tension midway between the crankshaft and alternator pulleys Fig 8 2 Deflection should be 1 4 to 3 8 6 to 9 mm with an applied force of 13 to 15 Ibs 6 to 7 kg 5 If belt deflection exceeds the tolerance loosen both alternator mounting screws Carefully pry the alternator to tighten the belt and at the same time tighten the alternator screws Recheck belt deflection 6 Close and lock the left rear engine access door HEX SCREW FILTER ELEMENT FUEL FILTER BASE DRAIN KL AVR COCK OA0302 Fig 8 9 Fuel Filter 8 1 5 500 Hour Intervals Fuel Filter 1 Unlock and open the right rear engine access door 2 Remove screw in top of the filter assembly Fig 8 9 3 Remove filter base and discard element 4 Clean base and head Model 6036 S N 9B0499 and Before Section 8 Engine 5 Position a new filter element between the base and head and install and tighten screw on top of filter assembly until snug 6 Remove air from the fuel system See paragraph 8 4 8 How to Bleed to Fuel Sys tem 7 Close and lock the right rear engine access door Fuel Lift Pump Sediment Chamber 1 Unlock and open the left rear engine access door COVER STRAINER FUEL LIFT PUMP Fig 8
10. 8 Unscrew the piston from rod Remove O ring 8 from inside of the piston 9 Slide stop tube 9 and gland 12 from the rod 10 Remove O ring 10 backup ring 11 wiper 2 rod seal 3 and step seal 17 from the gland Rod Wiper Rod Seal Piston Seal Piston Setscrew 11 If necessary remove the plugs 16 from bottom inside of the tube 13 Cleaning Discard all seals and backup rings Replace with a complete new seal kit Clean all metal parts in an approved cleaning solvent such as trichlorethylene Be sure to carefully clean all cavities and grooves Inspection Repair and Replacement Check that the rod 1 Fig 9 12 is straight If the rod is bent install new rod Setscrew Nylon O ring Stop Tube 10 O ring 11 Backup Ring 12 Gland 13 Cylinder Tube 14 Counterbalance Valve 15 Pilot Check Valve 16 Plug 2 17 Step Seal 18 O ring 6 19 Backup Ring 6 COMDNOARWNM gt MA0532 Fig 9 12 Boom Extend Cylinder Exploded View Model 6036 S N 9B0499 and Before 9 28 2 Inspect inside of the tube 13 for deep scoring and other damage If the tube is damaged replace with new tube 3 Remove small scratches on the rod or inside the tube with emery cloth of very fine grit Use the emery cloth with a rotary motion e Assembly NOTE Follow general assembly instructions in paragraph 9 2c 1 Install a new O ring 10 backup ring 11 wi
11. Repair cylinders as required para 9 2 5 Repair control valve as required para 9 3 1 Repair tandem pump para 9 4 1 Repair or replace cylinder and check valves para 9 2 5 Adjust pressure reducing valve para 9 1 5 Check and add oil to planetary wheel ends Refer to Owners Operators manual Adjust pedal linkage para 4 3 1 Bleed brake lines para 9 3 29 Adjust pressure reducing valve para 9 1 5 9 72 Trouble Probable Cause Section 9 Hydraulic System Remedy Service Brakes Fail to Release Service Brake Failure Park Lock Brake Fails to Release Park Lock Brake Fails to Set Power Steering Fail ure Total No 4 Wheel or Crab Steering or Failure to Change Mode 9 73 Brake pedal not adjusted correctly Faulty brake valve plunger piston or spring Ruptured hydraulic hose Faulty brake valve spring plunger piston or valve Pressure reducing valve failure Insufficient pressure at sequence valve Defective discs or leakage within brake Ruptured hydraulic hose Defective park lock switch Park lock release valve fails to shift Defective park lock Corrosion binding or worn parts in park lock Defective solenoid Defective switch Ruptured hydraulic hose Faulty power steering unit Tandem pump failure Defective solenoid in steer select valve Faulty steer select switch or wiring Broken spring in steer se lect valve Adjust pedal linkage para
12. 13 Apply a compression sleeve or other suitable tool to the gland in order to compress O ring 10 on the gland Insert the assembled piston rod and gland into the tube 13 Using 9 29 Section 9 Hydraulic System a pin spanner wrench thread the gland into tube Remove the compression tool IMPORTANT When sliding the rod and piston assembly in the tube be careful so that gland threads in the tube do not damage the piston seal Keep the rod in line with the tube barrel to prevent binding 14 Install new O rings 18 and backup rings 19 on the counterbalance valve 14 and pilot check valve 15 Use new valves if either or both valves were removed for replacement Lubricate outside of the valves with clean filtered hydraulic oil Install the valves and torque them to 45 lb ft 61 2 N m 15 Following reassembly test the cylinder at low operating pressure 100 psi or 6 9 bar to be sure the piston and rod are moving freely in both directions 16 Increase the operating pressure to the maxi mum 4000 psi or 275 6 bar for the cylinder and check for external leakage and free movement in both directions 17 Prepare the cylinder for installation by retract ing the piston and capping and plugging the ports f Installation 1 Using suitable lifting device install the boom extend cylinder Fig 9 9 on the forklift secur ing the base end of the extend cylinder to the outer boom with a pin and retaining rings
13. 14 Start the engine and maintain engine speed at 1000 rpm Operate the auxiliary control function several times to purge the system of air Place the auxiliary control lever in the forward position and hold until the pressure readings are taken Check the pressure gauge reading It should read 3 000 50 psi 206 7 3 4 bar If not adjust the main relief valve Fig 9 2 by turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m after adjustment Place the auxiliary control lever in the back ward position and hold until the pressure readings are taken Check the pressure gauge reading It should read 3 000 50 psi 206 7 3 4 bar If not adjust the main relief valve Fig 9 2 by turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Stop the engine Operate the hydraulic control after the engine has stopped to relieve any trapped pressure Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line Start the engine Operate the auxiliary control fully several times to purge the system of air Install the transmission cover after adjustment 9 22 9 2 CYLINDERS Rebuild cylinders only in a clean well lighted area where you can carefully inspect all components If a cylinder is to remain dismantled for any lengthy perio
14. 4 Ifthe park lock brake is set current flows through contacts in the brake switch to the neutral start switch 8 5 Ifthe transmission select lever is in neutral current flows through contacts in the neutral start switch to energize the coil of the starter relay 9 The relay closes contacts which allow current to energize the starter solenoid 3 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 10 9 Section 10 Electrical System eH o ONDON 10 11 TO THERMO START PLUG TO FUEL RUN SOLENOID Battery 12 V Positive Battery Cable Starter Solenoid Circuit Breaker 40 A Ignition Switch Ignition Key Park Lock Brake Switch Neutral Start Switch CIRCUIT BREAKER
15. Chain out of adjustment Improper chain lubrication Remedy Locate break and or stop leaks Repair Cylinder Troubleshoot components and repair or replace components Repair or replace chains Locate break and or stop leaks Repair Cylinder s Troubleshoot components and repair or replace Replace worn pins and lubricate at regular intervals Replace bearings and lubricate at regular intervals Check shim adjustment and shim properly Prep boom properly for long term storage Readjust chains Reset hose sheave tension Replace and readjust chains properly Replace chain s and lubricate at regular intervals Reference Section 9 Section 9 See para 3 1 4 Section 9 Section 9 See para 3 1 11 Section 9 See para 3 1 8 See para 3 1 10 See para 3 1 7 See para 3 1 9 See para 3 1 4 amp 3 1 6 See para 3 1 4 amp 3 1 5 Model 6036 S N 9B0499 and Before Section 3 Boom 3 5 SPECIFICATIONS For 13 00 24 10 ply Tires For 15 00 19 5 12 ply Tires Maximum lift height boom extended 36 ft 1 in 11 m 35 ft 5 in 10 8 m Maximum lift height boom retracted 20 ft 1 in 6 1 m 19 ft 3 in 11 7 m Maximum below grade depth boom 39 5 in 100 3 cm 40 5 in 102 9 cm extended Maximum reach from front of tire 22 ft 5 in 6 8 m 22 ft 10 in 7 0 m Maximum reach at maximum lift 45 0 in 114 3 cm 50 5 in 128 3 cm angle boom extende
16. 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 10 2 1 Pia 5 Oma MA0881 A Partial sectional view of component to be grounded B Stud bolt or capscrew 1 Hex nut or lock nut 2 Tooth or slot type lock washer or locking nut with slotted type lock washer 3 Flat washer Fig 10 2 Recommended
17. Exhaust fumes are highly toxic and can kill Escaping coolant can burn you seri ously To prevent serious injury and or death To prevent serious injury and or death A pressure explosion will cause serious injury To prevent damage to the system or the equipment and to eliminate the possibility of personal injury To prevent accidental injury To prevent serious injury and or death To prevent dangerous travel and load handling Over inflation can cause tires to burst and result in personal injury The safety precautions and practices in this manual are extremely important Not following them can cause personal injury or death Read this section carefully and be sure you understand all the precau tions and practices noted before attempting to service the forklift Model 6036 S N 9B0499 and Before This Page Left Blank Intentionally Section 2 General Instructions SECTION 2 GENERAL INSTRUCTIONS CONTENTS Par Title Page Par Title Page 2 1 INTRODUCTION 2 2 2 9 AFTER SERVICE STARTUP 2 2 CLEANING 2 2 AND CHECKS 2 5 2 3 REPLACEMENT 2 2 2 9 1 Starting After Servicing 2 5 2 4 HOSES AND TUBES 2 2 2 9 2 After Hydraulic Component 2 4 1 Inspection 2 2 Servicing 2 5 2 4 2 Installation 2 2 2 9 3 After Brake System Servicing 2 5 2 5 BEARINGS 2 3 2 9 4 After Fuel System Servicing 2 5 2 5 1 Removal 2 3 2 9 5 After Replacing Transmission 2 5 2 5 2 Cleaning 2 3 2 9 6 After Tire Servicing 2 5 2 5 3 Installati
18. If a fuel gauge malfunctions perform the following checks 1 Check for loose gauge mounting screws defective wiring faulty grounds and corrosion on fuel tank ground connection 2 If pointer in gauge does not move when ignition key is turned ON use a test lamp to see if current is flowing from the ignition switch to the terminal on the gauge Also be sure paint or corrosion doesn t prevent proper ground If pointer still doesn t move gauge is defective and must be replaced 3 If gauge doesn t indicate fuel level in tank be sure gauge is 0 30 ohm 12 V 10 45 Section 10 Electrical System 4 If gauge shows no indication look for an empty fuel tank no current to ignition terminal because of broken or disconnected lead grounded wire between sender and gauge gauge not grounded or sender defective 5 Excessive pointer fluctuation may be caused by loose wire connections or defective sender 6 Full scale reading at all times may occur if wire to sender is broken sender is not prop erly grounded of if sender is defective 7 If gauge indicates inaccurately sender may be defective or there may be low voltage at gauge terminals 8 If the pointer fluctuates when optional head lights are turned on the engine is not properly grounded b Fuel Gauge Bulb Replacement 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Remove four bolts 12 Fig 10 47 which secure the ri
19. lt c If the drive collar parks after it has com pleted an oscillation and has started the return swing move the adjustment stud 9 Fig 10 63 clockwise d lt Start the motor shut it off and note the new parking position of the drive collar e lt Repeat the procedures in paragraphs 3b c and d until the required parking position is obtained then tighten the cover fasten ing screws 1 to a torque of 18 to 22 Ib in 2to2 5N m Install wiper arm and blade in park position Operate the wiper and note the park position of the blade when the unit is turned off 6 If the blades don t park in the required posi tion readjust as described in step 3 NOTE Never adjust the arm and blade to park closer than 1 1 2 to 2 from the windshield mould ing The wipe angle of a 18 arm with a 18 blade should not exceed 127 j Installation 1 Attach the motor 33 Fig 10 62 to the motor mount 32 using three lock washers 31 and capscrews 30 2 Install the drive arm 28 and nut 27 on the gear and shaft assembly 7 Fig 10 63 3 While an assistant supports the windshield wiper motor from within the cab install the gasket 22 Fig 10 62 panto adapter 21 flat washer 20 and screw 19 4 Connect the wiring to the wiper motor a Install the fiber washer 18 washer 17 nut 16 and rubber cap 15 Install wiper arm 13 on knurled driver 14 Install washer 12
20. A Warning DO NOT get under a raised boom unless the boom is blocked up Always block the boom before doing any servicing which requires the boom to be up IMPORTANT If the boom has been extended you must first retract the boom before you attempt to lower the boom To retract the boom proceed as follows 1 Block the boom so it cannot be lowered 2 At the base end of the extend retract cylinder locate the counterbalance valve cartridge Fig 3 18 Loosen the retainer nut and turn the adjusting screw in clockwise until it bottoms out Doing this will render the counterbalance valve inoperative 3 Clear the area around the machine of all personnel and return to the operators cab 4 Move the boom control lever to the left and retract the boom 3 13 Section 3 Boom COUNTERBALANCE VALVE RETAINER NUT OA0552 Fig 3 19 Counterbalance Valves on Boom Hoist Cylinders After the boom has been retracted fully proceed as follows 1 Atthe base of each hoist cylinder locate the counterbalance valve cartridges Fig 3 19 Loosen the retainer nut on each cartridge and turn the adjusting screws in clockwise until they bottom out Doing this will render each counterbalance valve inoperative 2 Remove the blocking that is supporting the boom 3 Clear the area around the machine of all personnel and return to the operators cab 4 Move the boom control lever forward to lower the boom IMPORTA
21. IMPORTANT Do not touch this wire to the left SEND terminal post on the gauge or the sender capsule will be damaged 6 Refer to paragraph 10 8 2 for the installation of the gauge cluster Installation of the Sender 1 Install a new gasket in the tank opening 2 Carefully tilt and lower the sender assembly into the fuel tank 3 Loosely install the screw which secures the ground wire to the sender and fuel tank 4 Install the other four screws and alternately torque the five screws which secure the sender to the fuel tank from 10 to 14 Ib inch 1 13 to 1 58N m Use No 10 24 screws 5 Install the wire and nut on the center terminal of the sender 6 Connect negative cable to the batteries 10 9 OPTIONAL LIGHTING SYSTEM The optional lighting system Fig 10 53 provides e headlights 2 directional signal and hazard warning lights 3 at the front of the forklift e directional signal hazard warning stop and tail lights 23 and a rear work light 35 at the rear of the forklift and e an illuminated fuel level gauge The stop lights glow when the brake pedal is pressed The stoplights are combined with the directional signal lights emergency flasher lights and tail lights Occasionally check to be sure e all wiring connections are tight and clean e that each lighting unit is tightly mounted to provide a good ground and e that the headlights are properly adjusted Model 6036 S N 9B0
22. PISTON internally The differential pressure between the supply pressure and the internal pressure causes the relief valve poppet to unseat and fluid flows to the reservoir thus relieving the pressure If low supply pressure should occur due to pump cavitation the check valve poppet will unseat and allow fluid to flow back to the supply from the reservoir Refer to paragraph 9 1 for information on relief valve functions and testing PILOT PILOT POPPET SPRING RELIEF VALVE ae POPPET L TO CHECK VALVE POPPET RESERVOIR RELIEF PLUG ADJUSTMENT AREA SCREW MA0652 Fig 9 24 Relief Valve Sectional View Model 6036 S N 9B0499 and Before 9 46 Disassembly Remove the relief valve from the control valve housing Unscrew plug 1 Fig 9 25 and remove the relief valve cartridge from housing 8 Remove and discard O ring 9 from housing Remove acorn nut 19 and jam nut 17 from adjustment screw 15 Remove and discard O rings 16 and 18 Unscrew adjustment screw 15 from plug 1 Invert the plug Pilot spring 14 and poppet 13 should drop out Remove O rings 10 and 12 and backup ring 11 from the plug Remove piston spring 2 piston 3 and relief valve poppet 4 from check valve poppet 7 Remove and discard O ring 5 and bac
23. 1 Before reassembly be sure parts are clean and free from foreign matter Use an ap proved solvent such as trichlorethylene for cleaning 2 Protect the finish on the rod at all times Damage to the rod can cause premature seal failure 3 Use proper tool for specific installation task Clean tools required for installation before use 9 23 Section 9 Hydraulic System 4 Do not overstretch seals wipers and O rings Make sure that seals wipers and O rings are not twisted or distorted in their grooves 5 Lubricate piston seals and seal installation path with clean hydraulic oil from a filtered supply 6 Use a suitable compression tool when install ing glands into cylinders to prevent damage to the seals and O rings Place a little hydraulic oil on the seals and outside of glands to aid in installation 7 Follow the manufacturer s instructions when applying primer locking or retaining com pounds which are specified in reassembly procedures The use of primer is recom mended in some cases to decrease cure time Allow sealant compounds to cure fully The curing process may be hastened by the use of a heat gun to blow warm dry air on the parts 8 Following reassembly test cylinder at low operating pressure to be sure the piston and rod are moving freely in both directions 9 Increase the operating pressure to the maxi mum recommended for the cylinder and check for external leakage and free movement
24. 1 Level the forklift lower carriage to ground shut off engine and engage park lock 2 Unlock and open the right rear engine access door COOLANT OIL FILL OIL DIPSTICK OVERFLOW CAP FILTER BOTTLE OA0242 Fig 8 7 Coolant and Engine Oil 3 Check the level of coolant in the overflow bottle Fig 8 7 When the coolant is hot the bottle should be 3 4 full to full When the coolant is cool the bottle should be 1 4 to 1 2 full 4 Add coolant as required through the overflow bottle Use a 50 50 mixture of ethylene glycol and water 5 Close and lock the right rear engine access door Engine Oil Level 1 Level the forklift lower the carriage to ground shut off engine and engage park lock 2 Unlock and open the right rear engine access door 3 Remove the engine oil dipstick Fig 8 7 and check the level Oil should be between the full and add mark Replace dipstick 4 If required add 10W30 motor oil equal to API SE CC or SE CD Specifications 5 Close and lock the right rear engine access door 8 1 4 250 Hour Intervals Engine Oil and Filter Change 1 Operate the engine until it is warm approxi mately 5 minutes 8 4 2 Level forklift lower the carriage to ground shut off engine and engage park lock 3 Place a receptacle under the engine oil pan drain plug 4 Remove drain plug on rear face of the engine oil pan and allow oil to d
25. 2 Remove all plugs or caps from the hydraulic lines and securely tighten the lines to the cylinder A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Have a helper start the forklift engine Position the extend cylinder so that the rod is aligned with the rod end mounting holes as much as possible 5 Instruct the operator to extend or retract the cylinder slowly until the rod end eye is aligned with the intermediate boom mounting holes Secure the rod end to the boom with pin and retaining rings 6 Install the anti buckle bar Fig 9 11 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 7 Extend the boom as far as it will go then the retract it as far as it will go five times or until the operation of the boom extend cylinder is normal no jerks or spongy feel 8 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual 9 Test boom extend retract circuit operation as described in paragraph 9 1 2c 9 2 3 Slave Cylinder a Removal 1 Raise the boom as required to provide access to the slave cylinder Fig 9 9 A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Engage the park lock place the travel select lever in neutral and stop the engin
26. 6 A Circuit Breaker Hydraulic Pump 40 Case Ground Warning Lights Gauge 51 Horn Button Switch 49 Reverse Switch 53 Horn 25 Ignition Key Switch 24 Starter Solenoid 38 Ground to Engine Starter Solenoid 38 Air Circulation Fan 43 Backup Alarm 16 Washer Wiper Switch 44 Washer Wiper Switch 44 Fuel Run Solenoid 34 Thermo Start Plug 61 Neutral Start Switch 35 10 A Circuit Breaker 10 Ground Park Lock Brake Switch 46 Park Lock Brake Switch 46 Model 6036 S N 9B0499 and Before OA0482 1 Circuit breaker 6 A protects steering select valve circuit 2 Circuit breaker 10 A protects horn and backup alarm and optional cab heater fan circuit 3 Circuit breaker 6 A protects instrument panel park lock solenoid switch 4 Circuit breaker 40 A protects ignition system feed for entire electrical system 5 Circuit breaker 6 A protects enclosed cab windshield washer wiper and circulation fan circuits this breaker is optional and will not be found on forklifts with an open cab 6 Circuit breaker 15 A protects the optional lighting package Fig 10 6 Circuit Breakers 4 Disconnect wiring from all of the circuit break ers in the bracket 5 Remove two nuts lock washers and two washers and slide bracket over the studs b Installation of Circuit Breaker Bracket and Individual Circuit Breaker 1 Slide circuit breaker br
27. 61 ITEM 30 IS TIE WRAP WHICH IS NOT SHOWN PA0684 Park Lock Brake Switch Test Switch Steer Select Switch Horn Button Hourmeter Warning Lights Gauge Fuel Gauge Reverse Switch Windshield Wiper Motor Steer Select Valve Solenoid 2 Park Lock Release Valve Solenoid Heater Switch Kit Protection Conduit Shake Proof Washer 3 8 2 Capscrew hex head 3 8 16 x 1 2 Thermo Start Plug Fig 10 5 Drawing 2 Engine Harness and Components of Electrical System Model 6036 S N 9B0499 and Before 10 7 Section 10 Electrical System Electrical System Circuits Use with Fig 10 5 Electrical System Wire No Color From To Black Ignition Key Switch 24 Park Lock Brake Switch 46 White Hour Meter 50 Ground White Warning Lights Test Switch 47 Ground White Fuel Level Gauge 52 Ground White Steer Select Solenoid 55 Ground White Steer Select Solenoid 55 Ground White Park Lock Release Valve Solenoid 56 Ground Red 6 A Circuit Breaker 12 Ignition Key Switch 24 Yellow Engine Low Oil Pressure Switch 31 Brake Hydraulic Pump Solenoid Yellow Alternator 39 Starter Solenoid 38 Yellow Alternator 39 Alternator Warning Light 51 Not Used OAONDOARWNHNNNNDND Yellow Steer Select Switch 48 Yellow Red Red Red Red Steer Select Swi
28. 8 3 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 8 4 ENGINE FUEL SYSTEM The engine fuel system includes a fuel tank 1 Fig 8 18 a fuel level sender 2 and gauge a fuel pre filter 3 a fuel pump Fig 8 10 a fuel filter 22 Fig 8 18 and fuel lines to and from the fuel injection pump and fuel lines from the fuel injec tion pump to and from the fuel injectiors back to the fuel filter and fuel tank A separate line runs from the fuel filter to the Thermo Start plug Fig 8 14 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 8 18 A 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 21 The fuel then flows through a fuel filter tube a hose and a fuel pump tube to the fuel lift pump Fig 8 10 which is located on the left side of the engine A tube carries fuel under pressure from the fuel lift pump to the fuel filter 22 Fig 8 18 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 8 14 in the
29. Black Exhaust 11 13 14 16 18 19 20 22 24 25 27 28 29 31 32 33 61 63 Blue White Exhaust 4 16 18 19 20 25 27 31 33 34 35 45 56 62 Low Oil Pressure 4 36 37 38 39 40 42 43 44 58 Knocking 9 14 16 18 19 22 26 28 29 31 33 35 36 45 46 59 Erratic Running 7 8 9 10 11 12 13 14 16 20 21 23 26 28 29 30 33 35 45 59 Vibration 13 14 20 23 25 26 29 30 33 45 47 48 49 High Oil Pressure 4 38 41 Overheating 11 13 14 16 18 19 24 25 45 50 51 52 53 54 57 Excessive Crankcase Pressure 25 31 33 34 45 55 60 Poor Compression 11 19 25 28 29 31 32 33 34 46 59 Starts and Stops 10 11 12 Battery capacity low Bad electrical connection Faulty starter motor Incorrect grade of lubricating oil Low cranking speed Fuel tank empty Faulty stop control operation Blocked fuel feed line Faulty fuel lift pump 10 Choked fuel filter 11 Restriction in air cleaner 12 Airin fuel system 13 Faulty fuel injection pump 14 Faulty atomizers or incorrect type 15 Incorrect use of cold start equipment 16 Faulty cold start equipment 17 Broken fuel injection pump drive 18 Incorrect fuel pump timing 19 Incorrect valve timing 20 Poor compression 21 Blocked fuel tank vent 22 Incorrect grade of fuel CONOARWNY gt Key to Possible Causes 23 Sticking thr
30. MA0011 Fig 3 1 Boom Assembly 3 1 Section 3 Boom QUICK ATTACH PIVOT PIN GOOSENECK WITH GREASE FITTING Sie ee PIN LOCK GRILLE TILT PIN CYLINDER 3 2 QUICK ATTACH ASSEMBLY ROD END PIN MA0021 Fig 3 2 Gooseneck Prepare to replace the inner boom Fig 3 2 by removing the grille tilt cylinder as described in paragraph9 2 4 a Remove the quick attach pivot pin Fig 3 2 and quick attach assembly from the goose neck Remove the rear boom cover Fig 3 1 Pull the grille tilt cylinder hoses out the rear boom cover opening Working from the rear boom cover opening record the number of shims beneath each wear pad as you remove the side and top wear pads from the inner boom Fig 3 3 Refer to Fig 3 1 and remove the locknuts and washers that attach the extend and retract chains to the inner boom Use a sling and a suitable hoist to slide the inner boom out the front of the intermediate boom Refer to Fig 3 3 and remove bottom wear pad from the rear of the inner boom Inspection and Replacement Inspect the boom and welds and contact JLGif structural damage is detected Inspect hoses and replace if damaged Inspect and replace wear pads as described in paragraph 3 1 8 c installation 1 Refer to Fig 3 3 and install the bottom wear pad on the inner boom Install a new pad if it is excessively worn refer to paragraph 3 1 8 Apply Loctite Removable Threadlocker 2
31. MIL L 2104C Oils S A E Designation 0 F 18 C 30 F 1 C to to Over 30 F 1 C 80 F 27 C 80 F 27 C Castrol Ltd Castrol Deusol CRD 10W Deusol RX Super Agricastrol HDD 10W Agricastrol MP Agricastrol MP Esso Petroleum Co Ltd Essolube D 3HP 10W Essolube XD 3 10W Essolube XD 3 Mobil Oil Co Ltd Delvac 1300 Series 1310 Shell Rimula CT 10W 20W 20 Rimula X 10W 20W 20 Rimula X 10W 30 10W 30 Rimula X 15W 40 Rimula X 20W 40 Rotella TX 10W 20W 20 Rotella TX 20W 40 20W 40 8 8 Model 6036 S N 9B0499 and Before 8 2 ENGINE COOLING SYSTEM The engine cooling system consists of coolant passages in the engine a thermostat pump hoses a radiator and a radiator overflow tank The engine is cooled by the circulation of coolant through passages in the cylinder block and head Circulation is by thermo syphon action assisted by an impeller type water pump driven by a V belt from the crankshaft pulley The water pump bearings are pre packed with a special grease during assembly and do not require attention in service 8 2 1 Coolant Requirements The quality of coolant will determine the efficiency and life of the cooling system DO NOT USE HARD WATER in the cooling system Hard water or water with high levels of calcium and magnesium ions encourages the formation of silica gel formations especially after a number of heating and cooling cycles These gel formations can result in loss of cool
32. SK YTRAK Service Manual Model 6036 S N 9B0499 amp Before 8990151 Revised February 11 2005 Effectivity Page January 1997 001 Original Issue February 11 2005 B Replaced all branding with JLG Model 6036 S N 9B0499 and Before Effectivity Page Model 6036 S N 9B0499 and Before SECTION CONTENTS Section Subject Page Section 1 Safety Practices eae eer ee ene Ne ene eee ree eee 1 1 Section 2 General NSUUCHIONS 07005 dreeesrrtenare aay career eee actos 2 1 Section 3 EOIN aa e seavan Siaeevsn ti E a A E 3 1 Section 4 Operat r s CaP aitietaanventcavenanne aati EE E 4 1 Section 5 Wheel Assembly Tires and AXle cccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 5 1 Section 6 Drive Shafts and Drop BOX yc cctor etnias pentest ante eieoneerenecnens 6 1 Section 7 Transmission Clark Series 18000 cece cecceceeecsseeeseseeeesesueeeeeees 7 1 Section 8 Engine Perkins Series 4 236 and 14 236 cccssscccccccceeeeeeeeeeeeees 8 1 Section 9 Hydraulic System ac sce 2 care centin sreta ieee ere ns oeerenettalen eaten 9 1 Section 10 Electrical System 424s a erty neta ti a tier ete 10 1 Model 6036 S N 9B0499 and Before This Page Left Blank Intentionally Section 1 Safety Practices SECTION 1 SAFETY PRACTICES CONTENTS Par Title Page 1 1 INTRODUCTION 1 1 1 2 SIGNAL WORDS 1 1 1 3 PERSONAL CONSIDERATIONS 1 2 1 4 EQUIPMENT CONSIDERATIONS 1 2 1 5 GEN
33. Torque the U bolt assembly to 20 to 24 Ib ft 27 to37N m orthe bearing strap to 55 to 60 lb ft 75to82N m 4 Install the transmission cover on the forklift Drive Shafts Drop Gear Box to Axle 1 Position the drive shaft on supports under the fork lift so slip joint mounts to the drop box Fig 6 1 2 Secure this end of the drive shaft cross assembly to the axle input shaft yoke with a U bolt assembly Torque the U bolt assembly to 20 to 24 Ib ft 27 to37N m 3 Slide slip joint as far as possible into drive shaft remove tape and secure the drive shaft cross assembly to the drop box output shaft yoke with a U bolt assembly Torque the U bolt assembly to 20 to 24 Ib ft 27 to 37 N m 4 Remove supports from under the forklift 6 2 DROP GEAR BOX 6 2 1 End Yokes a Inspection Replace end yoke 3 Fig 6 4 if worn or damaged b Removal To remove end yoke remove screw 1 Fig 6 4 washer 2 and end yoke 3 c Installation To install end yoke press yoke 3 Fig 6 4 on shaft and secure with washer 2 and screw 1 6 2 2 OilSeals 6 3 Section 6 Drive Shafts and Drop Box a Inspection Replace oil seal 4 Fig 6 4 if worn or damaged b Removal To remove oil seal remove screw 1 Fig 6 4 washer 2 end yoke 3 and oil seal 4 c Installation 1 To install oil seal press oil seal and yoke on shaft 2 Press yoke 3 Fig 6 4 on shaft and secure with washer 2 and screw
34. cable to the batteries HOURMETER FUEL GAUGE WARNING LIGHTS Engine Oil Pressure Indicates low engine oil pressure Engine Water Temperature Indicates high coolant temperature OA0750 Alternator Charging Indicates alternator is not charging Transmission Oil Temperature Indicates high transmission Oil Temperature Fig 10 4 Warning Lights Signal Dangerous Operating Conditions 10 4 10 2 4 Warning Lights There are four warning lights in a cluster between the hourmeter and fuel gauge When you turn the ignition key to the RUN position the Engine Oil Pressure and Alternator Charge indicators will light This is anormal condition While the engine is running all lights should be OFF However if any of the lights go ON a potentially dangerous condi tion exists Directly to the right of the instrument cluster is a warning light bulb test button With ignition switch in RUN and the engine OFF depress this button to test all four warning lights If any of the lights are burnt out replace the bulb s immediately You will find the bulb number in the Electrical Specifications Table at the end of this section 10 3 WIRING HARNESSES The forklift has harnesses 1 and 2 Fig 10 5 for cab and engine wiring A forklift with an optional lighting system will have a separate lighting harness 1 Fig 10 53 Each wire within a harness is i
35. 1 Disconnect black electric terminal cable 5 Fig 10 68 by removing nuts at the solenoid 4 and at the housing of the motor 1 10 62 2 Remove solenoid 4 by removing two 1 4 20 by 1 4 Torx head screws 3 In warranty the pump and motor assembly is replaced as a complete unit Out of warranty the pump and motor can be serviced as separate items If further disassembly is required mark the orientation of the pump to the motor and remove four screws which secure the pump 2 to the motor 1 4 Lift pump 2 from motor 1 5 Remove coupling 6 from pump 2 c Cleaning and Drying Without submerging the motor 1 Fig 10 68 in the cleaning solvent clean the pump and motor assembly in an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect the pump and motor assembly 2 Discard the complete pump or motor if the pump 2 Fig 10 68 or motor 1 is damaged or defective 3 Test the coil of the solenoid 4 for continuity Discard solenoid if it is damaged or defective 4 Test solenoid operation using short heavy gauge wires connected to a fused or protected 6 A minimum output 12 Vdc power supply Discard solenoid if it fails to operate 5 Test pump motor operation using short heavy gauge wires connected to a fused or protected 6 A minimum output 12 Vdc power supply Discard motor if it fails to run e Assembly 1 If pump and motor was disassembled install coupling 6
36. 10 15 SPECIFICATIONS RATING inaona eis RG Gok tads cats E Ren Oe tA Ree 12 Vdc Negative Ground NUMBER AND TYPE OF BATTERIES o 2 in parallel Maintenance Free Lead Acid CIRCUIT BREAKER RATINGS Steering Select Valvano irrin iiur cceesh needs Avy eeeete dev eevecuesvihr eee eede cae A a Eaa ea 6A Horn and Backup Alarm Optional Heater Fan cccccceeeeeeeeeseeneeeeeneeeeseeeeeeeeeeeseeeeeneeees 10A Instrument Panel Park LOCK Switch cccccccccccccccececeeeeeeeeceeeeeceeeeseeaueesessececeeeeeeeeesesaaeaenseeseess 6A Ignition Switch Feed for entire Electrical System ccccccccceeeeeneeeeeeeeeeeeeaeeeeesaeeeseeeeeeteieeeeee 40 A Optional Enclosed Cab iriiritia enii i aai aeoiee a a i a iaa 6A Optional Lighting Package edesin aei aea aa a ae aaia 15A BULB QUANTITIES AND BULB NUMBERS FOR FORKLIFT Park Lock Brake Indicator Bulb isiin incirin ieie ari Nii anaa EEES ANNARA TAA EE AN E 1 68 Warning Light Gauge Bulbs ssssssesseeesineesenesssntsrrntterrnnsttrnertnnsrtntsttnnnernnnernnnerenterenn nena 4 GE 161 BULB QUANTITY AND BULB NUMBERS FOR OPTIONAL LIGHTING SYSTEM Headlight and Backup Light BulbS sesssssssseessessseesirrressriirrrnsstirnnnnnttinnnnnnttinnnnanetnnnnnnnennnn 3 4411 Tum Signal Switeh Bulbs segs a aaea a er eaea aE aR saia E 1 53 Turn Signal Bulbs nir a a eee tens e aa kn a Eaa a ee 2 S1156 Stop Tail BUDS yn h a ae aaa a aaa a a aA TE aa ae ees 2 1157 Fuel Level Indi
37. 13 Lubricate the pin through grease fitting using a good grade of multi purpose lithium based grease Install the attachment on the quick attach assembly Capscrew 3 4 STRETCH OVER LATCH MA0131 Washer Flat 9 Fitting grease both Latch ends Spring 10 Quick Attach Assembly Locknut 11 Fitting grease Capscrew and 12 Pin grille cylinder Locknut 13 Capscrew and Locknut Gooseneck 14 Rod grille tilt cylinder P qulerauech Fig 3 20 Quick Attach Assembly 3 15 Section 3 Boom 3 4 TROUBLESHOOTING Trouble Fails to Extend or Retract Fails to Raise or Lower Excessive Boom Pivot Pin or Cylinder Pivot Pin Wear Excessive Wear Pad Wear Drooping Chain or Jerky Boom Extend or Retract Functions Grille Tilt or Auxiliary Hydraulic Circuit Line Failures Excessive Chain Wear 3 16 Probable Cause Broken hydraulic line and or connection leaks Faulty Extend Retract Cylinder Faulty components in Extend Retract hydraulic circuitry Broken chains or chain connections Broken Hydraulic line and or connection leaks Faulty Hoist Cylinder s Faulty components in Raise Lower hydraulic cir cuitry Improper grease intervals Worn bearings Improper wear pad shimming Contaminated corroded or rusted wear pad sliding surfaces due to improper preparation for long term storage Chains out of adjustment Improper hose tension or hose sheave misaligned
38. 14 Refer to Fig 3 1 and install the rear boom from intermediate boom Fig 3 6 cover 3 1 2 Intermediate Boom Replacement pe ANTI BUCKLE BAR a Removal OUTER BOOM 1 Referto paragraph 3 1 1 a and remove the innerboom 2 Remove the rod end pin Fig 3 4 and retaining rings that attach the rod end of the boom extend retract cylinder to the intermediate boom Lower the rod end to the anti buckle INTERMEDIATE bar BOOM Fig 3 4 Extend Retract Cylinder Model 6036 S N 9B0499 and Before 3 3 ROD END PIN BASE END PIN EXTEND RETRACT CYLINDER ee Section 3 Boom 4 Usea sling and a suitable hoist to slide the intermediate boom out the front of the outer boom 5 Record the number of shims beneath each wear pad as you remove the rear bottom Fig 3 6 and all front wear pads Fig 3 5 from the intermediate boom 6 Examine the chain sheaves for wear and replace if necessary b Inspection and Replacement 1 Inspect the boom and welds and contact JLG if structural damage is detected PAD INSERT 2 SPACER 10 GA SHIM FLAT WASHER 4 LOCK WASHER 4 3 8 16 X 1 3 4 CAPSCREW 4 INNER BOOM GAP MUST BE 0 07 TO 0 13 1 8 TO 3 3 mm PAD 10 GA SHIM INSERT 4 LOCK WASHER 8 FLAT WASHER 8 3 8 16 X 3 4 CAPSCREW 8
39. 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
40. Detach the line from the bottom of the coolant overflow bottle and allow the bottle to drain 5 Flush the system with clean water Model 6036 S N 9B0499 and Before CYLINDER BLOCK DRAIN PLUG Section 8 Engine OA0262 Fig 8 16 Cylinder Block Drain Plug Remove cylinder block drain plug Fig 8 16 and drain engine block Replace drain plug Connect line to overflow bottle and close the petcock on the radiator Refer to paragraph 8 2 1 and fill radiator with 5 4 gallons 20 4 liter of coolant Replace the radiator cap Add coolant to overflow bottle until bottle is 1 4 to 1 2 full approximately 1 qt 0 9 liter Air Filter Primary Element Change Replace air filter primary element Fig 8 5 after six cleanings or annually 8 1 9 Post Delivery Check After 25 to 50 hours of operation or 500 to 1 000 miles 800 to 1600 km 1 10 Run the engine until warm Stop engine and drain lubricating oil from sump Fill sump to the full mark on the dipstick with clean new lubricating oil of the approved grade Replace the canister of the lubricating oil filter Tighten the cylinder head nuts and capscrews as specified in paragraph 8 9 Adjust valve tip clearances as described in paragraph 8 10 Check that the intake and exhaust manifold nuts are tight Check tension of alternator water pump drive belt as described in paragraph 8 1 2 Check the atomizers as described in para graph 8 4 9
41. Inspect the switch terminals for continuity in the switch halfway out and fully out positions and shorting in the switch in position 2 Replace the switch if it fails the tests in step 1 e Installation 1 Connect the wires as they were tagged during switch removal 2 Position the switch from under the right front console panel Install switch and hex nut Install lower console panel Connect negative cable to the batteries oa Fw Test switch in all three positions WINDSHIELD gt WASHER WIPER SWITCH OA0031 Fig 10 60 Windshield Washer Wiper Switch 10 10 WINDSHIELD WASHER WIPER 10 10 1 Windshield Washer Wiper Switch Enclosed Cab Only The windshield washer wiper switch Fig 10 60 is supplied on a forklift with an enclosed cab Turn knob to left to operate wiper at low speed to right to operate wiper at high speed Press and hold knob to activate windshield washer The wind shield washer fluid tank is located at the right side of the seat Model 6036 S N 9B0499 and Before The 6 A rated switch has a built in circuit breaker a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Prepare to remove the windshield washer wiper switch by removing the lower panel which is located below the steering wheel Tag and disconnect the wires from the switch Remove the knob by pulling directly upward on the knob 5 Remove the hex nuts
42. Lifting Equipment Compressed Air What to do Before using the forklift be sure the operator s cab and rear window are secure and serviceable Check all lifting equipment chains brackets hooks etc before use Be sure equipment is the proper capacity Never stand under a suspended load or raised implement Always use a general purpose nozzle to blow dust filings dirt etc from work area Always wear eye protection when using compressed air to clean a work area Look around before using an air hose Why Improper clothing can catch on controls or moving parts and cause accidents and or injury Permanent eye damage can be caused if foreign matter enters the eye Fumes dust or paint spray are harmful when inhaled Continuous loud noise can damage your hearing To protect feet from falling objects and to prevent slipping To avoid injury through incorrect han dling of heavy components Why The cab protects the operator from possible serious injury or death To prevent serious injury or death due to falling objects To prevent serious injury or death To prevent serious injury to operator and or co workers To prevent injury to other personnel in the work area Model 6036 S N 9B0499 and Before 1 4 EQUIPMENT CONSIDERATIONS cont Item What to do Section 1 Safety Practices Why Hand Tools Always use the proper tool for the job Always keep tools clean a
43. Lock Washer 4 Hex Head Capscrew 2 MAQ691 OarkoNn Fig 9 28 Brake Valve Installation Model 6036 S N 9B0499 and Before 9 50 OONDAPRON gt 9 51 Cup Section 9 Hydraulic System Tag and disconnect three hydraulic hoses 4 6 Remove cup 11 from plunger 10 Fig 9 30 from the right side of the service brake valve Cap and plug the open hose connectors 8 Remove O ring 22 cup 20 and backup ring 21 from plug 23 Remove plug 23 from housing 13 Remove jam nuts 4 Fig 9 28 lock washers 5 and capscrews 6 which secure valve to 9 Remove washer 19 sleeve 18 spring 17 the mounting bracket and guide 16 from the housing bore Remove the service brake valve from the NOTE Some valves may not have a sleeve 18 Machine 10 Remove valve and ball assembly 15 from Disassembly housing bore Remove ring 1 Fig 9 29 and boot 2 from 11 Remove O ring 14 from the valve and ball housing 13 assembly Remove piston 3 shim or shims 4 and c Cleaning and Drying Springe aand G mam Nouang morh Clean all metal parts in an approved cleaning Carefully remove O ring 7 to avoid scratch solvent such as trichlorethylene and blow dry ing the housing bore a d Inspection Repair and Replacement Carefully remove retaining ring 8 to avoid scratching housing bore 1 Inspect valve bore for deep grooves or other damage If there is any damage to the bore Remove washer 9 p
44. Model 6036 S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle Oil Capacity of Wheel End Front 54 oz 1 6 liter Special TRAK Wet Disc Brake Oil P N 8522042 Rear 56 oz 1 7 liter Special TRAK Wet Disc Brake Oil P N 8522042 Park Lock Unit Type Multiple Disc Park Lock spring apply hydraulic release dry disc design Maximum Speed 1700 rpm Release Pressure 364 psi 2 512 0 kPa min 3000 psi 20 700 0 kPa max Torque Rating 17 000in lbs 19210 0N m static breakaway Volume displacement to release park lock 1 2 cu in 19 6 cm Approximate Weight 44 Ibs 20 kg For use with mineral base hydraulic oil only NOTE Refer to pages 59 and 60 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for additional specifications 5 5 TROUBLESHOOTING Troubleshooting instructions are provided on pages 56 through 59 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 Model 6036 S N 9B0499 and Before 5 28 This Page Left Blank Intentionally Section 6 Drive Shafts and Drop Box SECTION 6 DRIVE SHAFTS AND DROP BOX CONTENTS Par Title Page 6 1 DRIVE SHAFT ASSEMBLIES 6 1 6 1 1 Drive Shaft Servicing 6 1 6 2 DROP GEAR BOX 6 3 6 2 1 End Yokes 6 3 6 2 2 Oil Seals 6 4 6 2 3 Internal Inspection and Servicing 6 4 6 3 SPECIFICATIONS 6 4 6 1 DRIVE SHAFTS 6 1 1 Drive Shaft Servicing a Removal Drive Shaft Transmission to Drop Gear Box 1
45. Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Backward Position When the auxiliary control lever is placed in the backward position the directional control valve spool is positioned so that pump applied pressure is directed through ports E to B Fig 9 8 to the male quick connect coupler Return pressure is directed through ports A to D to the return filter and reservoir If the filter becomes clogged hydraulic oil will bypass the filter when the pres sure reaches 10 to 15 psi 0 7 to 1 03 bar b Pressure Checks and Adjustments 1 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure AL Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar in the 30 gpm section outlet of the tandem pump Fig 9 8 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Model 6036 S N 9B0499 and Before 10 11 12 13
46. No voltage at backup Replace wiring and circuit See para doesn t sound alarm 16 Fig 10 5 breaker as required with travel select broken wire or circuit lever in REVERSE breaker 11 doesn t reset Defective reverse switch Replace reverse switch See para 53 Fig 10 5 Backup alarm Short circuit in wiring Determine and repair cause of See para sounds with travel short circuit select lever in NEUTRAL AND FORWARD Defective reverse switch Test and replace reverse See para 53 Fig 10 5 switch as required Switches and Solenoids STEERING SELECT SWITCH AND SOLENOID Steering select Short circuit or broken Eliminate short or repair or See para switch fails to wire replace wire select mode or selects incorrect steering mode Circuit breaker 12 Fig Replace circuit breaker See para 10 5 stuck in open position Steering select switch 48 Remove steering select See para Fig 10 5 is defective switch and check for continuity in each position and replace switch if defective Steering select solenoid Remove steering select See para 55 Fig 10 5 is defective solenoid and test for correct operation Gauges and Indicator Lights HOURMETER Hourmeter Defective wiring and Renew wiring and correct See para Doesn t ground ground Operate Incorrect voltage at meter Required voltage is 9 to See para terminals 36 Vdc Hourmeter is Check running indicator f
47. Remove rear radiator cover for access to radiator Model 6036 S N 9B0499 and Before 26 27 28 29 30 31 Section 8 Engine Install the transmission oil cooler on the rear support and connect it to the transmission Fill the transmission as follows a Install a cleaned drain plug and screen and gasket Fig 7 1 into the transmission sump housing b Fill transmission with Tractor Hydraulic Fluid to LOW mark on dipstick Fig 7 6 Install the radiator cover Install counterweight on the rear of the frame Check the fluid levels as follows a Start the engine and allow it to heat to operating temperature Do not operate engine for more than two minutes b Shut the engine off wait for engine to cool and check the coolant level Top it off as required by adding coolant through the overflow bottle c Be sure the engine oil level is between the full and add marks If it is below the add mark add 10W30 motor oil equal to API SE CC or SE CD specifications Engine crankcase capacity is 9 4 quarts 8 9 liter with a filter change d Check the transmission oil level If it is below the add mark add Tractor Hydraulic Fluid to bring it to the full mark on the dipstick Transmission capacity is 4 3 gallons 16 3 liter Install the transmission cover and close and lock both engine access doors 8 23 Section 8 Engine 8 9 HEAD TORQUE CHECK Run engine until coolant outlet temperature is
48. Remove the clamp attaching the throttle cable to the cable support Remove short clevis washer and jam nut from the cable end 4 Open the right side engine access door Remove the round head screws attaching the clamp Fig 4 9 to the throttle cable bracket Remove the clamp from the bracket 6 Remove the cotter pin clevis pin and two washers attaching the throttle cable clevis to the engine stop and throttle lever Fig 4 9 TWO WASHERS BRACKET STOP AND THROTTLE LEVER THROTTLE CABLE un LAMP FUEL PUMP j CLEVIS CLEVIS PIN AND COTTER PIN MA0201 Fig 4 9 Throttle Cable Engine Connection Model 6036 S N 9B0499 and Before Section 4 Operator s Cab 7 Remove the long clevis and jam nut from the cable end 8 Remove the throttle cable from the forklift Installation 1 Thread jam nut and long clevis completely onto one end of the cable Thread a jam nut washer and short clevis completely on the other end of the cable Further adjustment on the rod end will be required after the cable is installed 2 Secure long clevis end of throttle cable to the engine stop and throttle lever Fig 4 9 with clevis pin washers and cotter pin Be sure both washers are positioned between clevis and above engine stop and throttle lever 3 Install the cable in the clamp and secure the clamp on the throttle cable bracket with round head
49. Use a good quality Grade 46 hydraulic oil rated at 215 SSU at 100 F 5 F 88 C 3 C Refer to Specifications in this section 5 The feed line must be of adequate size with no more than 5 mercury vacuum adjacent to the pump inlet As a rule the feed line must Model 6036 S N 9B0499 and Before provide a feed flow velocity not in excess of 8 feet per second 6 Run the pump at least two minutes at no load and moderate speed not below 400 or over 1500 rpm If the pump becomes excessively hot shut down immediately and locate the problem source 7 Gradually increase pressure on pump in 500 psi increments until the desired test pressure has been reached This should take about five minutes 8 Average Output Specifications at 3500 psi 241 bar Pump Section Speed RPM Output GPM 30 gpm 1000 11 30 gpm 1500 18 30 gpm 2000 24 30 gpm 2500 30 15 gpm 1000 7 15 gpm 1500 11 15 gpm 2000 15 5 15 gpm 2500 20 j Recommended Start up Procedure for New or Rebuilt Pump After connecting the lines and mounting the replacement unit start up as follows 1 Make sure that the pump suction line is securely clamped at the pump inlet and the reservoir 2 Disconnect the fuel run solenoid to prevent the engine from starting 3 Turn the ignition switch to START position and crank the engine for 15 to 25 seconds This will prime the main tandem pump 4 Turn the ignition switch OFF 5 Reconnect the fuel run solenoi
50. clamps to posts Remove surface charge from any battery that has just been on charge IF THE GREEN DOT IS VISIBLE This includes batteries in the vehicle having been charged by the vehicle alternator Do not remove surface charge from batteries that have been in storage To remove surface charge apply a 300 ampere load across the terminals for 15 seconds Then turn off load and wait for 15 seconds to allow the battery to recover Battery temperature should be estimated by touch and also by the surrounding temperature it was exposed to during the preceding few hours before testing Select the nearest estimated temperature in the table below and determine the minimum voltage which must be maintained while the battery supplies a speci fied electrical load Apply a 260 A load test Observe voltage after 15 seconds with load connected then turn off load If voltage is below value determined in step 4 replace battery If voltage is at or above value determined in step 4 battery is good and may be returned to service Check the charge acceptance of the battery one more time before discarding it Battery Charging Do not charge battery if hydrometer is clear or light yellow replace battery Charge rates between 3 and 50 amperes are generally satisfactory as long as spewing of electrolyte does not occur or the battery does not feel excessively hot over 125 F 52 C Battery temperature can be estimated by touching or fe
51. d Inspection and Replacement 1 Inspect the pump and motor assembly 2 Discard the complete pump and motor assem bly if the pump 13 Fig 9 44 or motor 15 is damaged or defective e Assembly 1 If pump and motor assembly was disas sembled install coupling 14 Fig 9 44 on pump 13 2 Place the motor 15 in position on the pump and secure with four screws 11 and washers 12 3 Position the solenoid 10 on the housing of the motor and install two screws 8 and washers 9 to secure 4 Check torque on bottom nut on the motor ground terminal and power terminal and re torque to 100Ib in 11 3N m maximumif necessary 5 Connect black electric terminal cable 7 to the solenoid cable terminal and motor power terminal Torque this top terminal nuts to 35 Ib in 3 9N m maximum 6 Install connector 2 and elbow 4 in pump 13 f Installation 1 Place the pump and motor assembly on the frame and support in position Model 6036 S N 9B0499 and Before 2 Secure the pump and motor assembly to the frame with two 3 8 16 UNC 28 hex head capscrews 5 Fig 9 44 and lock washers 6 3 Connect the supply hose 1 and pump outlet hose 3 to appropriate pump port fittings 4 Connect the red electrical cable to the solenoid power terminal 5 Connect the yellow ground wire to the motor ground terminal 6 Connect the yellow switch wire to the solenoid switch terminal g Testing Test oper
52. engine is running shorts to ground With a good oil 1 Oil pressure switch 29 If open replace oil pressure See para pressure indicator Fig 10 5 should be switch bulb and the closed ignition key in RUN oil pressure indicator does not light before engine is started Gauges and Indicator Lights LOW OIL PRESSURE SWITCH FOR STEERING AND EMERGENCY HYDRAULIC PUMP There is battery voltage at Install a new oil pressure See para wire 16 Fig 10 5 with the switch ignition key in RUN and the engine not running Steering and 1 Oil pressure switch 31 If open replace oil pressure See para emergency Fig 10 5 should be sender switch hydraulic pump closed fails to operate when engine oil pressure is low There is battery voltage at Install a new oil pressure See para wire 4 Fig 10 5 with the switch ignition key in RUN and the engine not running Steering and Oil pressure switch 31 If closed replace oil pressure See para emergency Fig 10 5 should be open switch hydraulic pump operates when engine oil pressure is normal There is battery voltage at Install a new oil pressure See para wire 4 with the ignition key sender switch in RUN and the engine not running 10 74 Model 6036 S N 9B0499 and Before Section 10 Electrical System Trouble Probable Cause Remedy Reference Gauges and Indicator Lights ENGINE COOLANT HIGH TEMPERATURE SWITCH Coolant high Coolant high tem
53. give the battery terminals a protection against corrosion POWERPART Lay Up 3 can be used on the terminals 15 Seal the vent pipe of the fuel tank or the fuel filler cap with waterproof tape 16 Remove the fan belt and put it into storage 17 To prevent corrosion spray the engine with POWERPART Lay Up 3 Do not spray the inside of the alternator cooling fan area NOTE Before the engine is started after a period in storage operate the starter motor with one of the fuel run solenoids wires disconnected until oil pressure shows on the oil pressure gauge or the warning light goes out If the engine protection is done correctly according to the above recommendations no corrosion damage will normally occur Perkins Engines Ltd and JLG are not responsible for any damage that occurs in relation to a service storage period 8 25 Section 8 Engine 8 12 TROUBLESHOOTING Trouble Possible Causes see Key Low Cranking Power 1 2 3 4 Will Not Start 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 22 31 32 33 Difficult Starting 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 24 29 31 32 33 Lack of Power 8 9 10 11 12 13 14 18 19 20 21 22 23 24 25 26 27 31 32 33 61 63 Misfiring 8 9 10 12 13 14 16 18 19 20 25 26 28 29 30 32 Excessive Fuel Consumption 11 13 14 16 18 19 20 22 23 24 25 27 28 29 31 32 33 63
54. lever in neutral and stop the engine AY Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Depress the brake pedal to relieve any trapped pressure 3 Remove the electrical connector from solenoid on the park lock release valve 2 Fig 9 33 4 Remove the solenoid Fig 9 32 To check the solenoid apply 12 Vdc momentarily to the solenoid leads and check for spool movement If solenoid does not actuate it is defective Refer to Section 10 for additional electrical test information Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 5 Tag and disconnect the hydraulic hoses at connector 8 Fig 9 33 and run tee 9 and tube assembly 16 from connector 7 on the park lock release valve 6 Remove two hex nuts 27 lock washers 25 flat washers 26 and capscrews 24 Model 6036 S N 9B0499 and Before b vw BODY SOLENOID WITH SEALS MA0731 Fig 9 32 Park Lock Release Valve Lower park lock release valve 2 from valve mounting plate 30 Remove hydraulic fittings from valve as required Disassembly NOTE There are no serviceable parts in the park lock release valve Replace solenoid Fig 9 32 if faulty c Cleaning and Drying Without submerging the electrical portion
55. or 8 if there is and flat washers evidence of torsional fractures or other indica tions of impending failure TAP 8 RETAINER RINGS HERE AND RETAINER TO BE FULLY SEATED IN BEARING CAP GROOVE THE RINGS OUTBOARD INBOARD YOKE SHAFT YOKE SHAFT ee es se e RING BEARING CAP RETAINER RING BENT OVER STEP Fig 5 11 Retaining Ring Inspection 5 19 Model 6036 S N 9B0499 and Before OPPOSITE SIDE OF SEAT TO SET MA0271 Section 5 Wheel Assembly Tires and Axle 4 Replace roller bearing cups 24 or cones 23 if any are worn pitted or damaged 5 Replace oil seals 10 and 22 regardless of condition d Retaining Ring Inspection 1 Place the forklift in Crab Steer mode and turn the steering wheel full left to access shaft assemblies on the right side of the vehicle 2 Using a flashlight visually inspect the right front shaft assembly retaining rings through the opening between the axle housing and steer ing knuckle 3 Turn the wheel end clockwise or counterclock wise to expose both sides of all eight retaining rings 4 Inspect for the following Fig 5 11 e full seating of the retaining rings into the cap grooves e no back and forth movement of the ring e and overlap on the machined steps on the inboard side of the yoke ear 5 To set the rings tap suspected rings with a hammer and punch where shown on Fig 5 11 6 Inspect the right rear shaft assembly as instructed in
56. suction stainer in the reservoir Fig 9 3 Supply pressure is directed to either side of the extend retract cylinder piston by the shifting of a spool ina directional control valve found in the main control valve assembly The spool is shifted by the operator joystick and its associated control cable The joystick positions for extending or retracting the boom are as follows Center Position When the joystick is placed in the center or neutral position the directional control valve spool is positioned so that supply pressure is directed through ports F to C Fig 9 3 to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar MAIN CONTROL VALVE SLAVE CYLINDERS COUNTERBALANCE VALVE BOOM EXTEND oa eee TO GRILLE TILT AND 1 l l DIRECTIONAL CONTROL VALVE POSITIONS CYLINDER EXTEND RETRACT ABC ABC ABC l P Y i I PILOT OPERATED CHECK VALVE jarli DEF DEF DEF CENTER BOOM EXTEND PORT RELIEF VALVES TO BOOM HOIST CYLINDER 0 4000 psi PRESSURE GAUGE MA0441 RESERVOIR STRAINER RETURN SJ FILTER Fig 9 3 Boom Extend Circuit 9 5 Model 6036 S N 9B0499 and B
57. tandem pump and reconnect the hydraulic line 10 Start the engine Raise and lower the boom fully several times to purge the system of air 11 Install the transmission cover after adjustment c Testing The boom raise lower circuit should be tested when ever repairs or adjustments are made to components of the circuit 1 Start the engine park the forklift on level ground and level the frame 2 Check for signs of leakage of hydraulic oil from circuit hoses and other components Correct any leakage problem before testing 3 Raise and lower the boom fully several times to purge the system of air if necessary 4 Starting with the boom fully retracted and at its lowest position raise the boom at full engine speed The time required for full hoist should be 11 to 13 seconds no load 9 4 5 Starting at the fully raised position lower the boom at full engine speed The time required to lower the boom to its lowest position should be 8 to 10 seconds no load Repeat steps 4 and 5 to recheck performance If the boom raise lower circuit test does not meet performance requirements locate the cause of the problem and correct before putting the vehicle into service 9 1 2 Boom Extend Retract a Description Hydraulic pressure is applied in the boom extend retract circuit by the 30 gpm section rear half of the tandem pump which draws its fluid through a TO FRAME TILT CYLINDER Section 9 Hydraulic System
58. 1 Use new valves if either valve was removed for replacement Lubri cate outside of the valves with clean filtered hydraulic oil Install the valves and torque to 30 to 35 lb ft 40 8 to 47 6 N m 13 If removed install plugs 2 and grease fittings 14 14 Following reassembly test the cylinder at low operating pressure 100 psi or 6 9 bar to be sure the piston and rod are moving freely in both directions Model 6036 S N 9B0499 and Before 15 Increase the operating pressure to the maxi mum 4000 psi or 275 6 bar for the cylinder and check for external leakage and free movement in both directions 16 Prepare the cylinder for installation by retract ing the piston and capping and plugging the ports f Installation 1 Lubricate the frame tilt cylinder pivot pins with multi purpose lithium based grease 2 Using suitable lifting device install the frame tilt cylinder Fig 9 9 on the forklift securing the tube end to the axle mounting block with pivot pin shims locking capscrew and locknut 3 Remove all plugs or caps from the hydraulic lines and securely tighten the lines to the cylinder A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Have a helper start the forklift engine Position the frame tilt cylinder so that the base end is aligned with the rod end mounting holes in the frame as much as possible 6 Instru
59. 1 1 2 less than 51 mm but greater than 38 mm a Remove the rear cover from the outer boom and adjust the top extend boom chains b Tighten the locknuts Fig 3 14 for each chain Be sure each locknut is tightened equally so that chain maintains the same tension Equal chain tension can be checked by observing the position of the yoke on the outer boom Fig 3 13 The front of the yoke should be parallel with the front edge of the boom c Cycle the boom in and out then with the boom horizontal level fully extend the boom and retract it 2 which is 1 per section 51 mm which is 25 5 mm per section d Measure the chain sag Acceptable boom chain sag is between 3 4 and 1 3 4 19 and 45 mm If chain sag is less than 3 4 19 mm repeat steps a through d e Replace the rear cover of the outer boom 3 1 8 Wear Pad Replacement After the first 50 hours of operation or when severe wear is suspected There are 26 wear pads Fig s 3 3 3 5 3 6 and 3 8 between the outer intermediate and inner booms Five are attached to the inner boom thirteen to the intermediate boom and eight to the outer Four additional wear pads may be used in severe twist applications The wear pads and wear pads with spacers are shimmed to maintain a gap between the wear pads and the booms of 0 07 to 0 13 1 8 to 3 3 mm 3 11 Section 3 Boom IMPORTANT Inspect the pads as follows e Replace wear pads that are l
60. 10 Fuel Lift Pump 2 Remove fuel lift pump cover and strainer Fig 8 10 3 Wash any sediment from the lift pump and clean the cover and strainer 4 Install the cover making sure that it seats on the pump with NO leakage 5 Remove air from the fuel system See paragraph 8 4 8 How to Bleed to Fuel Sys tem 6 Close and lock the left rear engine access door NOTE Marginal fuel cleanliness conditions will require fuel system service more frequently Loss of engine power is often caused by dirty fuel filters Bleeding Fuel System Air must be vented from the fuel system whenever any part of the system between the fuel tank and injection pump has been disconnected for any reason or when the system has been emptied of fuel IMPORTANT DO NOT start the engine until the injection pump has been filled and primed as the pump can be seriously damaged due to lack of lubrication Remove air from the fuel system as follows NOTE More than one person may be required to perform this procedure 8 5 Section 8 Engine GOVERNOR VENT SCREW INJECTION Mites PUMP VENT SCREW OA0322 Fig 8 11 Vent Screws in Injection Pump 1 Unlock and open the right rear engine access door Loosen the governor vent screw in the fuel injection pump governor control cover Fig 8 11 2 Loosen the injection pump vent screw on the side of the fuel injection pump FUEL LIFT PUMP PRIMING LEVER 0A0332 Fig 8 12 Prim
61. 15 MA1111 Sleeve 16 Bracket 20 Belt Nut 17 Stud 21 Pulley Washer 18 Hex Nut 22 Alternator Washer 19 Washer Fig 10 28 Alternator Removal 7 If previous Steps 1 thru 6 check satisfactory check alternator as follows a Disconnect battery ground cable b Connect an ammeter in the circuit at the BAT terminal of the alternator c Connect battery ground cable d Turn on all electric equipment Connect a carbon pile battery tester across the batteries e Operate engine at moderate speed as required and adjust carbon pile as required to obtain maximum current output f If ampere output is within 10 amperes of rated output as stamped on alternator frame alternator most likely is not defec tive recheck Steps 1 thru 6 IMPORTANT If output in amperes is OK but indicator lamp stays on check diode trio and rectifier bridge in paragraph 10 6 1 f and 10 6 1 g 10 24 9 h If ampere output is not within 10 amperes of rated output determine if test hole Fig 10 27 is accessible If accessible go to Step h If not go to paragraph I Ground the field winding by inserting a screwdriver into the test hole Fig 10 27 IMPORTANT Tab is within 3 4 inch of casting surface Do not force screwdriver deeper than one inch into end frame i i Operate engine at moderate speed as required and adjust carbon pile as required to obtain maximum current output If output is
62. 4 from the rod 3 7 Remove rod wiper 5 Z seal 6 and O ring 7 from the gland 8 Remove O ring 8 and crown seal 9 from the piston Tube Piston Rod Gland 10 O ring O ring Crown Seal Lockwire Locknut 11 A SOMNDARWON gt O ON a Z Rod Wiper Z seal ba Cleaning Discard all seals and lockwire Replace with a complete new seal kit Clean all metal parts in an approved cleaning solvent such as trichlorethylene Be sure to carefully clean all cavities and grooves Inspection Repair and Replacement Check that rod 3 Fig 9 19 is straight and undamaged If the rod is bent or damaged install new rod Inspect inside of tube 1 for scoring and other damage If there is any damage to the tube replace it with a new tube MAO600 Fig 9 19 Steering Cylinder Exploded View Model 6036 S N 9B0499 and Before 9 40 3 Remove small scratches on inside of the tube with emery cloth of very fine grit Use the emery cloth with a rotary motion e Assembly NOTE Follow general assembly instructions in paragraph 9 2c 1 Fasten rod 3 in a soft jawed vise 2 Install new O ring 8 Fig 9 19 inside of piston 2 Carefully install the piston on rod 3 to avoid damage to the O ring 3 Apply Loctite Primer T and Threadlocker 271 to the locknut 11 in accordance with the manufacturer s instructions Install the locknut and torque it to 90 to 100
63. 6036 S N 9B0499 and Before Section 10 Electrical System MA1442 MA1441 1 Capscrew 7 Heater and Fan Unit 13 Valve 19 Grommet 2 Lock Washer 8 Hex Nut with Cap 14 Clamps 20 Hoses 3 Tooth Type Grounding Washers 9 Knurled Nut 15 Hose Connector 21 Sheet Metal Screws 4 Capscrew 10 Decal 16 Elbow 45 22 Fan Mounting Bracket 5 Lock Washer 11 Heater Fan Switch 17 Reducer 23 Core 6 Spacer 12 Suspension Support 18 Tie Wrap 24 Sheet Metal Screws Fig 10 67 Removal of Optional Cab Heater Switch and Heater Fan Motor Model 6036 S N 9B0499 and Before 10 59 Section 10 Electrical System 8 nut 9 to provide the desired projection of the switch stem through the suspension support Install decal 10 knurled nut 9 heater switch 11 and hex nut with cap 8 Connect wiring to switch 11 Slide heater and fan unit 7 into position Install two spacers 6 lock washers 5 and capscrews 4 Install two tooth type grounding lock washers 3 lock washers 2 and capscrews 1 Connect negative cable 2 Fig 10 38 to the batteries Test heater fan motor operation 10 12 2 Heater Fan Motor and Coil Enclosed Cab Only Removal Disconnect negative cable 2 Fig 10 38 from the batteries Remove two capscrews 1 Fig 10 67 lock washers 2 and tooth type grounding wash ers 3 Remove two capscrews 4 lock washers 5 and spacers 6 Slide heater an
64. 7 3 4 bar setting Grille Tilt Control Valve Grille Tilt Up Relief Valve 2650 50 psi or 182 6 3 4 bar setting 5 Boom Extend Relief Valve 2650 50 psi or 182 6 3 4 bar setting Po 6 Boom Hoist Control Valve 7 Main Relief Valve 3000 50 psi or 206 7 3 4 bar setting 8 Inlet Section 9 Boom Hoist Relief Valve 2650 50 psior 182 6 3 4 bar setting 10 Boom Extend Retract Control Valve 11 Boom Retract Relief Valve 2650 50 psior 182 6 3 4 bar setting 12 Grille Tilt Down Relief Valve 2650 50 psior 182 6 3 4 bar setting 13 Frame Tilt Left Relief Valve 1200 50 psi or 82 7 3 4 bar setting 14 Frame Tilt Control Valve Figure 9 22 Main Control Valve Components 9 45 Section 9 Hydraulic System a Main Control Valve Removal 1 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate all of the hydraulic functions boom raise lower extend retract grille tilt and frame tilt after the engine has stopped to relieve any trapped pressure 3 Remove the transmission cover A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 4 Remove dirt and grease from the hydraulic lines and fit
65. 8 to 3 3 mm and equal on all sides Re move or install shims as required 7 Working through the rear boom cover opening refer to Fig 3 6 and check the gap between the intermediate boom side and top wear pads and the outer boom The gap should be 0 07 to 0 13 inches 1 8 to 3 3 mm and equal on all sides Remove or install shims as required 8 Install the wear pads by applying Loctite 242 to the capscrews and torquing them to 31 lb ft 42 N m 9 Refer to Fig 3 4 and apply anti seize com pound to the rod end pin Secure the rod end of the boom extend retract cylinder to the intermediate boom with the rod end pin Fig 3 4 and retaining rings Model 6036 S N 9B0499 and Before PAD INSERT 1 LOCK WASHER 3 FLAT WASHER 3 3 8 16 X 7 8 CAPSCREW 3 GAP MUST BE 0 07 TO 0 13 1 8 TO 3 3 mm N Section 3 Boom PAD INSERT 1 LOCK WASHER 3 FLAT WASHER 3 3 8 16 X 7 8 CAPSCREW 3 A lt N i GAP MUST BE 0 07 TO GAP MUST BE 0 07 TO 0 13 1 8 TO 3 3mm 7 a PAD 10 GA SHIM INSERT 2 LOCK WASHER 4 FLAT WASHER 4 3 8 16 X 3 4 CAPSCREW 4 I 0 13 1 8 TO 3 3 mm peT wee PAD SPACER 10 GA SHIM INSERT 1 LOCK WASHER 2 FLAT WASHER 2 3 8 16 X 2 CAPSCREW 2 BOOM OUTER BOOM A MA0061 Fig 3 6 Rear Wear Pads Attached to Intermediate
66. 9 3 9 3 1 9 3 2 9 3 3 9 3 4 9 3 5 9 3 6 9 3 7 9 3 8 9 4 9 4 1 9 4 2 9 4 3 9 5 9 6 9 1 CIRCUITS Boom Raise Lower Boom Extend Retract Grille Tilt and Slave Circuit Frame Tilt Circuit Brake Circuits Power Steering Circuit Optional Auxiliary Circuit CYLINDERS Boom Hoist Cylinder Extend Cylinder Slave Cylinder Grille Tilt Cylinder Frame Tilt Cylinder Steering Cylinder Side Tilt Carriage Cylinder Optional VALVES Main Control Valve Assembly Brake Valve Park Lock Release Valve Steer Select Valve Sequence Valve Steer Relief Valve Pressure Reducing Valve Counterbalance Valve PUMPS Main Tandem Pump Steering and Emergency Brake Pump S N 7P0013 amp Before Steering and Emergency Brake Pump S N 7P0014 amp After TROUBLESHOOTING SPECIFICATIONS 9 1 9 1 9 5 9 8 9 11 9 14 9 17 9 20 9 23 9 23 9 27 9 30 9 33 9 36 9 39 9 42 9 45 9 45 9 50 9 54 9 56 9 57 9 57 9 58 9 59 9 60 9 60 9 68 9 71 9 78 A Warning e If anyone is injured by or if any hydraulic fluid is injected into the skin obtain medical attention immediately or gangrene may result e Wear appropriate eye protection Hydraulic fluid can cause permanent eye injury Do not wear loose fitting clothing when servicing the forklift 9 1 CIRCUITS NOTE Refer to the 6036 Hydraulic Schematic in the Troubleshooting Section 9 5 for an overall diagram 9 1 1 Boom Raise Lower a Description Hydraulic
67. A 0 980 0 970 B 0 875 REF C 0 100 0 090 MA0791 Fig 9 38 Bushing Puller A seal removal tool made by heating the tip of an old screwdriver and bending it as shown in Fig 9 39 Grind off the tip to fit the notch behind the shaft seal A bushing installation tool made from A I S 8620 Heat Treated Bearing Quality Steel as shown in Fig 9 40 A special steel sleeve made from bar stock which is 1 1 8 or 1 1 4 diameter by 4 5 8 as shown in Fig 9 41 This sleeve is used to insert the drive shaft through the lip seal without damage 1 4 INCH gt he n MA0801 Fig 9 39 Seal Removal Tool 5 A lip seal installation bar made from bar stock which is 1 3 4 in diameter by 2 long Break edges slightly Model 6036 S N 9B0499 and Before Section 9 Hydraulic System lt 3 00 _ eae 1 4 DIAMETER DRILL jo QO O gt 0 06 lt O gt A o 3 ke N q g gt Nao GRIND RELIEF ALLOWABLE 1 054 PLUS 0 000 MINUS 0 002 C D 1 250 DIAMETER MA0811 Fig 9 40 Bushing Installation Tool The following tools will also be required arbor press e awl steel ball 1 1 2 diameter clean lint free cloths deburring tool an old file with the cutting teeth ground off machinists hammer soft hammer Permatex Aviation Form A Gasket No 3 Non hardening Sealant or equivalent medium g
68. Be sure to line up dowel pins with the dowel holes Insert the connecting shaft 10 into the spline of the drive gear shaft Position the second gear housing 12 on the bearing carrier housing as described in step 8 Place the thrust plate 8 with seal 7 in the gear housing as described in step 11 Insert the drive and driven gears of the second section gear set 9 in their respective bear ings Make certain the gears are in contact with the face of the thrust plate Slip thrust plate 8 with seal 7 over gear journals and into housing bore The flat side of the seal should face up with the relief groove facing the outlet side Place port end cover 4 over the gear jour nals Align the dowel pins 5 with the holes in the mating casting Being careful not to pinch the gasket seal 11 tap the port end cover lightly in the center between bearing bores to engage the dowels and to move parts together in a final seating THRUST PLATE OF SEAL MA0831 Fig 9 43 Channel Seal Installation Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 19 Thread four studs 3 washers 2 nuts 1 into shaft end cover 16 and tighten alternately or cross corner Rotate the drive shaft with a 6 inch wrench to make certain there is no binding in the pump After the fasteners are tight and you are sure there is no internal binding torque the diagonally opposite fasteners to 200 lb ft 271 2N m
69. Before Section 10 Electrical System 10 6 2 Batteries A Warning All lead acid batteries generate hydrogen gas which is highly flammable If ignited by a spark or flame the gas may explode violently caus ing spraying of acid fragmentation of the battery and possible severe personal injuries Wear safety glasses when working near batter ies In case of contact with acid flush immedi ately with water a Description The batteries supply power to the starter and ignition systems to crank the engine They supply the extra power required when the electrical load requirements of the forklift exceed the supply from the charging system in case of a alternator or charging failure and acts as a voltage stabilizer in the electrical system smoothing out or reducing temporarily high voltage With the correct cables properly attached and with the batteries properly mounted the batteries never need periodic maintenance When starting the forklift crank for a maximum of 15 seconds then rest for two minutes to avoid burning up the starter Do not idle excessively Keep the batteries from freezing by maintaining a full charge A completely discharged battery will freeze at 18 F 8 C When winterizing the forklift test the start charge system in accordance with the diagnostic proce dures supplied with Generator Tester Model J 26290 refer to paragraph 10 6 1 a Required diagnostic equipment includes a variable c
70. Carrier Knuckle gi eU Nee Section 9 Hydraulic System 5 The steer cylinder socket is a taper fit in knuckle Use an impact fork to release the socket from the knuckle 6 Remove the cylinder from the forklift using a strap sling and hoist or other suitable lifting equipment 7 Measure the total length of the fully retracted cylinder with sockets in place and note or record the distance Loosen socket clamps and unscrew the socket assemblies from the cylinder b Disassembly 1 Remove all dirt and grease from the steering cylinder 2 Determine the direction that the gland 4 Fig 9 19 will be turning when it is removed so that the lockwire 10 will feed out through the tube hole 3 Using a sharp object such as a screwdriver pry up one end of the lockwire from its hole in the tube 1 4 Using a spanner wrench remove the gland allowing the lockwire to work its way out of the tube IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure MA0591 Fig 9 18 Steering Cylinder Installation 9 39 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 5 Pull rod 3 and attached parts straight out of the tube NOTE It may be necessary to apply heat to break the bond of the sealant between locknut 11 and rod 3 before the piston can be removed Refer to paragraph 9 2a 6 Remove locknut 11 piston 2 and gland
71. End Brake Oil 5 27 5 1 13 Mounting Optional Tire 5 4 SPECIFICATIONS 5 27 on Single Piece Wheel 5 9 5 1 14 Connecting Core Ejector Tool 33 TROUBLESHOOTING eg to Tire Valve Stem 5 9 5 1 Model 6036 6036T S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle 5 1 WHEEL ASSEMBLY AND TIRE A Warning Whenever you remove tire s and wheel s from forklift e Position forklift on a flat hard surface and support forklift with approved jack stands Use appropriate safety glasses safety shoes and appropriate clothing and equipment Do not wear rings or jewelry or use clothing or hair styles that could become caught in machinery or pinch points such as those created between tire and hub Allow no one to be under forklift or near drive line when engine is operating or drive line is in motion because clothing and limbs could be caught by and drawn into drive line resulting in serious personal injury or death Deflate tire completely before servicing as specified in paragraph 5 1 1 Use specialized tools for mounting and demounting tires These include 18 and 36 inch bead unseating tools tire irons a mallet for unseating beads a wire brush a remote control inflation line with clip on chuck so operator may stand aside during inflation and an air water pressure gauge that opera tor can observe during inflation Use safety cage or enclose tire in safety chains when inflating a newly mounted tire or deflating a t
72. FLOOR CLEVIS PIN AND LOCK CLIP JAM NUT CLEVIS Maota Fig 4 8 Throttle Pedal 2 Install the spring on the pedal and hook the other end over the support inside the console 3 Slide push rod into brake valve and secure the yoke to the pedal with clevis and cotter pins 4 Check the brake valve capscrews to be sure they are torqued to 30 lb ft 40 8 N m Adjust the pedal as described in paragraph c Install the lower panel below the control console c Adjustment 1 Remove the lower panel below the control console 2 Fully depress the brake pedal and set push rod for 1 2 13 mm minimum clearance under pedal arm as shown in Fig 4 7 3 Release brake pedal and adjust the adjusting nut Fig 4 7 so the pedal is 2 51 mm from the front cab wall Depress the pedal It must not contact the cab wall 4 Adjust push rod so it does not depress brake valve piston completely There must be 1 2 13 mm clearance between the end of the rod and the piston Tighten the rod jam nut to 30 lb ft 40 8 N m when adjustments are com plete 4 3 2 Throttle Pedal and Cable The throttle or accelerator pedal increases engine rpm A throttle cable connects it to a throttle and stop lever on the engine fuel pump Fig 4 9 A spring returns it to the raised position 4 6 a Throttle Pedal Assembly Removal Working beneath the operators cab remove the spring Fig 4 8 from between the pedal clamp and the clevis Remo
73. Fig 10 68 in pump 2 2 Refer to the orientation marks made in para graph b place the pump 2 in position on the motor 1 and secure with four screws 3 Position solenoid 4 on housing of motor 1 and install two 1 4 20 by 1 4 Torx hd screws 4 Torque bottom nut on the ground terminal on the housing of the motor 1 to 100 Ib in 11 3 N m maximum 5 Connect black electric terminal cable 5 by installing nuts at the solenoid 4 and at the ground terminal on the housing of the motor 1 Torque this top nut on the ground terminal on the housing of the motor to 35 Ib in 3 9 N m maximum Model 6036 S N 9B0499 and Before NOaProns Installation Lower the pump and motor assembly into position and secure to machine frame Connect supply and pressure hydraulic hoses to appropriate ports in pump 2 Fig 10 68 Reconnect wiring to solenoid and motor Replace hydraulic tank cover Position the appropriate yellow ground wire on the end head assembly 2 and secure with screw Position the appropriate yellow ground wire on the solenoid 4 and secure with nut PA0572 Motor End Head Assembly Pump Solenoid Check Valve Taptite Screw 1 4 20 x 1 4 Torx hd Terminal Cable Fig 10 69 Steering and Emergency Hydraulic Pump S N 7P0014 thru 9B0499 Model 6036 S N 9B0499 and Before Section 10 Electrical System 7 Position the red electrical cable on the sole noid 4 and secure
74. Filter Assembly 6 Fuel Return Hose 14 Capscrew hex head 22 Fuel Filter Assembly 7 Fuel Supply Hose 15 Lock Nut 23 Fuel Filter Element Kit for Item 22 8 Fuel Supply Hose 16 Mounting Bar Fig 8 18 Engine Fuel System Model 6036 S N 9B0499 and Before 8 11 Section 8 Engine b Disassembly 1 Remove five capscrews fuel level sender 2 Fig 8 18 and gasket from fuel tank 2 Remove fuel supply and return elbows 4 and 20 and rubber bushings 19 from fuel tank c Cleaning and Drying A Warning This procedure will not remove all fuel vapor Do not attempt any repair on tank where heat or flame is required as an explosion resulting in personal injury could occur If contaminated fuel or foreign material is in the tank the tank can usually be cleaned Replace tank if tank is damaged or if there are leaks in unreparable areas Clean the tank as follows 1 Have a dry chemical Class B fire extin guisher near the work area Disconnect the negative battery cable Remove and disassemble fuel tank as de scribed in paragraphs a and b Invert rock and drain tank 4 Clean tank with high pressure washer or flush with hot water for five minutes Invert rock and drain tank completely 5 If necessary add a diesel fuel emulsifying agent to the tank refill with water and agitate mixture for 10 minutes Drain tank completely Refer to manufacturer s instructions for correct emulsifying agent to wa
75. Ib ft 122 4 to 136 0 N m Allow sealants to cure 4 Install crown seal 9 on piston 2 Install rod wiper 5 Z seal 6 and O ring 7 on the gland 4 6 Install the assembled gland and seals on rod 3 7 Lubricate all parts and inside of the tube 1 with clean hydraulic oil 8 Apply a compression sleeve or other suitable tool to the gland in order to compress the O ring 7 on the gland Push the rod assembly straight into the cylinder tube with a steady even pressure until the gland butts up against the tube 9 Locate the hole in the tube and insert lockwire 10 10 Using a spanner wrench rotate the gland 360 degrees to install the lockwire 11 Following reassembly test the cylinder at low operating pressure 100 psi or 6 9 bar to be sure the piston and rod are moving freely in both directions 12 Increase the operating pressure to the maxi mum 4000 psi or 275 6 bar for the cylinder and check for external leakage and free movement in both directions 13 Prepare the cylinder for installation by retract ing the piston and capping and plugging the ports f Installation 1 Screw the socket assemblies 3 Fig 9 18 onto the retracted cylinder 4 Adjust position 9 41 Section 9 Hydraulic System of the socket assemblies by turning them until the total length equals the measured length taken during removal NOTE If there is no accurate recorded cylinder length the cylinder can
76. Install control linkage 7 using retaining pins 2 and cotter pins 1 Connect hydraulic lines to control valve Model 6036 S N 9B0499 and Before Section 9 Hydraulic System AY Warning Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury Start the forklift engine Inspect connections at the control valve for 3 Operate the brake pedal after the engine has leakage p p g stopped to relieve any trapped pressure 6 Operate joysticks to test the operation of the 4 control valve and hydraulic system Refer to paragraph 9 1 for instructions on adjustment of relief valve settings To gain access to brake valve 3 Fig 9 28 remove four hex head screws and lock washers 1 to detach the lower panel 2 which is located under the dash 7 Install the transmission cover 9 3 2 Brake Valve A Warning a Removal Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 1 Retract the boom and support it in a horizontal and level position 2 Engage the park lock place the travel select lever in neutral and stop the engine Hex Head Capscrew and Lock Washer 4 Lower Panel Brake Valve Hex Nut 2
77. Loctite 222 on the capscrews 2 Install capscrew 13 through flat washer 12 and the LEFT hole in the relay bracket Place a tooth type lock washer 11 over the end of the capscrew Insert end of screw through relay mounting plate 17 and secure the screw with a flat washer 12 and a lock nut 10 Repeat this installation through the right hole in the relay bracket but without using a tooth type lock washer between the relay bracket and the relay mounting plate 4 Install connector S from neutral start switch terminal 9 by installing lock washer 8 and hex nut 7 5 Connect starting motor feed cable 6 by installing lock washer 2 and hex nut 1 6 Connect positive battery cable 3 by installing lock washer 5 and hex nut 4 OFF POSITION RUN POSITION I THERMO START POSITION Se THERMO START AND START POSITION MA1061 Fig 10 23 Ignition Key Switch 10 19 Section 10 Electrical System 1 Thermo Start Plug 2 Intake Manifold MA1071 Electrical Terminal 4 Fuel Line Fitting Fig 10 24 Thermo Start Plug for Cold Weather Starting 10 5 5 Thermo Start Plug for Cold Weather Starting When the ignition key switch Fig 10 23 is turned to the Thermo Start position a Thermo Start plug 1 Fig 10 24 ignites a fuel air mixture in the intake manifold 2 to facilitate cold weather starting To use this starting aid for cold weather starting tu
78. Remove the covers from the joystick assem bly Fig 4 5 3 Loosen the lock screw until the control cable with lock screw and cable bushing can be removed from the slider 4 Unthread cable bushing from cable and remove lock screw from cable 5 Remove the transmission cover 6 Remove the clamp Fig 4 6 that secures the control cable to the bracket on the forklift frame 7 Remove the cotter and clevis pin that attaches the control cable to the spool on the main control valve 8 Remove the clevis and jam nut from cable end 9 Remove the cable from the forklift Installation 1 Route the control cable between the joystick and the main control valve 2 Secure the cable to the main control valve spool Fig 4 6 with clevis and cotter pins 3 Atthe other end of the cable slip the lock screw over the cable rod end 4 Thread the cable bushing onto the cable rod end and position it as shown in Fig 4 5 5 Insert the cable into the control slider Then thread the lock screw into the slider 6 Use a 5 8 inch open end wrench to hold the slider in position and tighten the slider lock screw work carefully so you don t rotate the slider IMPORTANT Do not exceed 55 Ib ft 75 N m 7 Adjust the cable at both ends so that it oper ates properly 8 Replace the covers on the joystick assembly 9 Install the lower panel below the side console 10 Install the transmission cover Model 6036 S N 9B0499 a
79. Repair or replace cylinder para 9 2 Disassemble cylinder and repair para 9 2 Repair or replace bearing in applicable compo nent Replace cartridges 9 2 1 Engage control valve fully Be sure that valve linkage and drain lines are unrestricted Repair or replace cylinder para 9 2 Install cylinder seal kit para 9 2 Inspect control valve and install seal kit para 9 3 1 Replace tube and install seal kit para 9 2 Disassemble valve inspect and clean Install seal and spring kit para 9 3 6 Clean all foreign material from parts and check operation para 9 3 6 Poppets must slide freely in valve body If poppets slide freely install seal and spring kit If poppets still stick replace valve Excessive clearances will cause internal leakage Replace relief valve Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Trouble Probable Cause Remedy Directional Control Valve Difficult to Shift Directional Control Valve Does Not Return Shifting of Operator Lever Fails to Cause Spool in Directional Control Valve to Shift Binding valve cable linkage Broken internal parts Scored valve body bore causing leakage between spool and body Broken centering spring Too much friction in linkage connecting valve to operat ing lever Dirt in valve Sheared pin in connection to valve Check main control valve forbroken spool Model 6036 S N 9B0499 and Before Check cable li
80. See para Section 10 Electrical System Trouble Probable Cause Remedy Reference Windshield Washer Wiper for Enclosed Cab GENERAL cont d Wiper motor parks 1 With the ignition switch in If the lamp lights proceed to See para 10 10 3 but above the RUN and the wiper switch step 2 if the lamp doesn t normal position in PARK remove light proceed to step 3 connector from wiper motor terminal P Use a test lamp to check for an OPEN between terminal P to ground If the lamp lights repair Repair or replace as required open in motor or replace holder assembly If the lamp doesn t light Repair or replace as required check arm and blade location and transmission linkage Windshield Reservoir is empty Fill reservoir See para washer pump runs but doesn t spray fluid on windshield Washer fluid is frozen Use windshield washer fluid See para with a low freeze point for low temperature operations Washer nozzle or hoses Clean or replace nozzle and See para are clogged hoses Broken kinked or Repair replace or connect See para disconnected hoses hoses Windshield Broken washer wiper Test switch for continuity in washer pump switch the washer depressed doesn t run position if switch is open replace switch Wire 33 between switch Repair or replace wire and washer pump motor is broken Broken washer pump Replace washer reservoir motor assembly Air Ci
81. System including filter and oil cooler 3 gallons 13 7 liter Transmission Filter 1 quart 0 95 liter Model 6036 S N 9B0499 and Before Section 6 Drive Shafts and Drop Box VENT FILL PLUG OIL SEAL END YOKE SCREW amp cence WASHER WASHER END YOKE OIL SEAL Ls x a Q FRAME l Q a lt a Q DROP BOX g INSPECTION COVER Q CAPSCREW G g LEVEL PLUG LOCK WASHER on late models LEVEL PLUG on early A models OIL SEAL D END YOKE SCREW amp WASHER DRAIN PLUG PA0261 Fig 6 2 Exploded View of Drop Gear Box Model 6036 S N 9B0499 and Before 6 5 This Page Left Blank Intentionally Section 7 Transmission SECTION 7 TRANSMISSION CLARK SERIES 18000 CONTENTS Par Title Page 7 1 TRANSMISSION PREVENTIVE 7 1 MAINTENANCE 7 1 1 Daily or 10 Hour Intervals 7 1 7 1 2 First 50 Hours and 500 Hour Intervals Thereafter 7 1 7 1 3 1000 Hour Intervals 7 2 7 2 HOW TO TOW THE FORKLIFT 7 2 7 3 HOW TO DRAIN TRANSMISSION 7 2 7 4 HOW TO BACK FLUSH OIL COOLER 7 3 7 5 TRANSMISSION REMOVAL 7 3 7 6 TRANSMISSION REPLACEMENT 7 3 7 7 INTERNAL SERVICING 7 3 7 8 INSTALLATION 7 3 7 9 TROUBLESHOOTING 7 4 7 10 SPECIFICATIONS 7 5 7 1 TRANSMISSION PREVENTIVE MAINTENANCE Warning To avoid severe burns DO NOT attempt this procedure when the engine cooling and hy draulic systems are hot Wait until they have cooled before proceeding Care must be e
82. Take up the slack 6 Disconnect hydraulic hoses as required from steering cylinders service brakes and park 2 Install the axle pivot pin and shims There must be no more than a 0 10 2 5 mm gap lock between the frame and axle Secure the pin in 7 Remove the drive shaft from the axle input place with a capscrew and locknut Tighten shaft end yoke Fig 5 7 locknut until snug against collar then an 8 Remove the capscrew and locknut securing the additional 1 4 turn axle pivot pin to the frame Remove the pivot 3 Secure the frame tilt cylinder rod end to the pin and shims frame mounting blocks Fig 5 7 with a pin and two retaining rings The pin must pass easily NOTE To remove the pivot pin from the front axle f through both mounting blocks If not shim the e thread a 1 2 bolt into front end of pin and pull blocks as required Lubricate the pin using the or pry on bolt or drain fuel from fuel tank grease fitting on the cylinder rod or 4 Install the drive shaft on the axle input shaft end yoke Be sure retaining rings are securely e remove tank and drive pin out from the back seated side 1 Drive Flange items 2 thru 16 Wheel End items 17 thru 43 Fig 5 7 Axle Connections FRAME TILT CYLINDER O SHIMS FRAME AXLE PIVOT PIN FRAME FRAME TILT CYLINDER ROD END PIN DRIVE MOUNTING SHAFT BLOCK END YOKE AXLE Y F AXLE MA0261 9 At the front axle remove two retaining rings from the frame tilt cylinder
83. Test the horn switch for continuity when the horn button is pressed If these tests do not reveal the prob lem remove the horn from the forklift and test the horn using short heavy gauge wires connected to a fused or protected 6 A minimum output 12 Vdc power supply MA0891 Tooth type lock washer Lock nut Ground wire Wire 31 OONO Fig 10 3 Backup Alarm as Viewed Through the Engine Door on Right Side of the Forklift 10 3 Model 6036 S N 9B0499 and Before Section 10 Electrical System 10 2 2 Backup Alarm and Reverse Switch A backup alarm sounds when the forward neutral reverse travel select lever is in reverse The alarm is located above the air cleaner in the engine compartment It is energized by a reverse switch that is mounted on the transmission shifter under the left front console panel a Backup Alarm Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries Disconnect alarm wiring While supporting the backup alarm remove two bolts 5 Fig 10 3 and lock washers 6 4 Lift backup alarm 10 from forklift b Backup Alarm Disassembly Do not disassemble the backup alarm c Backup Alarm Cleaning and Drying Without submerging the backup alarm clean the alarm using an approved solvent and dry witha lint free cloth d Backup Alarm Inspection and Replacement 1 Test backup alarm by using short heavy gauge wires connected to a fused or pro tected 6 A m
84. Tilt Circuit 9 11 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Left Position When the grille and frame tilt control lever is placed in the left position the directional control valve spool is positioned so that pump supply pressure is directed through ports E to A Fig 9 5 to the base extend end of the frame tilt cylinder piston If supply pressure reaches 1200 psi 82 7 bar the frame tilt left relief valve Fig 9 2 will open allowing hydraulic oil to return to the return filter and reservoir Fig 9 5 Return oil from the rod end of the frame tilt cylin der piston is directed back to the directional control valve though ports B to D Fig 9 5 to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 0 bar Right Position When the grille and frame tilt control lever is placed in the right position the directional control valve spool is positioned so that pump applied pressure is directed through ports E to B Fig 9 5 to the base retract end of the frame tilt cylinder piston If supply pressure reaches 1200 psi 82 7 bar the frame tilt right relief valve Fig 9 2 will open allowing hydraulic oil to return to the return filter and reservoir Fig 9 5 Return oil from the base end of the frame tilt cylinder piston is directed back to the directional control valve t
85. Using a pin spanner wrench unscrew the gland 8 from the tube IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure Model 6036 S N 9B0499 and Before TUBE PIVOT PIN FRAME TILT CYLINDER N FRAME ROD END PIVOT PIN MOUNTING BLOCK p p AXle Fig 9 16 Frame Tilt Cylinder Pivot Pins MA0571 5 Pull the rod 13 and attached parts straight out of the tube IMPORTANT When sliding the rod and piston assembly in the tube be careful so that gland threads in the tube do not damage the piston 5 Keep the rod in line with the tube barrel to prevent binding 6 Fasten the eye of rod 13 in a soft jawed vise and put a padded support below and near other end of the rod to prevent damage to the rod 7 Remove piston seal 10 piston NOTE It may be necessary to apply heat to break the bond of the sealant between nut 4 and rod 13 before the piston can be removed Refer to paragraph 9 2a 8 Remove nut 4 piston 5 and the gland 8 from the rod 9 Remove O ring 6 from inside of the piston 10 Remove O ring 9 backup ring 10 wiper 12 and rod seal 11 from the gland 11 If necessary to replace remove grease fittings 14 and plugs 2 c Cleaning 1 Discard all seals and backup rings Replace with a complete new seal kit 2 Clean all metal parts in an approved cleaning solvent such as trichlorethylene
86. V battery depending upon the rated voltage of the motor to one of the thru bolts 10 Fig 10 63 2 Test high speed operation by connecting the red lead to the positive terminal The output shaft will turn at 60 to 75 rpm with a maximum current draw of 3 A 3 Test low speed operation by connecting the green leads to the positive terminal The output shaft will turn at 45 to 58 rom with a maximum current draw of 2 A i Wiper Blade Park Adjustment Caution Keep hands away from linkage whenmotor is in operation to avoid serious personal injury After a windshield wiper drive unit has been installed in a vehicle but before the arm and blade are assembled to the drive arm 28 Fig 10 62 adjust blade park position as follows IMPORTANT The arm and blade should not be assembled to the drive arm 28 at this time 1 Operate the motor through the manual switch 2 Watch the drive collar on the wiper arm shaft assembly Turn the switch to the OFF position and note the park position of the drive collar NOTE The parking position of the drive collar must be at the end of a complete oscillation Model 6036 S N 9B0499 and Before Section 10 Electrical System 3 If adjustment is required to obtain the proper parking position proceed as follows a Loosen the cover fastening screws 1 Fig 10 63 If the drive collar parks before completing an oscillation turn the adjustment stud counterclockwise b
87. Washer Screw 2 Flat Washer 2 Nut Retainer Connecting Link Bowed Washer MA1393 Fig 10 62 Windshield Wiper Motor Removal and Disassembly 10 54 Model 6036 S N 9B0499 and Before e Installation 1 Prepare to install washer reservoir assembly by taping a tooth type lock washer 4 Fig 10 61 to back side of the lower right corner of reservoir Use a thin transparent tape Position reservoir assembly 8 in the forklift 3 Install two flat washers 4 and two bolts 3 through the holes in the top of the reservoir 4 Install the ground wire 5 flat washer 4 bolt 3 through the hold in the lower right corner of the reservoir The bolt will pass through the tooth type lock washer 4 which was taped to the reservoir in step 1 5 Connect the hose 2 6 Connect the positive wire 1 to the motor 7 Connect negative cable to the batteries 10 10 3 Windshield Wiper Motor Enclosed Cab Only The windshield wiper motor is located behind the steering column and brake valve Caution Keep hands away from linkage when motor is operating to avoid serious personal injury a Initial Testing 1 Ifthe motor fails to operate prepare to test the motor by disconnecting the negative cable from the batteries 2 Disconnect the wiring to the motor and test the motor using an independent 12 Vdc power source which supplies at least 6 A 3 Reconnect the negative cable to the ba
88. and forces hydraulic oil to flow from the rod end of the slave cylinder to the rod end of the grille tilt cylinder and from the base end of the grille tilt cylinder to the base end of the slave cylinder The grille tilt cylinder rod retracts to tilt the grille down and compensate for upward boom movement The amount of grille tilt cylinder rod movement is proportional to slave cylinder rod movement to always keep the grille at the same attitude When the boom is lowered the slave cylinder is retracted which causes pressure buildup on the base end of the piston Hydraulic oil flow and cylinder and grille action are just the reverse of raising the boom Oil flows through the counter balance valve without piloting c Pressure Checks and Adjustments Grille Tilt Up Relief Valve 1 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar at the 30 gpm section o
89. assembling the solenoid A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift onto the cartridge stem at the bench 2 Lubricate the internal valve piston using clean filtered hydraulic fluid 7 Prepare to test park lock engagement and disengagement by clearing the area around the forklift of persons and any obstructions to forklift travel 3 Energize the solenoid using 12 Vdc to see if the internal cartridge piston retracts into the stem Discard the park lock release valve solenoid cartridge if it doesn t shift 10 38 Model 6036 S N 9B0499 and Before e To test for engagement engage the park lock switch place the drive in forward or reverse and second or medium gear and apply full throttle The forklift should remain motionless in both forward and reverse positions e To test for disengagement firmly depress service brake pedal disengage park lock switch place drive in forward or reverse and first or low gear and slowly press the throttle pedal while releasing the brake pedal The park lock should release and the forklift should be free to travel 10 7 6 Reverse Switch The reverse switch Fig 10 45 causes a backup alarm to sound at the rear of the forklift when the travel select lever is shifted into REVERSE The reverse switch has two positions reverse and neutral Place travel select lever in REVERSE to test alarm Reverse alarm
90. attachment from the quick attach 3 Remove capscrew and locknut 13 Fig 3 20 locking grille tilt cylinder rod end pin 12 in the quick attach 4 Tap the grille tilt cylinder rod end pin from the quick attach 5 Remove capscrew and locknut 6 locking quick attach pin 8 in the quick attach 6 Tap the quick attach pin from the quick attach 7 Remove quick attach assembly 10 from gooseneck 7 8 Remove the latch assembly capscrew 1 flat washer 2 locknut 5 spring 4 spacer and latch 3 if any replacement is necessary Model 6036 S N 9B0499 and Before DaRoN N Section 3 Boom Installation If the latch assembly was removed install it as follows a Assemble flat washer 2 Fig 3 20 latch 3 spacer and spring 4 on the capscrew b Install capscrew 1 on the quick attach making sure the straight end of the spring rides on the top edge of the weldment plate c Install snug and then back off locknut 5 as required to permit free rotation of latch 3 d Stretch the spring hook over the latch Install quick attach assembly 10 on goose neck 7 with quick attach pin 8 Lock the pin in place with capscrew and locknut 6 Lubricate the pin through grease fittings using a good grade of multi purpose lithium based grease Install grille tilt cylinder rod 14 on the quick attach assembly with cylinder rod end pin 12 Lock the pin in place with capscrew and locknut
91. beads loose from rim relubri cate both tire beads and rim bead seat areas Reinstall core and repeat inflation procedures 5 1 14 Connecting Core Ejector Tool to Tire Valve Stem 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 With the pump not running and pump valve in CHECK position screw core ejector body onto stem with handle 4 of core ejector pulled out 3 Push handle of core ejector in until it makes contact with the core housing of the valve 4 Hold the core ejector in you left hand and strike the handle 4 with your right hand to force the core housing in ejector chuck 6 5 Turn handle 4 counterclockwise to unscrew the core housing pushing inward lightly so you can feel the threads disengage when com pletely unscrewed 6 Pull handle 4 out as far as it will go to retract core housing into ejector body The handle will pull out easier if rotated while pulling as packing nut 7 should be tight enough to prevent air or liquid leaks Model 6036 6036T S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle 5 1 15 Installing a Wheel on the Forklift 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 Remove the wheel assembly from the safety cage and place it on the axle hub 3 Secure the wheel assembly to the axle hub with ten wheel lug nuts Torque the nuts to 450 to 500 lb
92. before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar at the 30 gpm section of the tandem pump Fig 9 4 Model 6036 S N 9B0499 and Before A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 5 Start the engine Operate the grille tilt control several times to purge the system of air 6 Depress the accelerator to full throttle Place the grille and frame tilt control lever in the down position and hold until the grille tilt cylinder has fully retracted Continue holding the lever in the down position until the pressure readings are taken 7 Check the pressure gauge reading It should read 2650 50 psi 182 6 3 4 bar If not adjust the grille tilt down relief valve Fig 9 2 turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m after adjustment 8 Stop the engine Operate t
93. boom at their closest point Fig 3 12 Acceptable boom extend chain sag is between 3 4 and 1 3 4 19 and 45 mm If the measurement is less than 3 4 19 mm adjust the boom chains as described in the following steps RETRACT CHAIN LOCKNUT EXTEND CYLINDER OA0511 Fig 3 15 Retract Chain Adjustment Locknut 3 1 7 Chain Tension Adjustment 1 Retract the boom completely to check the position of the inner boom If the distance between the front edges of the intermediate and inner booms is between 1 1 2 and 2 1 2 38 and 64 mm and the extend chain is no closer than 3 4 19 mm from the inner boom proceed no further the boom chains are adjusted correctly 2 Ifthe distance between the front edges of the intermediate and inner booms is 2 or more but less than 2 1 2 51 mm or more but less than 63 mm Model 6036 S N 9B0499 and Before Section 3 Boom a Tighten the locknut Fig 3 15 on the bottom of the outer boom This retracts the inner boom and takes up the sag in the extend chains b Cycle the boom in and out then with the boom horizontal level fully extend the boom and retract it 2 which is 1 per section 51 mm which is 25 5 mm per section c Measure the chain sag Fig 3 12 Accept able boom extend chain sag is between 3 4 and 1 3 4 19 and 45 mm Ifthe chain sag is less than 3 4 19 mm repeat steps a through c 3 If the distance measured in Step 1 is less than 2 but greater than
94. capscrews Lift assembly from the forklift b Disassembly 1 Disconnect black electric terminal cable 7 Fig 10 69 by removing nuts at the solenoid 4 and at the housing of the motor 1 10 63 Section 10 Electrical System 2 Remove solenoid 4 by removing two 1 4 20 by 1 4 Torx head screws 3 In warranty the pump and motor assembly is replaced as a complete unit Out of warranty the pump and motor can be serviced as separate items If further disassembly is required mark the orientation of the pump to the motor and remove two screws which secure the pump 3 and end head assembly 2 to the motor 1 4 Lift pump 3 from motor 1 c Cleaning and Drying Without submerging the motor 1 Fig 10 69 in cleaning solvent clean pump and motor assembly in an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect the pump and motor assembly 2 Discard the complete pump and motor assem bly if the pump 3 Fig 10 69 end head assembly 2 or motor 1 is damaged or defective 3 Test the coil of the solenoid 4 for continuity Discard solenoid if it is damaged or defective 4 Test solenoid operation using short heavy gauge wires connected to a fused or protected 6 A minimum output 12 Vdc power supply Discard solenoid if it fails to operate 5 Test pump motor operation using short heavy gauge wires connected to a fused or protected 6 A minimum output 12 Vdc power supply
95. conditions A Abnormal indicator lamp operation B Abnormal charging system operation A Abnormal Indicator Lamp Operation Check the indicator lamp on the control console for normal operation as shown below Ignition Switch Lamp Engine OFF OFF STOPPED ON ON STOPPED ON OFF RUNNING If indicator lamp operates normally proceed to B ABNORMAL CHARGING SYSTEM OPERATION Otherwise proceed to either one of the following three abnormal conditions 1 Switch Off Lamp On In this case disconnect the two leads from the alternator No 1 and No 2 terminals If the lamp stays on there is a short between these two leads If the lamp goes out replace the rectifier bridge as covered in paragraph 10 6 1 g This condition will cause an undercharged battery 2 Switch On Lamp Off Engine Stopped This condition can be caused by the defects listed in step 1 above or by an open wire in the circuit To determine where an open exists proceed as follows a Check for an open circuit breaker a burned out bulb defective bulb socket or an open in No 1 lead circuit between alternator and ignition switch gt oz If no defects have been found proceed to B ABNORMAL CHARGING SYSTEM OPERATION Model 6036 S N 9B0499 and Before Section 10 Electrical System 3 Switch On Lamp On Engine Running Check for an open circuit breaker between indicator lamp and switch Other possibilities are covere
96. dry bearings by spinning with compressed air This can damage mating surfaces due to lack of lubrication 4 After drying components should be lightly coated with oil or rust preventive to protect them from corrosion d Inspection and Replacement 1 Replace drive flange washer 9 Fig 5 8 if worn 2 Replace planet gears 13 if worn scored or chipped 3 Replace single roller bearings 11 if worn pitted or damaged 4 Replace keyed washers 10 if worn pitted or scored 5 Replace planet gear shaft 8 if worn or scored e Assembly and Installation 1 Refer to page 31 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for assembly and installation instructions 2 Install the planetary gear assembly as de scribed in paragraph 5 2 2 3 After the drive flange is installed rotate the hub so drain fill plug 5 Fig 5 8 is up and fill hub with JLG Special Wet Disc Brake Fluid 8522042 Wheel End Service Brakes a Disassembly Refer to pages 15 and 16 of Spicer Dana Mainte nance Manual for Axle Models PS PR 7036 for disassembly instructions b Cleaning and Drying 1 Clean all parts with an approved petroleum based cleaner 2 Use clean lint free towels to dry components after cleaning DO NOT dry bearings by spinning with compressed air This can damage mating surfaces due to lack of lubrica tion Model 6036 S N 9B0499 and Before Section 5 Wheel Assembly Tires and A
97. engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar in the 15 gpm section outlet of the tandem pump Fig 9 6 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Start the engine and allow it to run at idle Check the pressure gauge reading at the tandem pump 7 Pressure gauge reading should read 575 25 psi 39 6 1 7 bar If not adjust the se quence valve turning the adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure 8 Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 9 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 10 Install the transmission cover after adjustment Pressure Reducing Valve 1 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury Model 6036 S N 9B0499 and Before Section 9 Hydraulic Sys
98. engine at idle 400 to 600 rpm Shift thru direction and speed clutches All clutch pres sure must be equal within 5 psi 0 34 bar If clutch pres sure varies in any one clutch by more than 5 psi 0 34 bar repair the clutch 7 5 This Page Left Blank Intentionally Section 8 Engine SECTION 8 ENGINE PERKINS SERIES 4 236 AND T4 236 CONTENTS Throughout this section the left or right side of the Par Title Page engine is the side of the engine when viewed from 8 1 ENGINE PREVENTIVE 8 2 the flywheel end MAINTENANCE 8 1 1 Daily Before Operation 8 2 7 8 1 2 First 50 Hours 250 Hours Thereafter 8 2 A Warn l n g 8 1 3 Daily or 10 Hour Intervals 8 2 8 1 4 250 Hour Intervals 8 4 Observe these and many other precautions 8 1 5 500 Hour Intervals 8 5 Do not smoke during refueling 8 1 6 1 000 Hour Intervals 8 6 8 1 7 2 500 Hour Intervals 8 7 Do not refuel with engine operating 8 1 8 Annually 8 7 Do not permit loose clothing long hair etc 8 1 9 Post Delivery Check 8 7 near parts which move 8 1 10 Lubricating Oils 8 8 P Never clean lubricate or adjust engine dur 8 2 ENGINE COOLING SYSTEM 8 9 ing operation without correct training 8 2 1 Coolant Requirements 8 9 8 2 2 Piston Cooling Jets 8 9 Keep away from parts which rotate fans can 8 2 3 Integral Cooler in Oil Filter 8 10 be invisible when rotating 8 3 ENGINE ELECTRICAL SYSTEM 8 10 Be sure engine operation will not cause a l concentration of
99. entire counterbalance valve if dam aged e Installation NOTE Be sure that all tube and hose connections to the pressure reducing valve have been made Refer to paragraph 9 3 7 1 Install elbows 6 Fig 9 36 reducers 7 and tube nuts 8 2 Position counterbalance valve 3 under pressure reducing valve 11 and secure to mounting plate 14 with two capscrews 1 lock washers 12 and hex nuts 13 3 Connect hydraulic hoses to elbows 6 f Bleeding Steering System A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 1 Start the forklift engine and run at idle 2 Turn the steering wheel fully left to right and back lock to lock several times in all three steering modes until they operate smoothly This should purge the steering system of air 3 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operator s Manual Model 6036 S N 9B0499 and Before 9 4 PUMPS 9 4 1 Main Tandem Pump a Removal 1 Engage the park lock place the travel selector lever in neutral and stop the engine Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic joystick to relieve any trapped pressure in the 30 gpm section of the tandem pump Slowly loosen the up
100. eroded or pitted Check center of thrust plates where the gears mesh Erosion here indicates oil contamina tion Pitted thrust plates indicate cavitation or oil aeration Discolored thrust plates indicate overheating probably due to insufficient oil 3 Examine the drive and driven gear set 9 Replace as a matched set if there is scoring on the gear hubs scoring grooving or burring of the outside diameter of the teeth or nicking grooving or fretting of teeth surfaces 4 Examine the gear housings 12 and 15 and replace it if necessary Wear in excess of 0 007 inch 0 18 mm cutout necessitates replacement of the gear housing Place a straightedge across bore If you can slip a 0 007 inch 0 18 mm feeler gauge under the Model 6036 S N 9B0499 and Before straightedge in the cutout area replace the gear housing Pressure pushes the gears against the housing on the low pressure side As the hubs and bushings wear the cutout becomes more pronounced Excessive cutout in a short period of time indicates excessive pressure or oil contamination If the relief valve settings are within prescribed limits check for shock pressures or tampering Withdraw oil sample and check it and tank for dirt Where cutout is moderate 0 007 inch 0 18 mm or less gear housing is in good condition and may be reused Examine integral gear shaft set 14 Examine the gears as described in paragraph 3 above Examine all drive shafts and replace if
101. from the forklift 9 Start the engine Turn the steering wheel several times to purge any air in the steering cylinder hydraulic lines 5 2 2 Wheel End With Service Brakes If removing the entire axle assembly from the forklift refer to paragraph 5 2 1 A suitable holding stand is desirable but not necessary If the axle is to remain on the forklift use support stands under machine and axle Steam clean the axle assembly prior to disassem bly Seal all openings before steam cleaning Refer to wheel and tire removal instructions in paragraph 5 1 3 and 5 1 2 Except when servicing the planetary gear assem bly raise axle until pressure is relieved from wheel end and lower axle onto support stands A Warning Wear safety glasses at all times when assem bling and disassembling the axle The smallest eye injury may cause loss of vision Planetary Gear Assembly a Removal Refer to page 13 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for removal instructions b Disassembly Refer to page 14 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for disassem bly instructions 5 15 Section 5 Wheel Assembly Tires and Axle c Cleaning and Drying 1 Clean the groove under drive flange washer 9 Fig 5 8 It is an access to the air vent 2 Clean all parts with an approved petroleum based cleaner 3 Use clean lint free towels to dry components after cleaning DO NOT
102. ft 612 to 680 N m Use the torquing sequence shown in Fig 5 5 OA0453 Fig 5 5 Wheel Torque Sequence 4 Remove the jack stands and lower the tire to the ground 5 1 16 Care of Core Ejector Keep packing nut 7 on plunger fairly tight to avoid leaks However do not set it so tight that plunger cannot easily be pushed into position When not in use for long periods of time keep core ejector submerged in a container of clear water 5 1 17 Care of Pump Do not pump all of the solution out of the reservoir A small amount of solution is required to keep air out of the pump and thus prevent corrosion and sticking If water is used be sure to place pump and reservoir where the water will not freeze 5 1 18 Tire Speed and Road Surface Limitations Forklift tires are designed for low speed operations not exceeding 25 mph 40 km hr If the forklift is towed at high speeds on the highway high temperatures may develop under the tread bars and weaken the rubber material and cord fabric There may be no visible evidence of damage at the time Later a premature failure occurs which Model 6036 6036T S N 9B0499 and Before experience shows was started by the overheated condition that developed when the unit was towed at high speed If tires are to operate for any length of time on roads or other hard surfaces it is advisable to increase pressure in the tire to the maximum recommendation to reduce the movement of the tread b
103. has a solid state regulator that is mounted inside the alternator slip ring end frame The regulator voltage setting never needs adjust ing and no provision for adjustment is provided The alternator rotor bearings contain sufficient lubricant to eliminate the need for periodic lubrica tion Two brushes carry current through two slip rings to the field coil mounted on the rotor and under normal conditions will provide long periods of attention free service The stator windings are assembled on the inside of a laminated core that forms part of the alterna tor frame A rectifier bridge connected to the stator windings contains six diodes and electri cally changes the stator ac voltages to a dc voltage which appears at the alternator output terminal Alternator field current is supplied through a diode trio which also is connected to the stator windings A capacitor or condenser mounted in the end frame protects the rectifier bridge and diode trio from high voltages and suppresses radio noise No periodic adjustments or maintenance of any kind are required on the entire alternator assem bly a Charging Circuit Operating Principles In Fig 10 26 TERMINAL NO 2 of the alternator is connected to the battery and the base emitter of transistors TR3 and TR1 is connected to the battery through resistor R5 thus turning these transistors on Also resistors R2 and R3 are connected to the battery through TERMINAL NO 2 but the disc
104. housing 7 Add tractor hydraulic fluid as required to bring fluid level up to full mark Transmission ca pacity is 4 3 gallons 16 3 liter 7 2 HOW TO TOW THE FORKLIFT Before you tow the forklift for long distances be sure to disconnect and remove both front and rear drive lines to avoid damage to the transmission Because of the design of the hydraulic system the engine cannot be started by pushing or towing For short distance towing consult your Owners Operators Manual 7 3 HOW TO DRAIN TRANSMISSION The procedure for draining the transmission is de scribed in paragraph 7 1 3 MA0321 1 Lock Nut 4 Flat Washer 2 Transmission Oil Cooler 5 Oil Cooler Support 3 Capscrew hex hd 6 Rear Support Fig 7 4 Transmission Oil Cooler Model 6036 S N 9B0499 and Before 7 4 HOW TO BACK FLUSH OIL COOLER The transmission oil cooler Fig 7 4 is mounted behind the radiator Periodically disconnect and back flush the oil cooler with oil and compressed air until all foreign material has been removed If necessary remove oil cooler from forklift and clean it using oil compressed air and steam IMPORTANT DO NOT use flushing compounds for cleaning purposes 7 5 TRANSMISSION REMOVAL Please refer to paragraph 8 6 for engine and transmission removal instructions they are re moved as a single unit Model 6036 S N 9B0499 and Before Section 7 Transmission 7 6 TRANSMISSION REPLACEMENT If the transmission is
105. iil ts CYLINDER s bee qq CRAB 4 WHEEL G H G H G H LJ LJ IJ 2 WHEEL ae 1COUNTER bas d i BALANCE i VALVE LEFT FRONT STEERING CYLINDER METERING SECTION CONTROL VALVE lt 7 rly VI SECTION Sree posses POWER STEERING UNIT LEFT TURN RIGHT TURN ABCD ABCD ABCD VALVE eee E FE F SECTIONS STEERING AND NO STEER EMERGENCY BRAKE PUMP 0 4000 psi PRESSURE GAUGE ae TO PRESSURE REDUCING VALVE TANDEM PUMP RETURN FILTER MA0481 Fig 9 7 Power Steering Circuit Model 6036 S N 9B0499 and Before 9 18 3 The steer select valve solenoid is energized and shifts the valve spool Oil is channeled through ports J to G and to the retract side of the left rear steering cylinder and the extend side of the right rear steering cylinder Return oil from each of the rear steering cylinders passes through steer select valve ports H to I to the retract side of the right front steering cylinder and extend side of the left front steering cylinder Return oil from each of the front steering cylinders flows through ports A to E of power steering control valve section to the return filter and reservoir Left Turn Crab Steer When a left turn is being made with the steering select switch in crab steer down position 1 The power steering control valve spool is shifted so that supply pressure is
106. in the solenoid Energize the solenoid using 12 Vdc to see if the plunger retracts Replace fuel run sole noid if it doesn t retract e Installation 1 Clean exterior of fuel injection pump 2 Install a new O ring on the fuel run solenoid 3 Remove protective plug from fuel injection pump 4 With spring and plunger in solenoid turn fuel run solenoid into fuel injection pump being careful to avoid cross threading Tighten until snug 5 Connect electric wires and connect negative cable to batteries Close and lock the engine access door Prepare to test fuel run solenoid by clearing personnel and any obstructions from the area around the forklift 8 Start the engine e f engine starts the solenoid is functioning e f engine fails to start solenoid may have a poor ground connection Check voltage at solenoid 9 Check for fuel oil leakage around solenoid 10 7 4 Park Lock Switch The park lock switch Fig 10 43 has two posi tions engaged and disengaged To engage lift cover and flip lever up To disengage lower switch cover a Removal 1 Disconnect negative cable 2 Fig 10 38 from batteries 2 Prepare to remove park lock switch Fig 10 43 by removing the lower panel which is located below the switch 3 Tag and disconnect electric wires from the switch 4 Remove hex nut cap seal and the hex nut which secures switch to left front console panel 5 Remove switch guard and de
107. ing the piston and capping and plugging the ports f Installation 1 Install the side tilt carriage cylinder 1 Fig 9 21 on the side tilt carriage 7 Secure the rod end to side tilt carriage 7 2 Secure the tube end to the pivot base 8 with snap rings 4 3 Lubricate the pivot pins with multi purpose lithium based grease Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 4 Remove all plugs and caps from the hydraulic lines and securely tighten the lines to the cylinder 5 Start the forklift engine and remove blocking from the carriage 6 Tilt the side tilt carriage five times through its full range or until the operation of the side tilt carriage is normal no jerks or spongy feel 7 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual 9 44 9 3 VALVES 9 3 1 Main Control Valve Assembly The main control consists of eight relief valves four directional control valves and an inlet and outlet section Fig 9 22 For a description of how each component operates in a specific circuit refer to paragraph 9 1 K MA0431 H i Outlet Section 2 Frame Tilt Right Relief Valve 1200 50 psi or 82
108. installed below the Model 6036 S N 9B0499 and Before rigid spacer Tighten securing nuts evenly to 12 Ib ft 16N m a Howto Locate Faulty Atomizer s A faulty atomizer can cause e Misfiring e Knocking in one or more cylinders e Engine overheating e Loss of power e Smoky exhaust black e Increased fuel consumption The particular faulty atomizer or atomizers may be determined by releasing the pipe union nut on each atomizer in turn with the engine running at a fast tick over If after slackening a pipe union nut the engine revolutions remain constant this denotes a faulty atomizer To test the atomizer 1 Withdraw this complete unit from the cylinder head 2 Invert the atomizer with the nozzle facing outwards and then retighten the unions 3 Slacken the unions of the other atomizer pipes to avoid the possibility of engine starting 4 Use the starter to turn the engine over until fuel sprays from the nozzle Examine the shape of the spray If the spray is unduly wet or streaky or obviously to one side or if the nozzle dribbles it may only be necessary to probe the nozzle holes to remove carbon A Caution Be careful to keep hands and face from coming in contact with spray as it will cause fuel oil to penetrate the skin IMPORTANT Do not attempt to adjust injection pressure without a testing pump and pressure gauge It is impossible to adjust the setting of at omizers with any degree of acc
109. into water never add water to calcium chloride as considerable heat is generated in this mixing process Let the solution cool to atmos pheric temperature before pumping it into the tire To mix and cool the solution place the pump control in the FILL position and use the pump to circulate the solution through the core ejector body and back into the reservoir 5 1 10 Filling a Tire or a Tube within a Tire with Hydrofill 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 Place the wheel assembly with the valve stem straight up in a safety cage Fig 5 1 Attach clip on chuck insert the valve core in the stem Fig 5 2 then withdraw handle of core ejector tool Stand to the side during inflation 3 Pressurize the tire to approximately 3 psi 0 21 bar Check for proper alignment of all compo nents e lf assembly is incorrect STOP DEFLATE correct the assembly and repeat the procedure e lf assembly is okay continue to inflate to 35 psi 2 4 bar A Warning Never inflate beyond 35 psi 2 4 bar pressure If beads have not seated by the time pressure reaches 35 psi 2 4 bar deflate the assembly reposition the tire on the rim relubricate and reinflate After seating beads adjust inflation to recommended pressure Allowing air pressure to build within the assembly in an attempt to seat the beads is a DANGEROUS PRACTICE In seating beads inflation beyond 35 ps
110. is inoperative or doesn t park check park switch actuator and brush holder assembly in wiper motor If wiper runs and parks use a test lamp to check for current flow between terminals P and L If lamp doesn t light check for open in green wire from wiper switch to wiper motor If lamp lights check for open in wire 32 to circuit breaker 12 Fig 10 5 Remove connectors from wiper terminals P and L Connect a jumper from terminal P to L and a 12 Vdc source to terminal P Check wiper linkage connection to wiper crank arm Wiper linkage is connected but wiper gear is stripped Linkage is disconnected If wiper is inoperative or doesn t park proceed to step 2 if wiper runs and parks proceed to step 3 Repair or replace as required If lamp doesn t light proceed to step 4 if lamp lights proceed to step 5 Repair or replace green wire as required if green wire provided continuity replace wiper switch Repair or replace as required If the wiper parks replace the wiper switch if the wiper still runs repair wiper motor by checking the park switch actuator and the brush holder assembly If the linkage is connected refer to step 2 if linkage is disconnected refer to step 3 Repair wiper motor Connect linkage and check system Model 6036 S N 9B0499 and Before See para See para See para See para See para See para See para See para
111. l GRILLE TILT PORT l RELIEF VALVES pE l a l w y l l l TO BOOM EXTEND a Sa CYLINDER TANDEM RESERVOIR _J PUMP _ 0 4000 psi Q l TO BOOM HOIST Sect cou gey STRAINER RETURN CYLINDER GAUGE S FILTER ane E AE ga IIN TI MA0452 iL I b il Fig 9 4 Grille Tilt and Slave Circuit oel Model 6036 S N 9B0499 and Before 9 8 grille tilt up relief valve Fig 9 2 will open allowing hydraulic oil to return to the return filter and reservoir Fig 9 4 Return oil from the rod side of the grille tilt cylinder piston is directed back to the directional control valve through ports B to D Fig 9 4 to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar The counterbalance valve Fig 9 4 will allow oil flow to the base end of the grille tilt cylinder but will not allow reverse oil flow from the base end of the grille tilt cylinder This prevents the grille from tilting down due to the load on the grille which causes back pressure on the grille tilt cylinder piston Without this check valve the back pressure would tilt the grille down if the extend line should fail Down Position When the fork and frame tilt control lever is placed in the down position the directional control valve spool is positioned so that pump supply pressure is directed through ports E to B Fig 9 4 to the ro
112. lines Faulty power steering unit External fluid leakage at tubes hoses or fittings Faulty relief valve setting Internal leakage in cylinder Internal leakage in control valve Defective tandem pump Leakage in auxiliary cylinder s Low level in reservoir Filler breather on reservoir is dirty Suction strainer clogged Suction line is restricted or loose Model 6036 S N 9B0499 and Before Check and set relief valve para 9 1 6 Install new cartridge or replace valve para 9 3 5 Install cylinder seal kit s para 9 2 6 Check and adjust wheel alignment as needed per paragraph 5 2 5 Check and tighten connections at valves pump and cylinders Repair or replace defective hose Install cylinder seal kit s para 9 2 6 Repair or replace power steering unit Replace steer select valve para 9 3 4 Check and tighten loose connections Operate steering to purge system of air Repair or replace power steering unit Check and tighten connections at valves pumps and cylinders Repair or replace faulty hose s Check and set frame tilt relief valve para 9 1 4 Repair cylinder as required para 9 2 7 Repair control valve as required para 9 3 1 Repair tandem pump para 9 4 1 Repair or replace cylinder s or check valve para 9 2 7 Check and fill hydraulic reservoir as described in Owners Operators manual Clean or replace filler oreather Clean strainer as described in Owners Operators ma
113. local Delco distributor OA0022 1 Steering Wheel 4 Service Brake Pedal 2 Horn 5 Ignition Key Switch 3 Accelerator Pedal Fig 10 39 Forklift Operating Components 10 7 SWITCHES AND SOLENOIDS 10 7 1 Ignition Key Switch By using the key the ignition switch 5 Fig 10 39 may be turned clockwise from the OFF position to the RUN THERMO START AND START positions The THERMO START AND START positions are spring loaded to return to the RUN position and must be manually held in place for cold starting or normal starting When starting in cold weather momentarily hold the key in the THERMO START position before turning it fully to the START posi tion Inthe OFF position the entire electrical system is shut down there is power to ignition switch and to starter solenoid only e Inthe RUN position all controls and indica tors are operable 10 33 Section 10 Electrical System e Inthe RUN position with the Park Lock engaged park lock warning oil pressure and alternator lights must be ON Press Bulb Check switch remaining warning lights must turn ON In the THERMO START position the ignition switch energizes the Thermo Start plug Fig 10 24 which ignites a fuel air mixture in the intake manifold to facilitate cold weather starting Refer to paragraph 10 5 5 for Thermo Start plug removal and installation instructions In the START position with the parking lock engaged and the travel select lever in
114. lock pins are seated in lock plate as shown in Fig 4 12 Tighten bottom nut while holding pivot bolt stationary Then torque bottom nut 250 to 300 Ib inch 28 to 34N m This will lock the preset to its home posi tion The effective torque value for your mirror could vary slightly The nut must be tight enough to prevent the lock plate from rotating it must hold the mirror assembly in position under forklift operating conditions and allow the mirror to pivot freely when moved by hand 5 Check preset function by rotating loop back and forth A definite click will be heard and felt as the loop is rotated past the home position 6 Return loop to home position The loop should snap firmly into place and the lock pins should be firmly located in the holes of the lock plate NOTE Use all weather grease periodically on the lock pins to maintain smooth operation 4 4 2 Mirror Cleaning and Inspection 1 The mirrors must be properly adjusted They must be kept free from condensation frost ice snow dust and dirt Rinse heavy grit from mirror before you clean it with glass cleaner and dry it with a soft cloth 2 Be especially careful when removing ice from mirror to avoid breaking or scratching mirror You can use a nonmetallic scraper heat or an approved chemical to lower the freezing point of the ice to aid in ice removal 3 Return each mirror to home position after cleaning 4 Replace m
115. must NOT sound in FORWARD or NEUTRAL a Removal 1 Prepare to remove reverse switch by removing lower panel 7 Fig 10 40 located below switch 2 Disconnect negative cable 2 Fig 10 38 from the batteries Tag and disconnect the wires from the switch Observe and mark hole location at top of switch and remove cotter pin 1 Fig 10 45 5 Disengage switch arm and remove washer 2 at pivot 6 Remove hex nut 3 lock washer 4 and washer 5 at bottom of switch 7 Remove capscrew 6 spacer 7 and switch from transmission shifter 9 b Disassembly Do not disassemble the switch c Cleaning and Drying Without submerging the switch clean the switch with an approved solvent and dry with a clean lint free cloth d Inspection and Replacement 1 Inspect the switch terminals for continuity in the reverse position and shorting in the neutral position 2 Replace the switch if it fails the tests in step 1 Model 6036 S N 9B0499 and Before Section 10 Electrical System e Installation 1 Connect electric wires as tagged during switch removal 2 Install capscrew 6 Fig 10 45 through lower mounting hole in switch 3 Install spacer 7 on screw and place screw in mounting hole in transmission shifter 4 Install washer 5 lock washer 4 and hex nut 3 Torque nut to 80 to 85 Ib in 9 to 9 6 N m 5 Install washer 2 on pivot at top of switch arm and place pivot in hole mark
116. of boom extend chains after the first 50 hours of operation and at 250 hour intervals thereafter 3 10 BOOM EXTEND CHAINS EXTEND CHAIN SHEAVE LUBE FITTING FRONT FACE OF YOKE MUST BE PARALLEL TO FRONT FACE OF OUTER BOOM OA0531 Fig 3 13 Yoke and Extend Chains Adjust the chains so that e the inner boom extends 1 1 2 to 2 1 2 38 to 64 mm from the front of the intermedi ate boom when the boom is retracted Fig 3 11 and e the extend chains are no closer to the intermediate boom than 3 4 19 mm when the boom is extended Fig 3 12 and e the front face of the yoke Fig 3 13 is parallel to the front face of the outer boom WEAR PADS EXTEND CHAIN LOCKNUTS ead PADS RETRACT CHAIN SHEAVE LUBE FITTING eames Fig 3 14 Rear Boom Cover Opening Model 6036 S N 9B0499 and Before Adjustment is accomplished using extend chain adjustment locknuts Fig 3 14 a ChainLocknutFunctions Loosen extend chain locknuts to extend the inner boom and increase extend chain sag Tighten outer boom retract chain locknut to retract the inner boom and decrease extend chain sag b Adjusting Procedure 1 Raise the boom to a horizontal level position Fully extend the boom then retract it 2 which is 1 per section 51 mm which is 25 5 mm per section 2 Measure sag in the extend boom chains between the bottom of the chains and the top of the inner
117. of the park lock release valve 2 Fig 9 33 clean valve in an approved cleaning solvent and blow dry d 1 Inspection and Replacement Inspect and replace solenoid electrical connector and or wiring if damaged Use new seals on solenoid Discard entire park lock release valve if damaged Installation Install connectors 7 and 8 Fig 9 33 and run tee 9 in park lock release valve 2 Position the assembled park lock release valve on valve mounting plate 30 Secure valve to plate using two capscrews 24 flat washers 26 lock washers 25 and hex nuts 27 Install tube assembly 16 Connect hydraulic hoses to connector 8 and run tee 9 Attach electrical connector to solenoid on valve 2 Bleed brake circuit as described in paragraph 9 3 2 g 9 54 9 55 Capscrew Steer Select Valve Electrical Connector Solenoid 2 Screw 4 Park Lock Release Valve Sequence Valve Pressure Reducing Valve Relief Valve Connector 4 Connector 1 Connector 1 Run Tee 1 Connector Run Tee 8 Run Tee 12 Connector 2 Branch Tee Tube Assembly Tube Assembly 3 Tube Assembly Capscrew 2 Lock Washer 8 Flat Washer Hex Nut 8 Capscrew 4 Capscrew 2 2 25 26 27 28 29 30 31 Lock Washer 2 Flat Washer 2 Hex Nut 2 Capscrew 2 Rubber Mount 4 Mounting Plate Subplate Section 9 Hydraulic System MAO741 H
118. or bushing 2 5 2 Cleaning Bearings acceptable for service should be cleaned in a suitable solvent and immersed in clean lubricating oil until needed 2 5 3 Installation 1 Be sure bearings are installed with care during servicing maintenance and repair 2 Install bearings in either of the following two ways e press fit on rotating parts such as shafts and gears and e push fit into static locations such as reduc tion gear housings 3 When possible always install the bearing into the rotating part first 4 Use the proper tools or a press when installing a bearing or bushing 5 Inthe absence of the proper tools or press heat the bearings and or casing in hot oil to assist in the installation 2 6 PRESSURE TESTING AND ADJUSTMENT Prior to pressure testing or adjustment be sure all hoses are in good condition and all fittings tight Use a pressure gauge with a range that is large enough to measuring the specified pressure Comply with the correct procedure to prevent damage to the system or the equipment and to eliminate the possibility of injury 2 3 Section 2 General Instructions Be sure that hydraulic oil is at operating tempera ture 80 to 120 F before adjusting relief valves pressure reducing valve or sequence valve If necessary operate the machine to raise the oil temperature The oil temperature can be checked by placing a hand against the side or the bottom of the reservoir If your
119. pad insert refer to Fig 3 3 b 1 Inspection and Replacement Inspect the boom and welds and contact JLGI if structural damage is detected Inspect hoses and replace if damaged Inspect and replace wear pads as described in paragraph3 1 8 Installation Using slings and a suitable hoist align the outer boom pivot collars with the main frame bearings Install the boom pivot pins and washer spac ers placing the spacers on the inside of the frame bearing Fig 3 10 Using No 10 and or 14 gauge shims shim to maintain a gap between the frame bearing and outer boom of 0 07 to 0 13 1 8 to 3 3 mm Model 6036 S N 9B0499 and Before PAD INSERT 1 LOCK WASHER 2 FLAT WASHER 2 3 8 16 X 7 8 CAPSCREW 2 GAP MUST BE 0 07 TO Section 3 Boom PAD INSERT 1 LOCK WASHER 2 FLAT WASHER 2 3 8 16 X 7 8 CAPSCREW 2 0 13 1 8 i 3 3 mm GAP MUST BE 0 07 TO 0 13 1 8 TO 3 3 mm INTERMEDIATE BOOM PAD SPACER 10 GA SHIM INSERT 1 LOCK WASHER 3 FLAT WASHER 3 Pr Seal 3 8 16 X 1 3 4 PAD 10 GA SHIM INSERT 4 LOCK WASHER 8 FLAT WASHER 8 3 8 16 X 3 4 CAPSCREW 8 el fo GAP MUST BE 0 07 TO 0 13 1 8 TO 3 3 mm OUTER BOOM PAD SPACER 10 GA SHIM INSERT 1 ae LOCK WASHER 3 FLAT WASHER 3 3 8 16 X 1 3 4
120. paragraph 5 2 2 5 2 5 Steering Cylinder and Tie Rod a Removal Refer to page 20 through 22 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for removal instructions COVER PLATE HEX BOLTS ALU b Il a RETAINER RING bS BRAKE MODULE WITH PRES SURE AND SPRING PLATES MA0281 Section 5 Wheel Assembly Tires and Axle b Cleaning and Drying 1 Clean all parts with approved petroleum based cleaner 2 Use clean lint free towels to dry components after cleaning 3 After drying components should be lightly coated with oil or rust preventive to protect them from corrosion c Inspection and Replacement 1 Be sure rod is straight and undamaged If rod is bent or damaged install new rod 2 Check condition of tube attaching hardware and hydraulic hoses Repair or replace as required d Installation Refer to page 24 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for installa tion instructions 5 2 6 Park Lock Unit The park lock unit consists of the park lock and a yoke shaft a Removal Refer to page 54 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for removal instructions b Disassembly Refer to page 55 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for disassem bly instructions SOCKET HEAD CAPSCREWS 0 PINION NUT DUST SLINGER YOKE SHAFT Fig 5 12 Park Lock Removal 5 21 Model 6036 S N 9B
121. pressure is applied in the boom raise lower circuit by the 30 gpm section rear half of the tandem pump which draws its fluid through a suction strainer in the reservoir Fig 9 1 Supply pressure is directed to either side of the right and left boom hoist cylinder pistons by the shifting of a spool in a directional control valve found in the main control valve assembly The spool is shifted by the operator joystick and its associated control cable The joystick positions for raising and lowering the boom are as follows Center Position When the joystick is placed in the center or neutral position the directional control valve spool is positioned so that supply pressure is directed through ports F to C Fig 9 1 to the return filter and reservoir Fig 9 1 If the filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar Raise Position When the joystick is placed in the raise position the directional control valve spool is shifted so that supply pressure is directed through ports E to A Fig 9 1 to the base end of both left and right boom hoist cylinder pistons If supply pressure reaches 2650 psi 182 6 bar the boom hoist Model 6036 S N 9B0499 and Before Section 9 Hydraulic System TO FRAME TILT CYLINDER TO GRILLE TILT AND SLAVE CYLINDERS TO BOOM EXTEND RETRACT CYLINDER
122. proceed to step 5 5 Tag and disconnect hydraulic hoses from connectors 6 on valve subplate 31 6 Remove two nuts 21 lock washers 19 and capscrews 23 and remove assembled valve 1 and subplate 31 Remove connectors 6 from the subplate Remove steer select valve 1 from the subplate by removing four capscrews 22 9 Remove and discard O rings between sub plate and steer select valve b Disassembly NOTE There are no serviceable parts in the steer select valve do not disassemble Replace solenoid s if defective Remove four screws 1C to detach each solenoid Model 6036 S N 9B0499 and Before c Cleaning Without submerging the electrical portion of the steer select valve clean valve in an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect solenoids electrical connectors and wiring and replace if damaged 2 Replace entire steer select valve if damaged e Installation 1 Install four new O rings in base ports of steer select valve 1 Fig 9 33 2 Position the steer select valve on valve subplate 31 and secure with four capscrews 22 NOTE If the valve subplate was removed for service continue with steps 3 through 5 3 Install connectors 6 in the subplate 4 Place the assembled steer select valve and valve subplate on mounting plate 30 Install two capscrews 23 lock washers 19 and nuts 21 to secure Connect hydraulic hose
123. removed from the forklift Start the engine Extend and retract the boom several times to purge the system of air Depress the accelerator to full throttle Place the joystick in the extend position and hold until the extend cylinder has fully extended Continue holding the joystick in the extend position until the pressure readings are taken Check the pressure gauge reading It should read 2650 50 psi 182 6 3 4 bar If not adjust the boom extend port relief valve Fig 9 2 by turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N _ m after adjustment Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 10 Start the engine Extend and retract the boom fully several times to purge the system of air 11 Install the transmission cover after adjustment Boom Retract Port Relief Valve Engage the park lock place the travel select lever in neutral level the boom and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A War
124. required to relieve any g trapped pressure 9 3 6 Steer Relief Valve a Removal 1 Engage the park lock place the travel selector lever in neutral and stop the engine A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns A Warning Relieve hydraulic pressure before servicing any 3 Tag and disconnect tube assemblies 15 16 hydraulic component Escaping hydraulic fluid and 17 from connector 10 and run tees 11 under pressure can penetrate the skin causing and 12 on the sequence valve 3 serious injury 4 Tag and disconnect hydraulic hose from run Wait for the hydraulic fluid to cool before servic tee 11 ing any hydraulic component Hot hydraulic fluid 5 Remove two hex nuts 21 lock washers 19 can cause severe burns flat washers 20 and capscrews 18 Re move sequence valve 3 from valve mounting 2 Tag and disconnect hydraulic hoses from plate 30 branch tee 14 Fig 9 33 and connector 13 6 Remove hydraulic fittings from the valve as required CARTRIDGE WITH SEALS b Disassembly NOTE There are no serviceable parts in the steer BODY sequence valve do not disassemble Remove sequence valve cartridge Fig 9 34 c Cleaning Clean metal parts of valve with an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect valve cartridge Fig 9 34 for wear scoring damaged
125. reservoir If supply pressure reaches 3 000 50 psi 206 7 3 4 bar the main relief valve Fig 9 2 will open allowing hydraulic oil to return to the reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar The counterbalance valve in each boom hoist cylinder serves as a safety device The counter balance valve functions as follows Should any of the hydraulic lines going to either hoist cylinder fail there will be a loss of hydraulic system pressure to the cylinder s Example f there was a hydraulic line failure in the pressurized lowering line during lower 9 2 Section 9 Hydraulic System ing the counterbalance valve would lose pilot 4 Install a tee and pressure gauge capable of pressure closing off flow returning to the measuring 0 4000 psi 275 6 bar in the reservoir The oil in the base end of the tandem pump outlet of the 30 gpm section cylinder would then be trapped which would Fig 9 1 immediately stop boom lowering and prevent an elevated load from falling to the ground uncontrolled The load can be lowered safely n to the ground by following the Emergency A Warn l n g Boom Lowering procedures in your Owners Operators Manual Before starting the engine be sure all hydraulic IMPORTANT DO NOT attempt to reset the connections are tight and all tools are removed counterbalance valve cartridges In the event that
126. right turn is being made with the steering select switch in crab steer down position 1 The power steering control valve spool is shifted so that supply pressure is applied through ports F to C Fig 9 7 to the intake side of the power steering metering section A measured amount of hydraulic oil is ex hausted from the metering section and routed back to the control valve where it is channeled through ports B to A Supply oil is routed from port A to the extend side of the right front steering cylinder and the retract side of the left front steering cylinder Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 4 Return oil from each of the front steering cylinders passes through the solenoid ener gized select steer valve from ports to G to the extend side of the right rear steering cylin der and the retract side of the left rear steering cylinder 5 Return oil from each of the rear steering cylinders flows through select steer valve ports H to J and power steering control valve section ports D to E to the return filter and reservoir b Pressure Checks and Adjustments 1 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the steering wheel after the engine has stopped to relieve any
127. rings securing the grille tilt cylinder tube to the gooseneck 9 Remove cylinder from forklift using strap sling and hoist or other suitable lifting equipment b Disassembly 1 Remove all dirt and grease from cylinder 2 Fasten the cylinder in a soft jawed vise or other acceptable holding equipment Do not damage the tube 3 If necessary to replace remove the grease fittings 14 and 15 4 Remove the counterbalance valve 13 Fig 9 15 and three O rings 16 and backup rings 17 from the tube 5 Using a pin spanner wrench unscrew the gland 8 from the tube IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure 6 Pull the rod 11 and attached parts straight out of the tube IMPORTANT When sliding the rod and piston assembly in the tube be careful so that gland threads in the tube do not damage the piston 4 Keep the rod in line with the tube barrel to prevent binding 7 Remove piston seal 3 from piston 4 8 Fasten the eye of the rod in a soft jawed vise and put a padded support below and near other end of rod to prevent damage to the rod NOTE It may be necessary to apply heat to break the bond of the sealant between nut 2 and rod 11 before the piston can be removed Refer to paragraph 9 2a 9 Remove nut 2 piston 4 and the gland 8 from the rod 10 Remove the O ring 5 from inside of the piston 11 Remov
128. rod end pin Fig 5 7 Tap the pin 5 13 Model 6036 S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle Screw self locking Planetary Gear Assembly Flange planetary drive Plug drain fill Plug Pin roll Shaft planet gear Washer drive flange Washer keyed Bearing single roller Ring spacer Gear planet Plate lining stop Ring retaining Gear sun spur Model 6036 S N 9B0499 and Before 17 Plate lining stop 32 18 Disc Assembly 33 19 Piston 34 20 O ring piston OD 35 21 O ring piston ID 36 22 O ring oil passage 37 23 O ring retainer 38 24 Spindle Assembly 39 25 Screw 40 26 Seat bleeder 41 27 Bleeder 42 28 Fitting brake 43 29 Retainer 30 Shim 31 Gear planetary ring Flange Front Axle and Service Brakes PA0332 Cone bearing outer Hub Assembly Hub planetary Cup bearing outer Cup bearing inner Bolt wheel Nut wheel Cone bearing inner Seal oil Deflector seal Seal oil Tubing brake Fig 5 8 Wheel End and Drive 5 Connect hydraulic hoses as required to steer ing cylinders service brakes and park lock Bleed the lines to the service brakes and park lock Remove the hoist from the ends of the axle Install the wheels on the axle as described in paragraph 5 1 15 8 Remove the support from under the frame A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed
129. rotor and reduction gears The hourmeter should operate whenever the engine is running If the hourmeter is intermittent or fails to operate check for faulty wiring or connections Check for proper voltage at meter terminal 8 to 32 Vdc To check accuracy observe the running indicator flag wheel The gauge is accurate to 1 percent at 75 F 24 C Model 6036 S N 9B0499 and Before a Removal of the Hourmeter 1 Refer to paragraph 10 8 1 for removal of gauge cluster 2 Disconnect spade connector at hourmeter 7 Fig 10 47 3 To remove hourmeter loosen nut on clip which secures hourmeter to gauge mounting plate 3 4 Lift hourmeter from gauge mounting plate b Cleaning and Drying Clean the hourmeter with a clean lint free cloth c Inspection and Replacement Inspect the hourmeter and replace if defective To check operation observe the indicator flag wheel d Installation of the Hourmeter 1 Position hourmeter 7 Fig 10 47 in gauge mounting plate 2 Install clip and nut which secures hourmeter to gauge mounting plate 3 Refer to paragraph 10 8 2 for installation of the gauge cluster 10 41 Section 10 Electrical System HOURMETER FUEL GAUGE WARNING OA0031 BUTTON Engine Oil Pressure Indicates low engine oil pressure Engine Water Temperature Indicates high coolant temperature Alternator Charging I
130. screws 4 Route cable on forklift to throttle panel under floor of operator cab 5 Attach the short clevis end of the cable to the support with a clamp Fig 4 8 6 Fasten the short clevis to the lever assembly with a clevis pin and lock clip Clamp cable to cable support Hook one end of the spring around the pedal clamp and the other end around the neck of the clevis Fig 4 8 7 Check that all connections are secure 8 If necessary adjust the pedal limit stop as described in the following paragraph 9 Close and lock right side engine access door Adjustment 1 Lightly depress the throttle pedal to full position 2 Adjust the limit stop screw until it touches the pedal 3 Tighten the locknut to 120 to 125 Ib inch 13 6 to14 1N m 4 Check engine rpm at full throttle If it is not between 2600 and 2860 rpm readjust the limit stop screw IMPORTANT During the full throttle check e operate no hydraulic function e do not steer and e be sure the transmission is in neutral 4 7 Section 4 Operator s Cab 4 4 REAR VIEW MIRRORS The forklift has two rear view mirrors e A6 1 2 by 10 flat glass mirror on the cab frame to the left of the operator e A 6 1 2 by 6 convex glass mirror on the forklift frame to the right of the operator The mirrors have an outer gasket for edge shock protection If a mirror shatters a replacement mirror can be installed in the mirror head 4 4 1 Mirror Head Adjust
131. serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame Model 6036 S N 9B0499 and Before 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar in the tandem pump outlet of the 30 gpm section Fig 9 1 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 5 Start the engine Raise and lower the boom fully several times to purge the system of air 6 Depress the accelerator to full throttle Place the joystick in the raise position and hold until the hoist cylinders have fully extended Con tinue holding the joystick in the raise position until the pressure readings are taken 7 Check the pressure gauge reading It should read 2650 50 psi 182 6 3 4 bar If not adjust the boom hoist port relief valve Fig 9 2 by turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m after adjust ment 8 Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 9 Remove the pressure gauge and tee from the
132. starter button and turn the load control to the OFF position 15 If the current draw and the armature shaft speed are within the ranges under Specifica tions the starter is good 16 Low armature shaft speed and high current draw are indications of too much friction Possible causes of too much friction are a Tight dirty or worn bearings b A bent armature shaft c Loose pole shoes pole shoes make contact with the armature d A short circuit in the armature coil Disas semble the starter Use an armature tester to test the armature Use the instructions included with the armature tester e lt Damaged field coil Do the tests de scribed in paragraph g 17 If the armature does not rotate and the current draw is high possible causes are a Field terminal making contact with the field frame Inspect the insulators for the field terminal b lt Damaged field coil Do the tests de scribed in paragraph g c Damaged bearings 18 If the armature does not rotate and the current draw is zero possible causes are a An open field circuit Disassemble the starter and inspect field coil connections b An open armature coil Disassemble the starter and check for burned commutator 10 17 Section 10 Electrical System bars Use an armature tester to test the armature Use instructions included with the armature tester c Brushes are not making good contact with the commu
133. starting motor feed cable 6 by removing hex nut 1 and lock washer 2 4 Disconnect neutral start switch connector 9 from terminal S from by removing hex nut 7 and lock washer 8 5 Remove starting motor relay 14 from relay mounting plate 17 by removing two self locking hex nuts 10 and flat washers 12 from behind plate On the left side of the starter motor relay remove a tooth type lock washer 11 from between the plate and the starter relay Then remove capscrews 13 6 If necessary remove relay mounting plate 17 by removing two capscrews 15 and two flat washers 16 Model 6036 S N 9B0499 and Before Section 10 Electrical System b Disassembly of Starting Motor Relay IMPORTANT Do not disassemble starting motor relay service only as a complete assembly c Cleaning and Drying Without submerging the starting motor relay clean the relay using an approved solvent and dry with a clean cloth d Inspection and Replacement 1 Test the operation of the relay by connecting a 12 Vdc positive source to terminal S and the negative lead to the mounting bracket replace the relay if you don t hear the contacts close 2 Inspect the general condition of the casing and terminals and replace the relay if damaged e Installation 1 If it was removed position the relay mounting plate 17 Fig 10 22 on the engine and secure it with two capscrews 15 and two lock washers 16 Use
134. steps 2 thru 5 7 Turn the forklift steering wheel full right to access the shaft assemblies on the left side of the vehicle 8 Inspect the left side shaft assemblies as instructed in steps 2 thru 5 e Assembly 1 Refer to page 23 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for steering knuckle assembly instructions 2 Refer to page 25 through 31 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for axle shaft and spindle assembly and installation instructions 3 Connect the tie rod and steering cylinder to the knuckle assembly Torque the socket assem bly nuts to 140 Ib ft 190 N_ m minimum Check to make sure the position of the offset in the tie rod clears the carrier assembly in full turn position both directions If full turn clearance is not found switch the tie rod assembly around end for end and then retorque the slotted nuts 4 Install cotter pins and bend each pin over to lock it in place Model 6036 S N 9B0499 and Before NOTE If the cotter pin cannot be installed after minimum torque is attained the nut must be advanced until the cotter pin can be installed IMPORTANT If the tie rod adjustment toe in has been changed it will be necessary to readjust it Position the steering knuckles in a straight ahead 0 turn angle position Position measuring bars on the spindle mounting face of the steering knuckles Measure across them on the carrier side and cover side
135. switch Test the neutral start circuit as follows e Starter MUST NOT operate with travel select lever in FORWARD or REVERSE positions e Starter MUST NOT operate when park lock is DISENGAGED e Starter MUST operate with travel select lever in NEUTRAL position SWITCH ACTUATING PIN A S X HYDRAULIC DECLUTCH NEUTRAL START SWITCH MA1231 Neutral Start Switch Switch Actuating Pin Control Valve Housing Assembly Forward Neutral and Reverse Valve Spool Oil Seal Valve Spool Stop Fig 10 41 Neutral Start Switch DaBRUN gt Model 6036 S N 9B0499 and Before Section 10 Electrical System MA1241 Fuel Injection Pump Fuel Run Solenoid Plunger Spring O ring Solenoid Engine Coolant Heater Low Oil Pressure Sender ONDJIBROUON gt Fig 10 42 Fuel Run Solenoid Coolant Heater and Low Oil Pressure Sender If the starter fails to rotate the engine with the travel select lever in NEUTRAL and the ignition key in the START 1 Check for problems in the shift lever linkage 2 Check the neutral start switch it may not be closing 3 Remove the switch from the control valve assembly and check the actuator pin in the control valve assembly for free movement 4 Make acontinuity check across the terminals of the switch with the actuator ball manually depressed If circuit is open replace the neutral start switch 10 7 3 Fuel Run Solenoid Th
136. the OPEN position Switches and Solenoids PARK LOCK SWITCH AND PARK LOCK RELEASE VALVE SOLENOID Park lock switch 1 Loose connections or Tighten connections and See para 10 7 4 fails to disengage broken wiring install new wiring as required park lock brake in disengaged position Park lock switch isn t Repair or replace park lock See para 10 7 4 closed in the disengaged switch if it isn t closed in the position disengaged position Solenoid fails to shift when If solenoid fails to shift refer See para 10 7 5 park lock switch is moved to paragraph 10 7 5 and from ENGAGED to repair or replace the park lock DISENGAGED release valve solenoid 10 72 Model 6036 S N 9B0499 and Before Section 10 Electrical System Trouble Probable Cause Remedy Reference Switches and Solenoids PARK LOCK SWITCH amp PARK LOCK RELEASE VALVE SOLENOID cont d Park lock switch 1 Park lock switch should be Repair or replace park lock See para 10 7 4 fails to engage open in the engaged switch if it isn t open in the park lock brake in position engaged position engaged position Listen for the shifting of the If solenoid fails to shift refer See para solenoid as an assistant to paragraph 10 7 5 and moves the park lock switch repair or replace the park lock from the disengaged to the release valve solenoid engaged position Switches and Solenoids REVERSE SWITCH AND BACKUP ALARM Backup alarm
137. the boom hoist cylinders is normal no jerks or spongy feel 8 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual 9 Test boom hoist lower circuit operation as described in paragraph 9 1 1c 9 2 2 Boom Extend Cylinder a Removal 1 Retract the boom and support it in a horizontal and level position with blocking 2 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 3 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 4 Disconnect the hydraulic lines from the extend cylinder and cap or plug open connections Remove the anti buckle bar Fig 9 11 Support the extend cylinder with a sling or other suitable device 9 27 Section 9 Hydraulic System 7 Remove the rod end pin and retaining rings attaching the rod end of the extend cylinder to the intermediate boom 8 Remove the base end pin and retaining rings securing the base end of the cylinder to the outer boom 9 Remove the cylinder from the forklift using a strap sling and hoist or other suitable equip men
138. the desired end position This selects the desired flow pattern of P to A and B to T or P to B and A to T When the solenoid 2 is de energized the control spool 3 is returned to its normal condition by the centering springs 4 A manual override 6 is provided for emergency operation of the valve without electrical power The valve is supplied with a rubber boot covered thumb button type manual override 10 8 GAUGES AND INDICATOR LIGHTS The gauge cluster contains an hourmeter warning lights and a fuel level gauge Removal and installation instructions for the gauge cluster are provided in paragraphs 10 47 and 10 48 10 8 1 Removal of the Gauge Cluster 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Remove four hex nuts 1 Fig 10 47 and lock washers 2 which secure gauge mounting plate 3 and gauge cover 4 to right console panel 5 and remove the four hex head screws 6 from the panel Carefully break the rubber seal around the gauge mounting plate and cover and separate the plate and cover 3 Service the gauge cluster as described in the following procedures for servicing of a specific component in the gauge cluster refer to paragraphs 10 8 3 10 8 4 10 8 7 and 10 8 8 4 Temporarily insulate all exposed wiring if it becomes necessary for you to connect the battery ground cable before you complete the removal and installation procedures 10 8 2 Installation of Gauge Cluster
139. the shaft assembly 2 Slide the sleeve assembly onto the splines of the drive shaft and tighten the dust cap IMPORTANT Be sure that the arrows or marks on the shaft and sleeve assemblies are aligned since the yokes on both ends of the drive shaft must be in the same plane to prevent excessive vibration 3 Install the cross and both bearings in the yoke 4 Install the two retaining rings in their grooves in the yoke 5 Repeat steps 3 and 4 for the other cross assembly 6 Using the grease fitting on the sleeve assem bly lubricate the shaft assembly spline with a multi purpose lithium based grease 7 Temporarily tape the two loose bearing caps to the cross so they do not fall off during assem bly of drive shaft onto the forklift f Installation Model 6036 S N 9B0499 and Before Section 6 Drive Shafts and Drop Box Drive Shaft Transmission to Drop Gear Box 1 Position the drive shaft assembly on the forklift so slip joint mounts to the drop box Fig 6 1 2 Remove tape and secure this end of the drive shaft cross assembly to the transmission output shaft yoke with a cap and bolt assembly or bearing straps Torque the cap and bolt assembly to 30 to 35 lb ft 41 to 48 N m or the bearing strap to 55 to 60 lb ft 75to82N m 3 Slide slip joints as far as possible onto drive shaft remove taps and secure the drive shaft cross assembly to the drop box input shaft yoke with a U bolt assembly or bearing strap
140. there is any wear detectable by touch in the seal area or at the drive coupling Maximum allowable wear is 0 002 inch 0 05 mm Wear in the shaft seal area indicates oil contamination Wear or damage to splines keys or keyways necessitates replacement If gears are replaced bushings 18 must be replaced Bushings should fit into bore with a heavy press fit Inspect all bushings for scoring or discoloration and replace if neces sary Use a bushing puller Fig 9 38 to remove bushings Replace all rubber and polymer seals includ ing all O rings channel seals shaft seals and gasket seals Examine the plugs 6 in the shaft end and port end covers to make sure that the plugs are in the proper position and tight There should be two plugs in both the shaft end and port end Replace any plugs which are damaged or cannot be tightened Assembly Stone all machined surfaces with a medium grit Carborundum stone If bushings have been removed deburr the bushing bores with fine emery cloth Rinse parts in an approved solvent Air blast all parts and wipe with a clean lint free cloth before starting assembly Grip shaft end cover 16 Fig 9 42 in vise with mounting face down If plugs 6 were re moved screw new plugs in tightly Stake plug with prick punch at both ends of screwdriver slot and around edges Peen the edge of the hole 1 32 to 1 16 0 79 mm to 1 59 mm with a 1 1 2 diameter steel ball 9 64 NOTE If
141. to be replaced as a complete assembly detach and transfer the following e Tandem Pump e Transmission Temperature Switch e Transmission Connector Kit from valve e Two Side Mount Brackets Neutral Start Switch comes with new transmission 7 7 INTERNAL SERVICING If servicing the transmission internally the tandem pump may require removal for disassembly Refer to the enclosed Clark 18000 Powershift Transmission Maintenance and Service Manual when servicing the transmission internally 7 8 INSTALLATION Please refer to paragraph 8 8 for engine and transmission installation instructions they are in stalled as a single unit 7 3 Section 7 Transmission 7 9 TROUBLESHOOTING Trouble Probable Cause Remedy Low Clutch Pressure Low Converter Charging Pump Output Overheating Noisy Converter Lack of Power 7 4 Low oil level Clutch pressure regulat ing valve stuck open Faulty charge pump Broken or worn clutch shaft or piston sealing rings Clutch piston bleed valve stuck open Low oil level Suction screen plugged Defective oil pump Worn oil sealing rings Worn oil pump Low oil level Worn oil pump Worn or damaged bear ings Converter stalls because of low engine rpm Worn oil sealing rings Worn oil pump Low oil level Fill to proper level Clean valve spool and housing Replace pump Replace sealing rings Clean bleed valve thoroughly Fill to proper level Cle
142. to one terminal and then the other terminal If wiper runs in high and low check for an open in wires from wiper terminals H and L to the wiper switch If wiper runs at one speed check for low and high speed brush leads shorting together internally Model 6036 S N 9B0499 and Before If the wiper runs in high proceed to step 2 if the wiper is inoperative proceed to step 3 Repair or replace as required if red wire provided continuity replace wiper switch Repair or replace as required If the wiper runs in low proceed to step 2 If the wiper is inoperative proceed to step 3 Repair or replace as required if black wire provided continuity replace wiper switch Repair or replace as required Repair or replace as required If the wiper runs in high and low proceed to step 2 if wiper runs at one speed proceed to step 3 Repair or replace as required Reference See para See para See para See para See para See para See para See para See para 10 79 Section 10 Electrical System Trouble Probable Cause Remedy Reference Windshield Washer Wiper for Enclosed Cab GENERAL cont d Wiper shuts off but blades do not return to park position Wiper will not shut off Wiper runs but blades do not move 10 80 Remove connector from terminal P of wiper motor and connect a jumper from terminal L to P anda 12 Vdc source to terminal P If wiper
143. toxic emissions 8 4 a ae na a Persons in area must be kept clear during a U iei ee Moles a engine and forklift operation 8 4 3 Fuel Level Sender and Gauge 8 12 Guards must be installed when running 8 4 4 Fuel EA e Do not remove radiator cap while engine is ee Euel Lift ump sie hot coolant is hot under pressure and dan 8 4 6 Fuel Filter 8 14 8 4 7 Fuel Injection Pump 8 16 gerous and can cause severe burns 8 4 8 How to Bleed the Fuel System 8 16 Relieve pressure in fuel and hydraulic sys 8 4 9 Atomizers Fuel Injectors 8 16 tems before servicing get medical assis 8 5 ENGINE EXHAUST SYSTEM 8 17 tance immediately if your skin comes in con tact with high pressure fuel or hydraulic fluid di ENGINE RENCYAL ole Diesel fuel can cause skin damage to some 8 7 ENGINE OVERHAUL 8 21 persons use gloves or special skin protec 8 8 ENGINE INSTALLATION 8 21 enone E Do not use salt water or other corrosive liq 8 9 HEAD TORQUE CHECK 8 24 uid in cooling system 8 10 STEM TIP TO ROCKER ARM Keep sparks and fire away from batteries CLEARANCE CHECK 8 24 Battery fluid can burn and is dangerous to 8 11 ENGINE STORAGE 8 25 the skin and especially the eyes 8 12 TROUBLESHOOTING 8 26 Some of the gaskets used on the engine Disclaimer and Scope of these Instructions These instructions are written for world wide use In territories where legal requirements govern engine smoke emission noise safety factors etc then all instructions data and di
144. trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar in the 15 gpm section outlet of the tandem pump Fig 9 7 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 5 Start the engine and allow it to idle 1000 rpm 6 Turn the steering wheel fully left to right and back lock to lock several times in all three steering modes until they operate smoothly This should purge the steering system of air Model 6036 S N 9B0499 and Before 7 Increase engine speed to full throttle and check the pressure gauge reading It should read between 575 25 psi 39 6 1 7 bar If not adjust the sequence valve by turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 8 Turn the steering wheel completely left or right and hold while checking the pressure gauge reading It should read 2475 25 psi 170 5 1 7 bar If not adjust the steering relief valve by turning the adjustment screw clockwise to increase relief pressure or counterclockwise to decrease relief pressure 9 Stop the engine and operate the steering wheel after the engine has stopped to relieve any trappe
145. warning bulbs should light 12 Turn ignition key to OFF and remove key from switch Model 6036 S N 9B0499 and Before c Removal of Warning Lights Gauge 1 Refer to paragraph 10 8 1 for removal of gauge cluster 2 Tag and disconnect connector from warning lights gauge 3 To remove warning lights gauge remove nut 18 Fig 10 47 lock washer 19 and clip 20 and remove warning lights gauge from gauge mounting plate 3 d Cleaning and Drying Clean warning lights gauge with a clean lint free cloth e Inspection and Replacement Inspect warning lights gauge replace if required f Installation of Warning Lights Gauge 1 Position warning lights gauge 8 Fig 10 47 in gauge mounting plate 3 2 Install clip 20 lock washer 19 and nut 18 to secure gauge 8 to gauge mounting plate 3 Install connector 15 on gauge 8 Refer to paragraph 10 8 2 for the installation of the gauge cluster 10 8 5 Engine Low Oil Pressure Sender The engine low oil pressure light warns the operator to discontinue forklift operation immedi ately because engine oil pressure is too low The engine low oil pressure light in the warning lights gauge is described in paragraph 10 8 5 The engine low oil pressure sender for this light 1 is shown in Fig 10 42 The oil pressure warning bulb lights to warn the operator to discontinue forklift operation immedi ately when engine oil pressure falls below 8 7 psi 0 6
146. which secure the switch to the panel b Disassembly Do not disassemble the switch c Cleaning and Drying Without submerging the switch clean the switch with an approved solvent and dry with a clean lint free cloth d Inspection and Replacement 1 Inspect the switch terminals for continuity with the switch in the right lift and depressed positions and shorting in the center position 2 Replace the switch if it fails the tests in step 1 e Installation 1 Connect the wires as they were tagged during switch removal 2 Position the switch from under the right front console panel 3 Install the switch and tighten the hex nut 4 Replace the knob and lower console panel 5 Connect negative cable to the batteries 10 10 2 Windshield Washer Motor and Reservoir Enclosed Cab Only The windshield washer motor and reservoir are a unit and cannot be serviced separately a Removal 1 Disconnect the negative cable at the batteries 2 Fig 10 38 2 Disconnect the positive wire 1 Fig 10 61 at the motor 7 Disconnect the hose 2 Remove three bolts 3 three flat washers 4 and the ground wire 5 Model 6036 S N 9B0499 and Before Section 10 Electrical System MA1381 Positive Wire Hose Bolt 3 Flat Washers Ground Wire Tooth Type Lock Washer Motor Washer Reservoir Assembly Fig 10 61 Windshield Washer Motor Removal ONOARONSs IMPORTANT Be careful to save the
147. with nut 8 Connect negative cable 2 Fig 10 38 to batteries 10 13 3 Steering and Emergency Hydraulic Pump S N 7P0014 thru 9B0499 The emergency hydraulic pump 3 Fig 10 69 performs three functions e When starting the engine the emergency steer pump supplies oil pressure as the engine is being started When oil pressure at the engine rises above 4 psi 0 3 bar the emergency steer pump ceases operation because the engine is turning fast enough for the tandem pump to supply sufficient hydraulic oil pressure for forklift operation If engine oil pressure again falls below 4 psi 0 3 bar the switch will close and the emergency steer pump will resume operation for as long as the battery has sufficient charge a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries Remove hydraulic tank cover Disconnect red electrical cable from solenoid 4 Fig 10 69 by removing nut 4 Tag and disconnect yellow ground wire from solenoid 4 by removing nut 5 Tag and disconnect yellow ground wire from end head assembly 2 by removing screw 6 Tag disconnect and plug the hydraulic supply hose at the pump Cap or plug the hose end and pump ports 7 Tag disconnect and plug the hydraulic pressure hose at the pump Cap or plug the hose end and pump ports 8 Prepare to remove pump and motor assembly by supporting assembly while an assistant removes two 3 8 16 UNC hex head
148. within 10 amperes of rated output check field winding as covered in paragraph 10 6 1 e and test regulator with an approved regulator tester If output is not within 10 amperes of rated output check the field winding diode trio rectifier bridge and stator as covered in paragraphs 10 6 1 e f g and h Model 6036 S N 9B0499 and Before c Alternator Removal 1 Disconnect negative cable 2 Fig 10 38 from batteries 2 Remove screw 1 Fig 10 28 lock washer 2 and washer 3 from tapped hole in alternator 3 Remove screw 4 lock washer 5 lever 6 and spacer 7 from tapped hole in engine 4 While supporting the weight of the alternator 22 remove self locking nut 8 washer 9 screw 10 sleeve 11 and sleeve 12 lift the alternator from the forklift and carry it to a clean work bench 5 If necessary remove hex nuts 13 washers 14 washers 15 bracket 16 and stud 17 6 If necessary remove hex nut 18 washer 19 belt 20 and pulley 21 d Alternator Disassembly 1 Remove the four thru bolts and pry alternator apart with a screwdriver at the stator slot 2 After disassembly place a piece of tape over the slip ring end frame bearing to prevent entry of dirt and other foreign material and also place a piece of tape over the shaft on the slip ring end 3 If brushes are to be reused clean with a soft dry cloth 4 To remove the drive end frame from the rot
149. 0 5 Remove hydraulic fittings from valve as required 9 58 b Disassembly NOTE There are no serviceable parts in the pressure reducing valve do not disassemble Remove pressure reducing valve cartridge Fig 9 34 c Cleaning Clean metal parts of valve in an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect valve cartridge Fig 9 34 for wear scoring damaged seals and other damage Replace cartridge if damaged 2 Discard entire pressure reducing valve if damaged e Installation 1 Install run tees 11 and 12 Fig 9 33 in pressure reducing valve 4 2 Position the pressure reducing valve on valve mounting plate 80 and secure with two capscrews 18 lock washers 19 and hex nuts 21 3 Connect tube assemblies 16 and 17 and hydraulic hoses to run tees 11 and 12 on the pressure reducing valve 4 Refer to paragraph 9 3 8 for installation of the counterbalance valve 5 Bleed brake circuit as described in paragraph 9 3 2g 9 3 8 Counterbalance Valve S N 8F0235 and before only a Removal 1 Engage the park lock place the travel selector lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Slowly loosen the fittings at the counterbal ance valve 3 Fig 9 36 to relieve any trapped
150. 0 38 from batteries 2 Tag and disconnect wiring from circuit breaker by removing hex nuts and lock washers 3 Each circuit breaker is held in the circuit breaker bracket by spring tension only Re move circuit breaker by inserting small slot screwdriver between circuit breaker bracket and left edge of circuit breaker and tilt breaker out of bracket Model 6036 S N 9B0499 and Before This Page Left Blank Intentionally Section 10 Electrical System i BA TOP TIONAL WINDSHIELD WIPER OPTIONAL CIRCUIT BREAKER OPTIONAL CAB HEATER OPTIONAL WINDSHIELD WASHER ae 1 PA1081 Backup Alarm Capscrew hex hd 5 16 NC x 3 1 2 2 Hex Nut 5 16 2 Lock Washer 5 16 2 Ring terminal 6 Hex Nut 3 8 2 Lock Washer 3 8 2 Washer Reservoir Assembly Ignition Switch with Keys Ignition Key Eyelet terminal 1 4 Transmission Temperature Sender Wire Assembly closed cab only Engine Low Oil Pressure Sender Tie Wrap 9 not shown Fig 10 5 Drawing 1 Cab Harness and Components of Ele
151. 0499 and Before Section 5 Wheel Assembly Tires and Axle 1 Screw socket head cap 4 7 Screw socket head cap 4 13 2 Plate cover 8 Disc rotor 7 14 3 Spline outer 9 Plate lining 7 15 4 Spring red 12 10 Plate thrust 16 5 Plate pressure 11 Bolt socket head shoulder 4 17 6 Plate spring 12 Screw bleeder 18 Ring retainer Bearing Ring retainer Seal oil Seal oil Seal case 2 Fig 5 13 Exploded View of Park Lock Model 6036 S N 9B0499 and Before 19 20 21 22 23 24 PA0281 Piston Ring backup Ring backup O ring O ring Pin dowel 4 5 22 LINING PLATE PIN CAPSCREW Section 5 Wheel Assembly Tires and Axle THRUST PLATE SHOULDER BOLT MAQ291 Fig 5 14 Plate and Disc Alignment c Cleaning and Drying 1 Clean all parts with approved petroleum based cleaner 2 Use clean lint free towels to dry components after cleaning DO NOT dry bearings by spinning with compressed air This can damage mating surfaces due to lack of lubrication 3 After drying components should be lightly coated with oil or rust preventive to protect them from corrosion d Inspection and Replacement 1 If yoke shaft Fig 5 12 shows wear in the area of oil seal 14 and 17 Fig 5 13 contact replace it 2 Replace all oil seals 16 and 17 O rings 22 and 23 and back up rings 20 and 21 regardless of condition 3 Replace bearing 14 if it is worn pi
152. 1 6 2 3 Internal Inspection NOTE JLG does not recommend servicing of gears shafts or bearings inside this drop box The drop box is manufactured in such a way that attempts at internal disassembly of these items may cause damage to other parts and possibly the drop box case The only serviceable items of this drop box are the yokes and oil seals If internal servicing of drop box is required while still under warranty JLG recommends that the box be re turned to the factory for rebuild or replaced with a new box Out of warranty repairs or rebuilding may be performed at the customer s discretion how ever it is not an easy job a Removal 1 Remove the transmission and hydraulic tank covers from the frame 2 Remove the U bolt assembly or bearing straps attaching the transmission drop gear box drive shaft cross assembly to the drop box input shaft yoke 3 Remove the U bolt assemblies attaching the axle drive shaft cross assemblies to the drop box output shaft yokes Slide slip joint back as far as possible on drive shaft Tape bearing caps to cross to prevent loss of bearings 4 Secure drop gear box in a sling connect sling to a hoist and remove slack from hoist line 5 Drain hydraulic tank Detach hose that runs between tank and drop box Remove bolt and washer attaching input yoke to drop box 6 From under the forklift remove two capscrews and lock washers securing the box to the frame 7 Fromabove r
153. 1 Clean gauge cover 4 Fig 10 47 2 Remove all old rubber sealant from gauge mounting plate 3 and gauge cover 4 3 Position cover over gauge mounting plate Examine the assembly for alignment and the cover for cleanliness Apply a bead of silicon rubber sealing compound along the top and bottom surface of the gauge mounting plate Model 6036 S N 9B0499 and Before OB ON Nut hex 1 4 6 Screw hex hd 1 4 by 3 4 Lock Washer 1 4 7 Hourmeter Gauge Mounting Plate 8 Warning Lights Gauge Gauge Cover 9 Seal Cap Right Console Panel 10 Bulb Test Switch Section 10 Electrical System A 17 MA1282 11 Fuel Gauge 16 Bulb 12 Flange Head Bolt 17 Fuel gauge light assembly 13 Bulb socket 18 Hex nut 14 Bulb 19 Tooth type lock washer 15 Connector 20 Clip Fig 10 47 Gauges and Indicator Lights 3 to minimize the entry of dust between the plate and the gauge cover 4 Leave the ends open to provide some ventilation 4 Position the plate and cover under the right console panel 5 and secure with four hex head screws 6 lock washers 2 and hex nuts 1 5 Connect any wiring removed in previous steps 6 Position right console panel 5 and overlay on control console and secure with four screws 12 10 8 3 Hourmeter The hourmeter 7 Fig 10 47 indicates the total elapsed hours of forklift operation It is a solid state electronic piece of equipment except for the number wheels
154. 10 Electrical System Remedy Starting System GENERAL Battery is discharged Ignition switch relay or solenoid inoperative Starting circuit is open or has high resistance Battery is discharged Defective starting motor connections or loose battery connections 3 Starting motor faulty 4 Relay or solenoid contacts are burned Engine is seized crankshaft cannot rotate Defective starting motor drive assembly Defective solenoid or pinion engagement levers Defective flywheel ring gear Discharged battery Excessive resistance in starting circuit 3 Defective starting motor 4 Excessively tight engine Fuel tank is empty Engine is malfunctioning Model 6036 S N 9B0499 and Before Check battery and charge or replace battery Check circuitry and repair or renew faulty components Check circuit connections and repair or renew faulty wiring Check battery and charge or renew Check clean and tighten connections Inspect repair or renew Renew relay or solenoid Repair or replace engine and transmission as required Inspect and repair or renew Inspect and repair or renew Inspect and renew Check battery and charge or renew Check circuit connections and repair or renew faulty wiring Inspect and repair or renew Investigate cause and repair or replace engine Fill fuel tank Contact authorized engine
155. 10 18 Red Voltmeter Lead 7 Connect the red voltmeter lead to the motor terminal on the starter solenoid Fig 10 18 Model 6036 S N 9B0499 and Before VOLTMETER LEAD MA1021 Fig 10 19 Black Voltmeter Lead 8 Connect the black voltmeter lead to the mounting flange on the starter Fig 10 19 I I I I i i OoOo Pai iO i iee i AMMETER iMm CLAMP aS l l i 1 fS S 5 i l MMMM 4 MA1031 Fig 10 20 Ammeter Clamp 9 Fasten the ammeter clamp around the positive battery cable so that the tip of the arrow is toward the starter Fig 10 20 VOLTMETER AMMETER LOAD CONTROL IGNITION SWITCH P4 TERMINAL REMOTE HAND HELD START TACHOMETER PMN BUTTON Fig 10 21 Remote Start Button and Hand Held Tachometer Model 6036 S N 9B0499 and Before Section 10 Electrical System 10 Connect the leads from the remote starter button to the Battery and Switch terminals Fig 10 21 IMPORTANT Steps 11 12 and 13 must be done rapidly Do not load the battery for more than 15 seconds at one time After the battery has been loaded for 15 seconds let the starter cool for 60 seconds 11 Actuate the starter and turn the load control until the voltmeter indicates 11 volts 12 Look at the ammeter and make a record of the ammeter indication 13 Use the hand held tachometer Fig 10 21 and check the armature shaft speed Make a record of armature shaft speed 14 Release the remote
156. 10 8 9 terminals of low voltage Pointer fluctuates Engine not properly grounded Improve engine ground See para 8 3 when headlights are turned ON Optional Light Circuit DIRECTIONAL AND EMERGENCY FLASHER SWITCH Turn signals Bulb s burned out flasher Replace bulbs See para 10 9 1 operative on one cannot be heard side One or more bulbs are inoperative with hazard warning system ON Open wiring or ground If test bulb lights repair open See para 10 9 1 connector ground connection if not One or more bulbs are repair open wiring between inoperative with hazard bulb socket and turn signal warning system ON Use switch test light and check circuit at bulb socket Short to ground flasher Locate and repair short to See para 10 9 1 can be heard but no bulbs ground by disconnecting front operate and rear circuits separately Turn signals Defective flasher located Replace flasher See para 10 9 1 inoperative below instrument panel near brake pedal 10 76 Model 6036 S N 9B0499 and Before Section 10 Electrical System Trouble Probable Cause Remedy Reference Optional Light Circuit MOMENTARY BRAKE LIGHT STOP LIGHT AND SWITCH Stop and tail light Stop and tail light bulb s Replace stop and tail light See para bulbs fail to light 23 Fig 10 53 are burned bulb s when brake pedal out is pressed Momentary brake switch Replace momentary brake See para 9 is open whe
157. 12 or motor 13 is damaged or defective _ Pa f ED A 6 Tag disconnect and plug the hydraulic supply hose 1 at the connector 2 Wire or otherwise secure the hose to the frame to hold it up and prevent oil from draining out of the reservoir Cap the connector 7 Tag disconnect and plug the pump outlet hose 3 at the elbow 4 Cap the elbow 8 Have an assistant support the pump and motor assembly while removing two capscrews 5 and lock washers 6 and remove from the forklift b Disassembly 1 Disconnect black electric terminal cable 7 Fig 9 45 from the solenoid cable terminal and the motor power terminal 2 Remove solenoid 4 by removing two screws 8 3 Remove check valve 11 if replacement is necessary 7 1 Supply Hose S 2 Connector 3 Pump Outlet Hose 4 Elbow 5 Capscrew 2 6 Lock Washer 2 7 Terminal Cable y 8 Screw 2 Z 9 Solenoid CO N AA 10 Pump aF fi 11 Check Valve 12 End Head Assembly 13 Motor MA0851 Fig 9 45 Steer and Emergency Brake Pump and Motor S N 7P0014 and After 9 69 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System e Assembly 1 Ifthe pump and motor assembly was disas sembled mount the end head assembly 12 Fig 9 45 and pump 10 i on the motor 13 and secure 2 Install check valve 11 in the end head assembly 12 3 Install the solenoid 9 on the housing of the motor 1
158. 13 FROM ALTERNATOR MA0901 Starter Relay Starter Starter Ground Cable Negative Battery Ground Cable Circuit Breakers Brake Light Male Terminal Wire Assembly Fig 10 7 Starting Circuit When the ignition key is released after start ing it returns to a neutral position where it directs current to circuit breakers 13 which distribute current for the operation of forklift controls gauges and equipment 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 10 10 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 Check for broken wires and damaged insula tion on the wires Replace all broken or damaged wiring Check all connections at the starter solenoid key switch and wiring harness plugs Clean and tighten all connections If the starter st
159. 18 Bushing 8 Fig 9 42 Main Tandem Pump Exploded View 9 63 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 8 Remove connecting shaft 10 Remove thrust plate 8 seal 7 and seal 11 9 Remove integral gear set 14 Keep these together as they are a matched set Be careful not to damage the machined surfaces of the gears 10 Remove thrust plate 8 seal 7 and seal 11 11 Lift or pry off the first section gear housing 15 Be careful not to damage machined surfaces 12 Remove thrust plate 8 seal 7 and seal 11 13 Grip the shaft end cover 16 in a vise with the mounting face down Remove double lip seal 17 by inserting the special seal removal tool Fig 9 39 into the notch between the double lip seal and the shaft end cover Tap the seal out and discard Remove and discard all rubber and polymer seals e Cleaning Clean metal tandem pump components in an approved cleaning solvent and blow dry f Inspection Repair and Replacement 1 If either a dowel 5 Fig 9 42 or a dowel hole is damaged the dowel or machined casting or both must be replaced Pull defective dowels as required 2 Examine thrust plates 8 and replace if necessary The thrust plates seal the gear section at the sides of the gears Wear here will allow internal slippage that is oil will bypass within the pump A maximum 0 002 0 05 mm wear is allowable Replace thrust plates if they are scored
160. 3 and secure with two screws 9 4 Connect black terminal cable 7 to the sole noid cable terminal and the motor power terminal f Installation 1 Place the pump and motor assembly on the frame and support in position Model 6036 S N 9B0499 and Before g Secure the pump and motor assembly to the frame with two 3 8 16 UNC 28 hex head capscrews 5 Fig 9 45 and lock washers 6 Connect the supply hose 1 and pump outlet hose 3 to appropriate pump port fittings Connect the red electrical cable to the solenoid power terminal Connect the yellow ground wire to the end head assembly 12 Connect the yellow switch wire to the solenoid switch terminal Testing Test operation of steering and emergency brake pump para 9 1 6 9 70 9 5 TROUBLESHOOTING Trouble Probable Cause Section 9 Hydraulic System Remedy Cannot Lower Elevated load Cavitation and Noise Ruptured Hose Hose Cover Sepa rated from Wire Damaged Threads on Fittings Boom Hoist or Ex tend Function Slow or Malfunctioning 9 71 Ruptured hoist or extend hose Loss of engine power or hydraulic pump failure Faulty main control valve Fluid level in reservoir is low Filler breather is clogged Air leaks in suction line Loose tandem pump mounting hardware Loose pump sections Defective tandem pump Damaged hose due to tight bend Pressure setting for main relief valve is too high Hose
161. 4 3 1 Repair brake valve as required para 9 3 2 Replace hose Bleed brake lines para 9 3 29 Repair brake valve as required para 9 3 2 Install pressure reducing valve cartridge para 9 3 7 Adjust or replace cartridge para 9 3 5 Repair service brakes using repair kits as re quired para 5 2 2 Replace hose Replace park lock switch para 10 7 4 Replace solenoid or valve para 9 3 3 Install seal kit or other kits in park lock as re quired para 5 2 6 Install repair kits in park lock as required para 5 2 6 Replace solenoid para 9 3 3 Replace switch para 10 7 4 Replace hose Repair or replace power steering unit Repair tandem pump para 9 4 1 Repair steer select valve para 9 3 4 Replace switch or repair wiring as required para 10 7 7 Repair steer select valve para 9 3 4 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Trouble Probable Cause Remedy Steers too Slowly Front or Rear Wheels Not Parallel in 2 or 4 Wheel Steering Steering is Spongy or Noisy Auxiliary Equipment Slow or Malfunctions Auxiliary Equipment Drifts or Creeps Tandem Pump Fails to Deliver Fluid Steer relief valve not set correctly Defective sequence valve Steering cylinder leakage Wheel misalignment External leakage in system Internal leakage in cylinder Internal leakage in power steering unit Defective steer select valve Air in steering
162. 42 to the capscrews and torque them to 31 Ib ft 42 N m 2 Connect the extend chains at the top rear of the inner boom temporarily secure the other end of the chains to the top front of the inner boom 3 Use slings and a suitable hoist to slide the repaired or new inner boom and extend chains into the intermediate boom 4 Working through the rear cover opening temporarily install the top and side inner boom wear pads on the inner boom Fig 3 3 Re place pads that are excessively worn Use the same amount of shimming as used when the pads were removed IMPORTANT The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert the ends must range from flush to 0 19 5 mm recessed in the wear pad insert refer to Fig 3 3 5 Check the wear pad gap between the inner boom side and top wear pads and the inter mediate boom The gap should be 0 07 to 0 13 1 8 to 3 3 mm and equal for all top and side wear pads Install or remove shims as required 6 Install the wear pads by applying Loctite 242 to the capscrews and torquing them to 31 Ib ft 42 N m 7 Secure the retract chain to the inner boom with washers and locknuts Make sure the chains are not twisted 8 Tie the grille tilt cylinder hoses together and push them through the inner boom to the opening at the inner boom gooseneck 9 Refer to Fig 3 2 and install the quick attach assembly on the gooseneck with the quick attach pivot pin Pos
163. 499 and Before Loose or corroded connections may cause a discharged battery difficult starting dim lights and possible damage to the alternator and charging circuit 10 9 1 Directional and Emergency Flasher Switch The directional signal lever and the hazard emer gency flasher slide controls Fig 10 55 are located directly below the steering wheel The ignition switch must be in the RUN position for directional signal lights to be operated with the directional signal switch lever With the directional signal switch in the neutral position stepping on the brake pedal will illumi nate the rear stop lights on both sides If direc tional signals are operating on either side step ping on the brake pedal will turn on the stop light only on the side which is not flashing DIRECTIONAL SIGNAL LEVER EMERGENCY FLASHER TAB i eee OA0622 Fig 10 55 Directional Signal Switch Lever and Emergency Flasher Control Tab Push the lever of the directional signal switch to the left and down to signal a left turn to the right and up for a right turn A green pilot light will flash to indicate proper functioning If pilot light doesn t flash check for defective lamp or pilot bulb before checking flasher The signals are not self cancelling the lever must be moved to the center OFF position after the indicated turn is negotiated 10 49 Section 10 Electrical System a How to Operate the Emergency Flashers To operate
164. 6 Pull the rod 12 and attached parts straight out of the tube IMPORTANT When sliding the rod and piston assembly out of the tube be careful so that gland threads in the cylinder tube do not damage the piston 9 Keep the rod in line with the tube barrel to prevent binding 7 Remove the piston seal 8 from the piston 8 Fasten the eye end of the rod in a soft jawed vise and put a padded support below and near the other the end of the rod to prevent damage to the rod NOTE It may be necessary to apply heat to break the bond of the sealant between nut 3 and rod 12 before the piston can be removed Refer to paragraph 9 2a 9 Remove the nut 3 piston 9 and gland 4 from the rod 10 Remove the O ring 7 from inside of the piston 11 Remove the O ring 6 backup ring 5 wiper 11 and rod seal 10 from the gland 4 c Cleaning 1 Discard all seals and backup rings Replace with a complete new seal kit 2 Clean all metal parts in an approved cleaning solvent such as trichlorethylene Be sure to carefully clean all cavities and grooves 9 30 d Inspection Repair and Replacement 1 Check that the rod 12 Fig 9 13 is straight If the rod is bent install new rod 2 Inspect inside of the tube 2 for scoring and other damage If there is any damage to tube replace it with new tube 3 Remove small scratches on the rod or inside the tube with emery cloth of very fine grit Use the eme
165. 9 2 5 Frame Tilt Cylinder a Removal 1 Level the frame Place blocking between frame and axle to maintain machine stability when frame tilt cylinder is removed 2 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 3 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 4 Remove the snap rings locking the rod end pin in the axle mounting block Tap the pin from the mounting block 5 Start the engine and fully retract the frame tilt cylinder Then shut engine OFF Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 6 Disconnect the hydraulic lines from cylinder and cap or plug open connections 7 Remove the pin shims capscrew and locknut securing the frame tilt cylinder tube to the frame Fig 9 16 8 Remove the frame tilt cylinder from the forklift using a strap sling and hoist or other suitable equipment b Disassembly 1 Remove all dirt and grease from cylinder 2 Fasten the frame tilt cylinder in a soft jawed vise or other acceptable holding equipment Do not damage the tube 3 Remove both check valves 1 Fig 9 17 and related O rings 15 and backup rings 16 4
166. Be sure to carefully clean cavities and grooves 9 36 0100 gt O1 GON 9 37 Inspection Repair and Replacement Check that rod 13 Fig 9 17 is straight If the rod is bent install new rod Inspect inside of the tube 3 for scoring and other damage If the tube is damaged replace with new tube Remove small scratches on the rod or inside of the tube with emery cloth of very fine grit Use the emery cloth with a rotary motion Remove staking burrs from the nut 4 and the Check Valve 2 Plug 2 Cylinder Tube Nut Piston O ring Piston Seal Gland O ring Backup Ring Rod Seal Wiper Rod Grease Fitting 2 2 O ring 6 ba ae r N a Z Backup Ring 6 l Sy a N ea NS y 7 SE Pa Section 9 Hydraulic System bottom of the piston 5 with a fine file Clean parts with trichlorethylene after repair e Assembly NOTE Follow general assembly instructions in paragraph 9 2c 1 If removed install the plugs 2 and grease fittings 14 Install new O ring 9 Fig 9 17 backup ring 10 wiper 12 and rod seal 11 on gland 8 as shown in Fig 9 17 Lo 14 MA0581 Fig 9 17 Frame Tilt Cylinder Exploded View Model 6036 S N 9B0499 and Before Section 9 Hydraulic System NOTE The wiper lip should be toward the outer end of the gland and seal lips toward the inner end of the gland Use tools that will not damage the seals If the back
167. Boom 3 1 3 Outer Boom Replacement a Removal 1 Refer to paragraphs 3 1 1 a and 3 1 2 a and remove the inner and intermediate booms 2 Disconnect and remove the extend and retract chains from the outer boom Check the condition of the chains and replace if worn or damaged 3 Referto paragraph 9 2 2 a and remove the boom extend retract cylinder 4 Refer to Fig 3 7 and remove the locknut and capscrew that secures the slave cylinder rod end pin Remove the pin Check the condition of the bearing in the cylinder rod end replace bearing if worn or damaged 5 Refer to Fig 3 8 and disconnect the grille tilt cylinder hoses from the tubing at the hose guides and remove the hoses from the boom Model 6036 S N 9B0499 and Before HOIST CYLINDER ROD END PIN BOOM PIVOT EXTEND RETRACT CYLINDER BASE SLAVE CYLINDER END PIN ROD END PIN MA0071 Fig 3 7 Outer Boom Pivot Pins 3 5 Section 3 Boom HOSES 6 WILLLIL LLL ELLE LLL L LLL LLL LEE LEE LIAL DILL ELE AD LZOL LE LE LLL ALLL LLL OUTER BOOM Z INTERMEDIATE BOOM LEEZLLLLLLZL LL LL LLL ELD ELIE LL DEED OD ELE ELD ELE LELE LEZ zezezeezz INNER BOOM bee ZZZZZZZZZZZZZZIT 72 CZZZZZZZZZZIZIZIZZI ZZZIZZZ7 HOSE GUIDE GRILLE TILT CYLINDER CLAMP CONNECTION TUBING TO MAIN CONTROL VALVE SUPPORT PLATE MA0081 Fig 3 8 Grille Tilt Cylinder Hoses Disconnect and ca
168. Breathing asbestos dust may be hazardous to your health and may cause serious respiratory or other bodily harm Follow O S H A standards for proper protective devices when you work with asbestos materials Before you use silicone rubber sealant RTV and lubricating grease and oils become familiar with and follow all safety recommen dations provided product manufacturer and supplier When working with these products follow industrial hygiene practices before eating thoroughly wash hands and face Do not eat drink or smoke in areas where there is potential for significant exposure to these materials When discarding materials observe all local state and federal laws and regulations for approved disposal procedures Wear industrial strength safety goggles or glasses whenever you work on the forklift or forklift components It is impossible to know evaluate and advise the service trade of all conceivable ways in which service might be done or of the pos sible hazardous consequences of each way Accordingly whenever you use a service procedure or tool which is not recommended you must first satisfy yourself thoroughly that neither personal or vehicle safety will be jeopardized by the service method you select Model 6036 6036T S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle IMPORTANT e When replacing a fastener replace it with one of equal or higher grade and quality Torque fasteners are recom
169. CH T 371 TRANSMISSION MOUNTED STARTER S ENGINE HARNESS ne oer RELAY 38 ee AEE EEA TRANSMISSION i ENGINE TEMP SWITCH I I l 18 I l I I LOW OIL 19 PRESSURE STARTER SENDER I l 5 I I I I 16 l 4 FUEL RUN 40 SOLENOID EMERGENCY 28 PUMP OIL ALTERNATOR 28 34 PRESSURE SWITCH PEPE S os Z Z Hs5 WATER TEMP SENDER 31 BACKUP ALARM 8 20 Fig 8 26 Engine Harness Connections MA0381 Model 6036 S N 9B0499 and Before b Remove the U bolt assembly or bearing straps Fig 6 1 attaching the drive shaft cross assembly to the drop box input shaft yoke Slide slip joint towards transmission so cross slips out of drop box input shaft yoke NOTE Wrap tape around bearings and cross so bearings don t drop off cross c Remove the cap and bolt assembly or bearing straps securing the drive shaft cross assembly to the transmission output shaft yoke NOTE Wrap tape around bearings and cross so bearings don t drop off cross d Remove drive shaft assembly from forklift 18 Detach and remove the hydraulic lines from the main pump IMPORTANT Be sure main suction line is raised above level in reservoir 19 Detach and remove the transmission cooler lines at the transmission 20 Remove the engine and transmission from the forklift frame as follows a Attach a suitable engine hoist to the lift plates Fig 8 25 on the top of the engine b Remove both transmission mounts from the transmission
170. CROSS RING B ASSEMBLY SEAL NI S GREASE Ge FITTING S BEARING gearing Y oe RETAINING RING U r OR TRANSMISSION TO BEARING MA 0302 DROP BOX DRIVE STRAP SHAFT DROP BOX TRANSMISSION OUTPUT INPUT SHAFT SHAFT YOKE YOKE SLIP JOINT DROP BOX TRANSMISSION AXLE DRIVE SHAFTS AXLE INPUT SHAFT YOKE FRONT AXLE PARK REAR AXLE ASSEMBLY LOCK ASSEMBLY 6 2 Fig 6 1 Drive Shafts and Drop Box MA 0301 Model 6036 S N 9B0499 and Before c Cleaning and Drying 1 Disassemble and clean all parts using an approved cleaning fluid 2 Remove any burrs or rough spots from any machined surfaces d Inspection and Replacement 1 Individually inspect each cross bearing caps and needle bearings for signs of wear or missing parts NOTE If all parts of the cross assemblies check to be in good condition pack the bearing caps with a good grade of MP grease Reassemble equal numbers of needle bearings into each cap and reassemble the cross assembly into the drive shaft yokes 2 Replace the cross assembly as a complete assembly if any parts are worn or missing Replace the felt seal if worn or damaged Replace the sleeve or shaft assemblies if they are severely dented or damaged 5 Cross assemblies should flex and be free from excessive bind A slight drag is desirable ona new cross assembly Excessive looseness causes unbalance e Assembly 1 Install dust cap Fig 6 1 split retaining ring and felt seal on
171. Check that all fasteners are tight Run the engine and check for fuel coolant and lubricating oil leakage If necessary have the idle speed adjusted as recommended in paragraph 8 4 7 f 8 7 Section 8 Engine Do not use a lubricating oil to the MIL L 2104C inati specification in naturally aspirated engines for the SIar Eabricaung ous first 500 to 1 000 miles 25 to 50 hours of opera Lubricating oils for naturally aspirated engines tion should meet the requirements of U S Ordnance Specification MIL L 46152 or MIL L 2104C Lubricating oils for use in Perkins Diesel Engines should have a minimum viscosity index of 80 Lubricating oils for turbocharged engines should Some of these oils are listed below Any other oils meet U S Ordinance Specification MIL L 2104C which meet these specifications are also suitable MIL L 46152 Oils S A E Designation Company Brand 0 F 18 C 30 F 1 C to to Over 30 F 1 C 80 F 27 C 80 F 27 C Castrol Ltd Castrol Deusol CRX 10W 20 30 Castrol Deusol CRX 10W 30 10W 30 10W 30 Castrol Deusol CRX 20W 50 20W 50 Deusol RX Super 20W 40 20W 40 Esso Petroleum Co Ltd Essolube XD 3 10W 20W 30 Essolube XD 3 15W 40 10W 30 Mobil Oil Co Ltd Delvac 1200 Series 1210 1220 1230 Delvac Special 10W 30 10W 30 10W 30 Shell Rimula X 10W 20W 20 30 Rimula X 10W 30 10W 30 10W 30 Rimula X 15W 40 15W 40 Rimula X 20W 40 20W 40 Rotella TX 10W 20W 20 30 Rotella TX 20W 40 20W 40
172. D TERMINAL PE BATTERIES tO O O caer MA1092 Fig 10 26 Charging Circuit Showing Internal Circuits of a Typical 12 SI Alternator As alternator speed increases current is provided for charging the battery and operating electrical accessories Also with the alternator operating the same voltage appears at the BAT and No 1 terminals and the indicator lamp goes out to indicate the alternator is producing voltage If an open should occur in the TERMINAL NO 2 circuit TR3 and TR1 will turn off no field current will flow to prevent overcharge and indicator lamp current will flow to a ground through R6 to indicate a defect Also an open in the field circuit will cause the indicator lamp to turn on through R6 As the alternator speed and voltage increase the voltage between R2 and R3 increases to the point where zener diode D1 conducts current Transis tor TR2 then turns on and TR3 and TR1 turn off With TR1 off the field current and system voltage decrease and D1 then blocks current flow causing TR3 and TR1 to turn back on The field current and system voltage increase and this cycle then repeats many times per second to limit the alternator voltage to a preset value 10 22 Capacitor C1 smooths out the voltage across R3 resistor R4 prevents excessive current through TR1 at high temperatures and diode D2 prevents high induced voltages in the field windings w
173. Discard motor if it fails to run e Assembly 1 If the pump and motor assembly was disas sembled place the end head assembly 2 Fig 10 69 and pump 3 in position on the motor 1 and secure with two screws 2 Refer to the orientation marks made in para graph b position the solenoid 4 on the housing of the motor 1 and install two 1 4 20 by 1 4 Torx head screws 3 Connect black electric terminal cable 7 by installing nuts at the solenoid 4 and at the housing of the motor 1 Torque this top nut on the ground terminal on the housing of the motor to 35 Ib in 3 9 N m maximum f Installation 1 Lower pump and motor assembly into position and secure to machine frame by installing two 3 8 16 UNC hex head capscrews 2 Connect the supply and pressure hydraulic hoses to appropriate ports in the end head assembly 2 Fig 10 69 10 64 3 Reconnect wiring to solenoid and motor 4 Position the appropriate yellow ground wire on the end head assembly 2 and secure with screw 5 Position the appropriate yellow ground wire on the solenoid 4 and secure with nut 6 Position the red electrical cable on the sole noid 4 and secure with nut 7 Connect negative cable 2 Fig 10 38 to the batteries 10 14 TROUBLESHOOTING CONTENTS Title Page WARNING DEVICES 10 65 Horn Backup Alarm Reverse Switch and Warning Lights 10 65 CIRCUIT BREAKERS 10 66 STARTING SYSTEM 10 67 Starter Starting
174. ERAL CONSIDERATIONS 1 3 1 6 OPERATIONAL CONSIDERATIONS 1 3 1 7 FINAL WORD 1 4 1 1 INTRODUCTION Practically all SERVICE work involves the need to drive the forklift The Owners Operators Manual supplied with each forklift contains detailed safety practices relating to driving and operating These practices apply to the service technician and should be read understood and practiced Prior to performing any service on the forklift consideration should be given to factors that may have an effect upon safety not only on the me chanic but also the bystanders 1 2 SIGNAL WORDS A This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The symbol is used in conjunction with the following signal words to attract your attention to safety messages found throughout this manual The message that follows the symbol contains impor tant information about SAFETY To avoid injury and possible death carefully read and thoroughly understand each message Model 6036 S N 9B0499 and Before The signal word DANGER signifies that an imminently hazardous situation to a person on or near the forklift exists This danger to persons is such that it will result in a high likelihood of death or permanent injury if the recommended precautions or practices are not taken The signal word WARNING signifies that a potentially hazardous situation to a person on or near the forklift exists which could result in
175. EY 1 4 TO 3 8 eS 6TO9 mm ye BELT DEFLECTION CRANKSHAFT PULLEY _ OA0362 Fig 8 2 Fan Belt Deflection 4 Check fan belt tension midway between the crankshaft and alternator pulleys Fig 8 2 Deflection should be 1 4 to 3 8 6 to 9 mm with an applied force of 13 to 15 Ibs 6 to 7 kg 5 If belt deflection exceeds the tolerance loosen both alternator mounting screws Carefully pry the alternator to tighten the belt and at the same time tighten the alternator screws Recheck belt deflection 6 Close and lock the left rear engine access door 8 1 3 Daily or 10 Hour Intervals Air Cleaner 1 Lower carriage to ground shut off engine and engage park lock Model 6036 S N 9B0499 and Before RESTRICTION INDICATOR INDICATOR WINDOW my OA0202 Fig 8 3 Air Cleaner Restriction Indicator 2 Unlock and open left rear engine access door Check air cleaner restriction indicator Fig 8 3 If red band has appeared the primary element must be cleaned or replaced steps 4 thru 8 NOTE Momentarily press reset button on top of indicator after you service element AIR CLEANER VACUATOR AUTOMATIC DUST EJECTOR OA0212 Fig 8 4 Vacuator Valve 3 Unlock and open the right rear engine access door Remove dust and dirt from the vacuator valve Fig 8 4 Lips of automatic dust ejector must close but not adhere together PRIMARY ELEMENT WING NUT COVER W
176. Fuel Pre Filter 4 Nut 2 Plug 5 Ferrule 3 Washer 6 Drain Cock Fig 8 19 Fuel Pre Filter 8 4 4 Fuel Pre Filter Drain water from fuel pre filter Fig 8 8 and 8 19 every 250 hours of operation 1 Unlock and open the right rear engine access door 2 Loosen drain cock 6 Fig 8 19 on underside of fuel pre filter and drain all water from bowl Tighten drain cock after draining Close and lock access door Model 6036 S N 9B0499 and Before a Removal 1 Remove fuel pre filter inlet and outlet tubes 11 Fig 8 18 2 Support filter with one hand and remove lock nuts 15 and capscrews 14 and remove fuel pre filter from mounting bar 3 Remove locknut 15 capscrew 12 lock washer 13 and mounting bar 16 b Disassembly Loosen the hex head screw in the top of the filter and separate the filter base from the filter head c Cleaning and Drying Clean the pre filter using an approved solvent and dry with a clean lint free cloth d Assembly Assemble filter base to filter head using hex head screw e Installation 1 Install mounting bar 16 Fig 8 8 using cap screw 12 lock washer 13 and lock nut 15 2 Hold filter in position and install capscrews 14 and lock nuts 15 to secure filter to mounting bar PRIMING LEVER OA0332 Fig 8 20 Fuel Lift Pump 8 4 5 Fuel Lift Pump Clean fuel lift pump sediment chamber Fig 8 10 and 8 20 every 500 hours of operation 1 Unlo
177. Grille Tilt Reliefs 2650 50 psi 182 6 3 4 bar Frame Tilt Reliefs 1200 50 psi 82 7 3 4 bar Sequence Valve Setting 575 25 psi 39 6 1 7 bar Pressure Reducing Valve Setting 525 25 psi 36 2 1 7 bar Model 6036 S N 9B0499 and Before 9 78 Section 9 Hydraulic System 9 6 SPECIFICATIONS cont HYDRAULIC SYSTEM CONT Performance Boom Extend Horizontal No Load 12 to 15 seconds Boom Retract Horizontal No Load 10 to 13 seconds Boom Raise No Load 11 to 13 seconds Boom Lower No Load 8 to 10 seconds Grille Tilt Up No Load 4 to 6 seconds Grille Tilt Down No Load 3 5 to 5 5 seconds Frame Tilt Full Left to Full Right No Load 8 to 12 seconds Frame Tilt Full Right to Full Left No Load 7 to 11 seconds Steering Wheel Turns Lock to Lock 4 0 to 4 5 turns 9 79 Model 6036 S N 9B0499 and Before This Page Left Blank Intentionally Par 10 1 10 1 1 10 1 2 10 2 10 2 1 10 2 2 10 2 3 10 2 4 10 3 10 4 10 5 10 5 1 10 5 2 10 5 3 10 5 4 10 5 5 10 6 10 6 1 10 6 2 10 7 10 7 1 10 7 2 10 7 3 10 7 4 10 7 5 10 7 6 10 7 7 10 7 8 10 8 10 8 1 10 8 2 10 8 3 10 8 4 10 1 Section 10 Electrical System SECTION 10 ELECTRICAL SYSTEM CONTENTS Title Page Par Title SYSTEM COMPONENTS 10 2 10 8 5 Engine Low Oil Pressure Switch Service Warnings 10 8 6 Engine Coolant and Recommendations 10 2 High Temperature Sender Effective Ground Connections 10 3 10 8 7 Alternator Not Char
178. Hydraulic System ea MA0620 Fig 9 21 Optional Side Tilt Carriage Cylinder Exploded View Remove piston seal 13 from piston 3 NOTE It may be necessary to apply heat to break the bond of the sealant between nut 6 and rod 5 before the piston can be removed Refer to paragraph 9 2a 8 Remove nut 6 piston 3 and the gland 4 from the rod 9 Remove O ring 12 from inside of the piston 10 Remove O ring 10 backup ring 11 wiper 9 and rod seal 8 from the gland 11 If necessary to replace remove grease fittings 14 12 If bearing 7 needs replacement press bearing from the cylinder tube c Cleaning 1 Discard all seals and backup rings Replace with a complete new seal kit 9 43 Clean all metal parts in an approved cleaning solvent such as trichlorethylene Be sure to carefully clean all cavities and grooves Inspection Repair and Replacement Check that rod 5 Fig 9 21 is straight If the rod is bent install new rod Inspect the inside of tube 1 for scoring and other damage If there is any damage to the tube replace with new tube Remove small scratches on the piston rod or inside of the tube with emery cloth of very fine grit Use the emery cloth with a rotary motion Remove staking burrs from the nut 6 and the bottom of piston 3 with a fine file Clean parts with trichlorethylene after repair Model 6036 S N 9B0499 and Before Section 9 Hydraulic System e Asse
179. ISENGAGED ENGAGED I m T i aan GE TE 0 1000 psi l a PRESSURE l 3 pe l ne PARK GAUGE g I i LOCK i i ete I I i i i XN of N af TO POWER me STEERING PARK LOCK 1 lt 5 STEERING AND ae IN i ph RELEASE SERVICE EMERGENCY I1 Phi J BRAKE BRAKE PUMP le E F H VALVE BRAKES APPLIED BRAKES NOT APPLIED e a ie PRESSURE _ REDUCING ee eee TANDEM 0 4000 psi PRESSURE GAUGE RESERVOIR SERVICE BRAKE VALVE POSITIONS STRAINER To MA0472 Fig 9 6 Brake Circuits Model 6036 S N 9B0499 and Before 9 14 positioned so that hydraulic flow is blocked at port C Fig 9 6 no pressure is applied to the service brakes Return flow from the service brakes passes through ports B to D to the reservoir When the brake pedal in the operator s cab is depressed the brake valve spool is positioned so that flow is directed through ports C to A Fig 9 6 to the service brake pistons As pressure is ap plied the pistons press the brake discs together slowing or stopping the wheel The brake pedal will return to the up position when released Park Lock Release Valve When the park lock switch on the instrument panel is placed in the engaged up position the park lock release valve solenoid is de energized and the valve spool is spring positioned so that hydrau lic flow from the park lock piston is dir
180. ITH WING NUT j A OA0222 Fig 8 5 Air Cleaner Primary Element Model 6036 S N 9B0499 and Before Section 8 Engine 4 Remove the air cleaner cover wing nut cover and primary element Fig 8 5 A Warning Wear safety glasses when using compressed air to clean element 5 Clean the primary element with compressed air or by washing e f using compressed air direct no more than 100 psi 6 9 bar into the element Move the nozzle up and down while rotating the element e f washing soak the element for 15 minutes in a non foaming detergent and water solution Rinse until the water is clear Air dry DO NOT use compressed air to dry the element 6 Carefully inspect the primary element for tears and holes 7 Thoroughly clean inside the primary element cannister 8 Replace the primary element after six clean ings or annually WING NUT SAFETY ELEMENT OA0232 Fig 8 6 Air Cleaner Safety Element 9 After you replace three primary elements install a new safety element Fig 8 6 DO NOT clean the safety element IMPORTANT Make sure the primary element cannister is thoroughly cleaned before removing the safety element Dirt could enter the intake manifold and cause internal engine damage 10 Install the air cleaner cover and wing nut Be sure the wing nut is tight 11 Check all hose connections at this time 12 Close and lock access doors 8 3 Section 8 Engine Engine Coolant
181. Motor Relay and Thermo Start Plug 10 68 CHARGING SYSTEM 10 69 Alternator and Batteries 10 69 SWITCHES AND SOLENOIDS 10 71 Ignition and Neutral Start Switches 10 71 Fuel Run Solenoid 10 72 Park Lock Switch and Release Valve Solenoid 10 72 Reverse Switch and Backup Alarm 10 73 Steering Select Switch and Solenoid 10 73 GAUGES AND INDICATOR LIGHTS 10 73 Hourmeter 10 73 Warning Lights 10 74 Engine and Steering Low Oil Pressure Switches 10 74 Engine Coolant High Temperature Switch 10 75 Alternator Warning Light 10 75 Transmission High Oil Temperature Switch 10 75 Fuel Level Gauge 10 76 OPTIONAL LIGHT CIRCUIT 10 76 Directional and Emergency Flasher Switch 10 76 Momentary Brake Light and Switch 10 77 Headlight and Rear Work Light Switch 10 77 WINDSHIELD WASHER WIPER 10 78 AIR CIRCULATION FAN 10 81 CAB HEATER 10 81 BRAKING AND STEERING PUMP 10 82 Model 6036 S N 9B0499 and Before Section 10 Electrical System Trouble Probable Cause Remedy Reference Warning Devices HORN Horn doesn t No voltage at horn 7 Fig Replace wiring and circuit See para sound when horn 10 5 broken wire or circuit breaker as required button is pressed breaker 11 doesn t reset Corroded electrical ground Repair electrical ground See para at horn mounting 3 Loose or broken wiring Repair or replace wiring See para 4 Defective horn switch 49 Test horn switch for continuity See para Fig 10 5 with horn button pressed replac
182. ND WASHER CABLE MOUNTING STRAP CONTROL CABLE ANGLE BRACKET N LOCKNUT AND CAPSCREW CLAMP MA0141 Fig 4 3 Shifter Assembly 4 2 1 Steering Wheel and Steering Unit The steering wheel changes the direction of forklift travel in two wheel four wheel or crab steering modes as designated by the steering select switch Refer to your Owners Operators Manual for a description of these steering modes The wheel is attached to the steering unit with a nut that must be torqued to 50 lb ft 68 N m The steering unit is attached to the control console with four flange head screws and lock washers 4 2 2 Travel Select and Range Select Levers Use the travel select lever to place transmission in Forward F Neutral N and Reverse R and the range select lever to select Low 1 Medium 2 and High 3 gears The levers are mounted in a transmission shifter assembly Fig 4 3 A cable attached to each lever 4 2 terminates at a linkage which moves a spool in the transmission control valve a Transmission Shifter Removal 1 Remove lower panel Fig 4 2 below the control console 2 Remove the clamps that secure the control cables to the angle brackets 3 Remove the cotter pins and washers that attach the swivels to the bellcranks Label and remove the cables from the shifter assembly Fig 4 3 Remove the swivel from the end of each cable by turning it counterclockwise 4 Disconnect the reverse switch red and black lead wir
183. NT This procedure is to be used in emergency situations only By turning the counter balance cartridge adjusting screws to make the valve inoperative the pressure settings of the cartridge have been altered DO NOT attempt to reset these cartridges Remove and replace all three cartridges with new parts Failure to replace these cartridges with new parts will result in erratic extreme bouncing lowering action which may cause damage to other components 3 2 2 Hydraulic Line Failure Warning In the event of a hydraulic line failure in any of the boom control circuits extreme CAUTION must be taken when attempting to lower an elevated load Hydraulic oil under high pressure will escape through the fault in the line which may result in the boom retracting or lowering at a rapid rate DO NOT perform this procedure unless you are absolutely sure of what you are doing Consult your local JLG Distributor or the JLG Service Department before proceeding 3 14 IMPORTANT If the boom has been extended you must first retract the boom before you attempt to lower the boom 1 Block the boom so it cannot be lowered 2 If the line failure is isolated to the hoist circuitry only boom retraction can be performed by operating the boom control lever in the normal fashion 3 If the line failure is in the boom extend line the boom must be retracted by following the next step a At the base of the extend retract cylinder loc
184. ONTENTS Title BOOM ASSEMBLY Inner Boom Replacement Intermediate Boom Replacement Outer Boom Replacement Chain Replacement Chain Lubrication Chain Tension Check Chain Tension Adjustment Wear Pad Replacement Hose Tensioning Long Term Storage Preparation Boom Lubrication Points EMERGENCY BOOMLOWERING Loss of Engine Power or Hydraulic Pump Failure Hydraulic Line Failure QUICK ATTACH ASSEMBLY TROUBLESHOOTING SPECIFICATIONS EXTEND CHAIN Model 6036 S N 9B0499 and Before Section 3 Boom SECTION 3 BOOM Page 3 1 BOOM ASSEMBLY 3 1 The boom assembly Fig 3 1 consists of inner intermediate and outer booms The intermediate 3 3 boom slides in the outer boom and the inner boom 35 slides in the intermediate boom As the boom 3 9 extend retract cylinder extends or retracts the 3 10 intermediate boom a pair of extend chains and one 3 10 retract chain moves the inner boom in the same 3 11 direction 3 11 e IMPORTANT The inner intermediate and outer 3 13 boom replacement instructions in paragraphs 3 1 1 3 13 through 3 1 3 must be completed in sequence Replacement of two or more booms as a unit 3 13 requires special considerations that are not covered in these instructions 3 13 3 14 3 1 1 Inner Boom Replacement nas a Removal d 1 Park forklift on level surface engage park lock 3 17 and retract boom INTERMEDIATE BOOM BOOM EXTEND RETRACT CYLINDER OUTER BOOM RETRACT CHAIN REAR BOOM COVER
185. OSE CONNECTIONS ZzraAc rommMIv0OD gt To Brake Valve Return To Park Lock To Rear Brake Cylinder To Rear Brake Cylinder To Steering Unit To Front Steering Cylinder To Control Valve To Steering Unit Outlet To Steering Unit Inlet To Brake Valve Inlet To Reservoir To Small Pump Inlet To Emergency Pump Outlet Fig 9 33 Valve Plate Assembly Underside View Exploded S N 8G0236 and After Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 9 3 4 Steer Select Valve a Removal 1 Engage the park lock place the travel selector lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Slowly loosen fittings at steer select valve as required 1 Fig 9 33 to relieve any trapped pressure 3 Remove the electrical connectors 1A from the solenoids 1B on steer select valve 1 A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 4 Tocheck a solenoid apply 12 Vdc momentar ily to the solenoid leads and listen for an audible click that indicates spool movement If there is no sound the solenoid is probably defective Refer to Section 10 for additional electrical test of the steer select valve NOTE If no service is required for valve subplate 31 Fig 9 33
186. Remove the transmission cover from the forklift 2 Remove the U bolt assembly or bearing straps Fig 6 1 attaching the drive shaft cross assembly to the drop box input shaft yoke Slide slip joint towards transmission so cross slips out of drop box input shaft yoke NOTE Wrap tape around bearings and cross so bearings do not drop off cross 3 Remove the cap and bolt assembly or bearing straps securing the drive shaft cross assembly to the transmission output shaft yoke NOTE Wrap tape around bearings and cross so bearings do not drop off cross 4 Remove the drive shaft assembly from the forklift Drive Shafts Drop Gear Box to Axle 1 Provide a suitable support under the shaft 2 Remove the U bolt assemblies Fig 6 1 attaching the drive shaft cross assembly to the drop box output shaft yoke Slide slip joint towards transmission so bearing cross slips out of the drop box output shaft yoke NOTE Wrap tape around bearings and cross so bearings do not drop off cross Model 6036 S N 9B0499 and Before 3 Remove the U bolt assemblies securing the drive shaft cross assembly to the axle input shaft yoke NOTE Wrap tape around bearings and cross so bearings do not drop off cross 4 Remove the axle drive shaft assembly from the forklift b Disassembly 1 Using an approved nonflammable cleaning fluid clean the drive shaft assembly Fig 6 1 with a brush Wipe dry before disassembling 2 Place the d
187. Sequence of Parts for Electrical Grounding of a Component at a Mechanical Support 10 1 2 Effective Ground Connections Effective ground connections are essential to the efficient operation of electrical components The sequence for installing attaching parts at electrical grounds is shown in Figs 10 1 and 10 2 Refer to special grounding instructions for the optional windshield washer reservoir and cab heater a 10 8 __ A Mounting plate is welded to and supported by forklift frame B Air cleaner mounting band C Air cleaner assembly Cie Gs Hex nut Lock washer Tooth type lock washer Hex head bolt Hex head bolt Section 10 Electrical System 10 2 WARNING DEVICES Warning devices are a horn and a backup alarm Warning lights indicate when engine coolant reaches 210 F 99 C when engine oil pressure falls below 4 psi 0 3 bar when the alternator isn t producing voltage and when hydraulic oil exceeds 250 5 F 121 3 C Please refer to paragraph 10 8 4 10 2 1 Horn Press the momentary contact horn button 2 Fig 10 39 on the control console to sound the horn 7 Fig 10 5 which is located near the gear drop box The sound is produced by a solenoid actuated diaphragm in the horn that develops a resonating air column in the horn projector If the horn doesn t sound when you press the horn button check for an open circuit breaker corro sion on the horn mounting or a loose wire
188. Starter relay 36 Fig 10 5 is not energized due to broken wiring or a defective circuit breaker 10 Starter relay 36 Fig 10 5 is frozen in the closed position Replace wiring or circuit breaker Temporarily disconnect wiring to starter relay and replace starter relay Model 6036 S N 9B0499 and Before Reference See para See para See para See para See para See para See para See para Trouble Probable Cause Section 10 Electrical System Remedy Reference Starting System THERMO START PLUG FOR COLD WEATHER STARTING Intake manifold 1 Discharged batteries remains cold after ignition key switch is momentarily turned to THERMO START position Broken wiring or circuit breaker 10 Fig 10 5 3 Loose connections 4 Clogged or bent fuel line to Thermo Start plug 5 Defective plug 6 Broken ignition switch Intake manifold Thermo Start plug is ON remains continuously due to broken abnormally hot ignition switch or a short during normal circuit in the wiring engine operation Charge batteries only if electrolyte is not frozen if frozen remove batteries from forklift completely thaw and then charge Replace wiring or circuit breaker Tighten connections Clean or replace fuel line Replace Thermo Start plug Remove and test ignition switch in all positions replace if defective Remove and test ignition switch in all positio
189. able to the batteries 4 Test fan operation 10 12 CAB HEATER ENCLOSED CAB ONLY 10 12 1 Cab Heater Switch Enclosed Cab Only The cab heater fan is only operable when the ignition switch is in the RUN position The heater fan switch 11 Fig 10 67 is located on the left side of the seat base NOTE During summer operation close the heater line shut off valve 13 at the left corner of the engine just above the alternator a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Remove two capscrews 1 Fig 10 67 and lock washers 2 and tooth type grounding washers 3 3 Remove two capscrews 4 lock washers 5 and spacers 6 4 Slide heater and fan unit 7 forward to provide access to the cab heater switch 11 Tag and disconnect wiring from switch Remove hex nut with cap 8 knurled nut 9 decal 10 and heater switch 11 from suspension support 12 b Inspection and Replacement 1 Test the mechanical operation of the switch toggle switch positions are HI LOW and OFF 2 Test switch for continuity in the HI and LO positions and for a short in the OFF position 3 Replace switch if it fails to pass the tests in steps 1 and 2 c Installation 1 If negative cable 2 Fig 10 38 had been reconnected to the batteries disconnect this cable 2 Position heater fan switch 11 Fig 10 67 in suspension support 12 and adjust knurled Model
190. acket over two studs and secure using two washers lock washers and hex nuts 2 Position the terminal marked BAT on the circuit breaker terminal plate to your right and snap each circuit breaker into bracket using a small slot screwdriver 3 Secure tagged wiring to respective terminals using lock washers and hex nuts 4 Connect battery ground cable to the battery Check operation of circuits Model 6036 S N 9B0499 and Before Section 10 Electrical System 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 When starting in a cold environment 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 7 flows through the positive battery cable 2 to the starter solenoid 3 2 It then flows to circuit breaker 4 and to terminal 1 of the ignition switch 5 3 When the key 6 is turned to the START position current flows through contacts in the ignition switch to the park lock brake switch 7
191. als 1 Replace fuel filter element 2 Clean sediment chamber of fuel lift pump 3 Clean or replace element of dry type air cleaner if not indicated earlier Model 6036 S N 9B0499 and Before 8 1 7 2 500 Hour Intervals 1 Inspect and service proprietary equipment such as starter motor alternator turbocharger if applicable etc Service atomizers fuel injectors para 8 4 9 3 Check and adjust valve tip clearances para 8 10 8 1 8 Annually Engine Coolant Change A Warning e To avoid severe burns DO NOT attempt this procedure when engine is hot Wait for engine muffler and tail pipe to cool before proceeding To prevent personal injury never remove the radiator cap while the cooling system is hot The system is under pressure and coolant can cause severe burns and eye injury Wear safety glasses Always turn the cap slowly to the first stop and allow the pressure to escape before removing cap completely 1 With forklift on level ground unlock and open the left rear engine access door 2 Remove radiator cap PETCOCK MUFFLER OA0252 Fig 8 15 Radiator Petcock 3 Attach a hose to petcock at bottom left corner of radiator Fig 8 15 to allow draining directly into a container Open petcock and drain the coolant from the radiator NOTE If engine is turbocharged drain oil cooler in lubricating oil filter by removing inlet or outlet connections flush cooler and reconnect hose 4
192. an and tight brush wear and the commutator After the starter motor has been in service for some time remove the starter motor from the engine and submit it to a thorough bench inspec tion by qualified personnel 1 14 Starting Motor Relay 15 Capscrew Brush wear is a fair indication of the amount of work done by the starter Replace brushes when length approaches 5 16 7 9 mm Brush spring tension Correct tension is 30 to 40 oz 0 85 to 1 13 kg Replace springs if tension has dropped below 25 oz 0 71 kg Turn commutator if it is pitted or badly worn Check bearings for excessive side play of armature shaft Check pinion movement Clean and lubricate the indented bearing inside the pinion sleeve using Shell SB2628 grease for temperate and cold climates and Shell Retinex for hot climates Clean and lubricate the indented bronze bearing in the intermediate bracket Use Ragosine Molypad Molybdenised non creep oil for this purpose Installation Position the starter on the flywheel housing install three lock washers 9 Fig 10 15 and three nuts 8 and torque the nuts to 3 4 Ib ft 4 6N m Connect the wires 3 through 6 to the starter solenoid 7 Connect the positive battery cable 2 to the starter 15 17 16 MA1051 16 Lock Washer 17 Relay Mounting Plate Fig 10 22 Starting Motor Relay 10 18 Model 6036 S N 9B0499 and Before 4 Connect the positive cable 2 to
193. an suction screen Replace pump Remove disassemble and re build converter assembly Replace pump Fill to proper level Replace pump Disassemble converter to deter mine what bearing is faulty Tune engine and check governor Remove disassemble and re build converter assembly Replace pump Fill to proper level Model 6036 S N 9B0499 and Before 7 10 SPECIFICATIONS System Capacity inc filter and oil cooler Filter Capacity Tractor Fluid Converter Outlet oil temperature Outlet pressure Controls Clutch Type Oil Filtration Clutch Pressure Model 6036 S N 9B0499 and Before Section 7 Transmission 4 3 gallons 16 3 liter 1 quart 0 95 liter John Deere J20 A Detroit Diesel C 3 C 2 Ford Tractor M2C134B White Farm UTHF Q1766 Q1722 180 to 200 F 82 to 93 C Transmission in Neutral 25 psi 1 72 bar minimum pressure at 2000 rpm engine speed 70 psi 4 82 bar outlet pressure with engine operating at no load governed speed Forward and Reverse is Manual Speed Selection is Manual Multiple discs hydraulically actuated spring released automatic wear compensated and nonadjustable Oil cooled and lubricated Inner Disc Friction Outer Disc Steel Full flow oil filter safety bypass Strainer screen in sump at bottom of transmission case 180 to 220 psi 12 40 to 15 16 bar with e park lock set Never use service brakes e oil temperature at 80 to 200 F 82 93 C e
194. and Starter Solenoid 1 The positive lead of the voltmeter stays connected to positive battery cable Fig 10 10 2 Connect the negative lead of the voltmeter to the starter motor terminal on the starter solenoid 3 Push in and hold the starter button and select the lowest range for the voltmeter Read the voltmeter Model 6036 S N 9B0499 and Before 4 Select the voltmeter range that will measure 12 V and release the starter button 5 If the voltage indication was a 0 5 Vdc or less complete Test 5 b More than 0 5 V complete Test 3 and Test 4 BATTERY TERMINAL MA0941 Fig 10 11 Measuring Voltage Loss in Positive Battery Cable d Test 3 Voltage Loss in Positive Battery Cable 1 Positive lead of voltmeter stays connected to the positive battery cable Fig 10 11 Select lowest voltage range for the voltmeter 3 Connect the negative lead of the voltmeter to the battery terminal of the starter solenoid 4 Pushin and hold the starter button and read the voltmeter 5 If the voltage indication was a More than 0 4 V replace the battery cable b 0 4 V or less complete Test 4 STARTER MOTOR TERMINAL BATTERY TERMINAL STARTER MA0951 Fig 10 12 Measuring Voltage Loss in Starter Solenoid Model 6036 S N 9B0499 and Before Section 10 Electrical System Test 4 Voltage Loss in Starter Solenoid Connect the positive lead of the voltmeter to the battery terminal on the sta
195. and frame c Remove the capscrew vibration mount rebound washer and locknut attaching the engine mount to the frame d Pull the engine and transmission out the rear of the forklift 21 With the engine and transmission adequately supported separate the engine from the transmission as follows a Remove one of the two access hole plastic plugs on the engine flywheel housing b Remove the eight torque converter drive plate screws and washers c Remove the eleven capscrews securing the converter housing to the flywheel housing d Using a suitable engine hoist separate the transmission from the engine Model 6036 S N 9B0499 and Before Section 8 Engine 8 7 ENGINE OVERHAUL Refer to the Perkins Engine Workshop Manual for the 4 236 Series engines 8 8 ENGINE INSTALLATION 1 Install two 2 5 64 mm guide studs in the engine housing as shown in Fig 8 27 FLYWHEEL HOUSING FLYWHEEL MA0391 Fig 8 27 Guide Studs 2 Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole 3 Install a 4 0 100 mm long locating stud 0 375 24 fine thread in a drive plate nut as shown in Fig 8 28 4 Rotate the drive plate to align the locating stud with the flywheel drive plate mounting screw hole positioned in step 2 5 Position the transmission on the flywheel housing with the guide and locating studs aligned 6 Install the nine capscrews se
196. and nut 11 Connect wiring to wiper motor o M9 N Position the brake valve 8 and install two capscrews 7 four lock washers 6 and two jam nuts 5 10 Install clevis pin 9 and cotter pin 10 10 57 Section 10 Electrical System 11 Connect spring 4 12 Position the right front console panel 3 and right console overlay 2 and install four flange head capscrews 1 13 Connect the negative cable 2 Fig 10 38 to the batteries WIRE MA1431 Fig 10 66 Air Circulation Fan Removal 10 11 FAN SWITCH AND FAN MOTOR OPTIONAL The circulation fan is only operable when the ignition switch is in the RUN position The fan switch is located at the base of the fan mount a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Disconnect wire Fig 10 66 from fan at terminals 3 Support the fan with one hand and remove four screws with the other hand b Disassembly Do not disassemble there are no serviceable parts in the fan c Cleaning and Drying Without submerging motor or bearings clean fan with a nonmetallic bristle brush using an approved solvent and dry with a clean cloth d Inspection and Replacement Test fan using a 12 Vdc source which supplies at least 4 A replace if defective 10 58 e Installation 1 Position the fan and install four screws Fig 10 66 2 Connect wire at terminal Connect negative c
197. andem pump which draws its fluid through a FRAME TILT PORT FRAME TILT RELIEF VALVES CYLINDER Section 9 Hydraulic System suction screen in the reservoir Fig 9 5 Pressure is directed to either side of the frame tilt cylinder piston by the shifting of a spool in a directional control valve found in the main control valve assembly The spool is shifted by the grille and frame tilt control lever and its associated control cable Control lever positions for tilting the grille are as follows Center Position When the grille and frame tilt control lever is placed in the center or neutral position the directional control valve spool is positioned so that pump supply pressure is directed through ports F to C Fig 9 5 to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar MAIN CONTROL VALVE DIRECTIONAL CONTROL VALVE POSITIONS PILOT OPERATED CHECK VALVE TO GRILLE TILT AND SLAVE CYLINDERS RIGHT ABC ABC ABC eRAHIE s TO BOOM EXTEND RETRACT CYLINDER TO BOOM HOIST CYLINDERS GAUGE MA0461 DEF DEF DEF CENTER RESERVOIR TANDEM PUMP 0 4000 psi Js PRESSURE STRAINER RETURN aN FILTER Fig 9 5 Frame
198. applied through ports F to B Fig 9 7 to the intake side of the power steering metering section A measured amount of hydraulic oil is ex hausted from the metering section and routed back to the control valve section where it is channeled through ports C to D to port J in the steer select valve The steer select valve solenoid is energized and shifts the valve spool Oil is channeled through ports J to H and to the retract side of the right rear steering cylinder and the extend side of the left rear steering cylinder Return oil from each of the rear steering cylinders passes through select steer valve ports G to to the retract side of the right front steering cylinder and the extend side of the left front steering cylinder Return oil from each of the front steering cylinders flows through ports A to E of the power steering control valve section to the return filter and reservoir Right Turn 2 Wheel Steer When a right turn is being made with the steering select switch in 2 wheel steer center position 1 The power steering control valve spool is shifted so that supply pressure is applied through ports F to C Fig 9 7 to the intake side of the power steering metering section A measured amount of hydraulic oil is ex hausted from the metering section and routed back to the control valve section where it is channeled through ports B to A 9 19 Section 9 Hydraulic System Supply oil is routed from port A
199. arbon pile battery tester 500 A minimum with ammeter a separate digital voltmeter that is calibrated frequently and an inductive clamp on ammeter Test areas are batteries starter motor replacement test starter circuitry and battery cable test sole noid circuit test magnetic switch control circuit test alternator wiring test and a alternator output test Water never has to be added to the batteries There are no filler caps Each battery is sealed except for small vent holes in the cover The vents allow what small amount of gasses that are pro duced in the battery to escape The special chemical composition inside the battery reduces gassing to a very small amount at normal charging 10 29 Section 10 Electrical System voltages Besides reducing gassing the special chemistry greatly reduces the possibility of over charge damage The vents require keeping the battery in an upright position to prevent electrolyte leakage Tipping the battery beyond a 45 angle in any direction can allow a small amount of electrolyte to leak out the vent hole DO NOT exceed this 45 angle when carrying or installing a battery Evidence of electrolyte leakage does not necessar ily mean a battery is defective The battery has top post terminals Securely tighten clean cable clamps to the posts Grease or special spray sealers may be applied over the connections b Visual Inspection of a Battery Inspect for damage such
200. area free from drafts Both heat and light are sources of oxidation on the tire surfaces a result of which is crazing and weather checking Never store tires on oily floors or otherwise in contact with solvents oil or grease Further tires should not be stored in the same area with volatile solvents Such solvents are readily absorbed by rubber and will damage and weaken it Store tires away from electric motors generators arc welders etc since these are active sources of ozone Ozone attacks rubber and causes crazing and weather checking 5 10 5 2 AXLE ASSEMBLY The axle assembly rotates and turns the wheels Both front and rear axles consist of a differential carrier assembly a left and right axle steering joint and a left and right wheel end Fig 5 6 The A Warning Do not attempt carrier and differential removal and installation and differential and pinion disassembly and assembly without thoroughly understanding instructions in Spicer Dana publications and correspondence which applies to your forklift Refer to paragraph 5 3 Wear safety glasses at all times when working on forklift and forklift components If it becomes necessary to disassemble any parts inside the carrier it is suggested that the entire axle be removed from the forklift and held tight in a stand or rack with carrier pinion positioned up When removing axle assembly make sure forklift is properly supported an improperly supported vehi
201. ars that causes excessive wiping action 5 1 19 Care and Storage of Tires Store unmounted tires vertically on tread If stored for an extended period rotate tires periodically to reduce stress concentrations in the area of ground contact Tires should not be stored flat and stove piped as they will become squashed and dis torted making mounting on the rim difficult particularly for tubeless tires Inflated tires should be stored under the conditions noted above with inflation pressure reduced to 10 psi 0 7 bar Tires should not be stored out of doors However it there is no alternative tires so stored must be protected from the elements An unbroken Opaque covering is required as protection from sun and rain Exposure to weather will cause crazing and cracking of the rubber surfaces as well as deterio ration of the tire carcass particularly where rain water is permitted to accumulate in the tires When extended storage is anticipated the forklift should be blocked up so the tires are out of ground contact Inflation pressure in the tires should then be reduced to 10 psi 0 7 bar Other precautions as noted above should be observed If it is not possible to block up the forklift inflation pressure in the tires should be increased 25 percent The forklift should be moved from time to time to change the location of stress concentra tions in the tire ground contact area Store tires indoors in a cool dark dry
202. as a cracked or broken case or cover that could permit loss of electrolyte If obvious physical damage is noted replace battery Handle the battery with care Determine cause of damage and correct as needed Z OS GREEN DOT DARK CLEAR P mP MO AN N UN 65 OR ABOVE BELOW 65 STATE OF CHARGE STATEOF oS CHARGE LOW LEVEL ELECTROLYTE MA1201 Fig 10 37 Typical Hydrometer Operation 10 30 c Built In Hydrometer A special temperature compensated hydrometer is built into the cover of each battery to show at a glance the battery s state of charge The hydrome ter has a green ball within a cage which is attached to a clear plastic rod refer to Fig 10 37 It is important when observing the hydrometer that the battery have a clean top to see the correct indication A flashlight may be required in some poorly lit areas IMPORTANT Always look straight down when viewing the hydrometer The green ball will float at a predetermined specific gravity of the electrolyte that represents about a 65 percent state of charge When the green ball floats it rises within the cage and positions itself under the rod Visually a green dot then shows in the center of the hydrometer refer to Fig 10 37 The built in hydrometer provides a guide for battery testing and charging In testing the GREEN DOT means the battery is charged enough for testing If the green dot is
203. ate the counterbalance valve cartridge Fig 3 18 Loosen the retainer nut and control the rate of retraction by turning the adjusting screw into the cartridge very slowly clockwise Hydraulic oil from inside the extend retract cylinder will escape through the fault in the line 4 If the line failure is in the boom retract line the boom must be retracted by following the next 3 steps a At the base of the extend retract cylinder locate the counterbalance valve cartridge Fig 3 19 Loosen the retainer nut and turn the adjusting screw in clockwise until it bottoms out Doing this will render the counterbalance valve inoperative b Clear the area around the machine of all personnel and return to the operators cab c Move the boom control lever to the left to retract the boom 5 Ifthe line failure was isolated to the extend retract circuit only the boom can now be lowered by operating the boom control lever in the normal fashion after the blocking is re moved After the boom has been retracted fully proceed as follows 1 Remove the blocking that is supporting the boom 2 Ifthe line failure is in the boom hoist line the boom must be lowered by following the next step a Using two people to perform this procedure will make boom lowering much easier At the base end of each hoist cylinder locate the counterbalance valve cartridges Fig 3 19 Loosen the retainer nut and control the rate of boom lowering b
204. ation GL 5 to the level of from the axle housing the plug hole The oil should be a 90W or multi grade 80W 90 with EP properties Model 6036 S N 9B0499 and Before 5 26 6 AXLE FILL AND LEVEL PLUG AXLE DRAIN PLUG Fig 5 18 Axle Fill and Drain Plugs OA0422 Change 1000 hour intervals Place a receptacle under the axle housing drain plug Fig 5 18 Clean area around the axle fill and level plug and drain plug and remove both plugs Allow the oil to drain completely Install the drain plug Fill the axle with gear oil meeting military specification MIL L2105C API classification GL 5 to the level of the level plug hole The oil should be a 90W or multi grade 80W 90 with EP properties Axle capacity is 18 quarts 17 liters Install the fill and level plug 5 3 3 Wheel End Brake Oil Magnetic Plug Check First 50 hours Level the forklift ground the carriage shut off the engine and engage the park lock Be sure that the arrow on the wheel end housing is pointing down Fig 5 19 2 Clean the area around the magnetic drain plug and remove the plug 3 Remove any metallic debris that may have collected on the end of the plug 4 Reinstall the plug WHEEL END VENT PLUG DRAIN PLUG OA0432 Fig 5 19 Wheel End Drain and Vent Plugs 5 27 Section 5 Wheel Assembly Tires and Axle Level Check 250 hour intervals Level the forklift ground the carriage shut off the engine and engage the pa
205. ation of steering and emergency brake pump para 9 1 6 9 4 3 Steering and Emergency Brake Pump S N 7P0014 and After a Removal 1 Engage the park lock place the travel selector lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Slowly loosen the fittings on the steering and emergency brake pump as required to relieve any trapped pressure 3 Tag and disconnect yellow ground wire from the end head assembly 10 Fig 9 45 4 Tag and disconnect wire from switch terminal on solenoid 9 5 Disconnect red electrical cable from power terminal on solenoid A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 9 68 Section 9 Hydraulic System NOTE Normally the pump and motor assembly is replaced as a complete unit If the unit is under warranty do not disassemble further refer the unit to your JLG authorized dealer c Cleaning and Drying Without submerging the motor 13 Fig 9 45 in the cleaning solvent clean the pump and motor assembly in an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect the pump and motor assembly 2 Discard the complete pump and motor assem bly if the pump 10 Fig 9 45 end head assembly
206. attery 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 Caution Never drain or store fuel in an open container due to the possibility of fire discard the fuel in an approved manner 4 Prepare to drain remaining fuel by centering a receptacle which can hold the remaining fuel beneath the elbow 20 Fig 8 18 at the bottom of the tank Loosen hose clamp 5 at the bottom of the tank twist fuel supply hose 7 off elbow 20 and drain fuel into receptacle Discard the fuel in an approved manner 5 Loosen hose clamp 5 and twist the fuel return hose 6 off elbow 4 6 Disconnect wires 17 and 21 from fuel level sender 7 Lift and tilt the rear of the tank to remove it from the forklift Model 6036 S N 9B0499 and Before Section 8 Engine 10 To 7 vs N LIFT T a PUMP FROM a THERMO a LIET 20 START _ 5 eg wae TO FUEL S INJECTION PUMP FROM FUEL 123 INJECTION PUMP Or t Se AM Tl x we we E LE PA0424b 1 Fuel Tank 9 Tie Wrap 17 Fuel Pump Tube 2 Fuel Level Sender 10 Hose Support 18 Fuel Filter Tube 3 Filler Cap with Tether 11 Fuel Filter Tube 19 Rubber Bushing 4 Elbow 90 with standpipe 12 Capscrew hex head 20 Elbow 90 with standpipe 5 Hose Clamp 13 Lock Washer 21 Fuel Pre
207. b ft 306to374N m f d Secure the engine mount to the frame with acapscrew vibration mount rebound washer and locknut Torque to 225 to 275 lb ft 306t0374N m e Remove the engine hoist Attach the main pump to the transmission DRIVE PLATE ACCESS HOLE MOUNTING DT SCREW HOLE FLYWHEEL N HOUSING 2 1 2 GUIDE STUDS FLYWHEEL DRIVE PLATE sion with U bolt or bearing strap Torque U bolt 20 to 24 Ib ft 27 to 37 N m or bearing strap 55 to 60 Ib ft 75t082N m Install the transmission control cables as lows Place the transmission control valve spools Fig 4 4 in the center position Secure the control cables to the bracket being sure to have the clamp and cable grooves aligned Position swivel and lock nut on rod end as shown in Fig 4 4 Tighten the locknut Be sure the shifter levers are in the center or middle position Reposition the swivel and lock nut so it aligns with its hole in the swivel linkage control arm Secure the swivel to the control arm with cotter pin 4 LOCATING STUD CONVERTER HOUSING we MA0401 Fig 8 28 Locating Stud Model 6036 S N 9B0499 and Before 15 19 20 21 22 23 24 25 Attach the throttle control cable to the engine fuel injection pump as follows a Fasten the throttle cable to the throttle cable bracket with a clamp being sure to align the grooves in the cable and clamp b Secure the throttle cable clevis
208. bar Battery voltage is applied to one side of the bulb and a ground path is provided by the engine low oil pressure sender The bulb will also light momentarily due to low oil pressure when the ignition key is turned to start the engine After the engine starts and builds normal oil pressure the sender opens and the light goes out a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Unlock and open right engine access door Model 6036 S N 9B0499 and Before Section 10 Electrical System 3 Tag and disconnect wire from terminal of low oil pressure sender Fig 10 42 4 Remove low oil pressure sender b Disassembly Do not disassemble the engine low oil pressure sender c Cleaning and Drying Without submerging sender clean sender as required by using a fiber bristle brush and an approved solvent d Inspection and Replacement 1 Check engine oil level before testing sender Correct low oil level condition 2 Test the sender for continuity while installed on engine With wire disconnected from sender terminal connect an ohmmeter or continuity tester between the sender terminal and a ground point Continuity should be present Connect wire to terminal on sender and start the forklift If warning light remains ON after pressure has built up in the engine the sender is defective 3 Replace the sender if it fails to pass the tests in step 2 e Installation 1 Install low oi
209. be adjusted as described in the following steps 2 Turn the steering knuckle to full inside turn position on either the left or right side Adjust the socket assembly position in or out on the rod end and also the barrel end if necessary so that the retracted length of the cylinder matches the length required to install the cylinder IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure 4 Install nuts 2 securing the cylinder socket assemblies to the axle carrier 4 and knuckle 5 Torque the nuts to 140 Ib ft 190N m minimum Install cotter pins 1 Tighten the socket clamps Torque the clamp bolts and nuts to 60 to 70 Ib ft 82 to 95 N m Turn the other steering knuckle to its full inside turn position and adjust the cylinder steps 3 through 5 Remove all plugs or caps from the hydraulic lines and securely tighten the lines to the cylinder Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 8 Start the engine Turn the steering wheel fully left to right and back lock to lock several times in all three steering modes until they operate smoothly This should purge the steering system of air The maximum number of turns of the steering wheel should not exceed 4 1 2 turns lock to lock Shut down the engine Check the hydraulic oil level and fill as desc
210. behind the left access door at the back of the engine The starter drive engages teeth on the flywheel when cranking the When the ignition key is turned to the start posi tion a solenoid 11 Fig 10 14 on the starter motor yoke is energized and actuates a forked engine engagement lever 3 to energize the drive pinion The starter motor is a four pole four brush ground assembly 6 with the engine flywheel On occa return motor with series parallel connected field sions of tooth to tooth abutment axial movement coils A solenoid operated pre engaged drive of the pinion is arrested while a helically splined assembly is mounted on an extension of the sleeve in which the pinion is carried continues to armature shaft move forward This causes the pinion to rotate 10 14 Model 6036 S N 9B0499 and Before relative to the flywheel When the teeth become aligned spring pressure slides the pinion into mesh with the flywheel When the pinion is properly engaged with the flywheel teeth a pair of contacts are closed in the rear of the unit Closure of the contacts connects the motor to the battery the armature rotates and the starter pinion cranks the engine When the engine fires the operator returns the ignition key to the run position the solenoid unit is de energized and the spring loaded plunger in the solenoid withdraws the starter pinion to its out of mesh position The armature 9 is brought rapidly to rest by the centrifugal act
211. cal b Disassembly Do not disassemble the park lock switch Model 6036 S N 9B0499 and Before Cleaning and Drying Clean and condition the hex nut cap seal using an appropriate vinyl cleaner Without submerging the switch clean the switch with an approved solvent and dry witha clean lint free cloth Inspection and Replacement Inspect the switch terminals for continuity and shorting in the ENGAGED and DISENGAGED positions Replace switch if it fails the tests in step 1 Installation Connect electric wires as tagged during switch removal Position park lock switch Fig 10 43 under panel Position switch guard over switch stem Install hex nut and hex nut cap seal Connect negative cable 2 Fig 10 38 to batteries Prepare to test park lock engagement and disengagement by clearing the area around the forklift of persons and any obstructions to forklift travel e To test for engagement engage the park lock switch place the drive in forward or reverse and second or medium gear and apply full throttle The forklift should remain motionless in both forward and reverse positions e To test for disengagement firmly depress service brake pedal disengage park lock switch place drive in forward or reverse and first or low gear and slowly press the throttle pedal while releasing the brake pedal The park lock should release and the forklift should be free to travel 10 7 5 Park Lock Release Valve Sole
212. carefully lower it to the cab floor without disconnecting the wires 8 Tag and disconnect the wires b Disassembly Do not disassemble the momentary brake light switch c Cleaning and Drying If the switch is to be reinstalled without submerg ing the switch clean the switch in an approved solvent and dry it using clean lint free cloths d Inspection and Replacement 1 Inspect the switch plunger for freedom of movement 2 Inspect the boot for pliability and for cracks 3 The switch is normally ON push to OFF release and switch will spring return to ON Test continuity across the switch terminals with the switch released in the ON position e Installation 1 Refer to the tags attached in paragraph a and connect the wires to the switch 2 Remove the boot from the switch and insert the switch 5 Fig 10 58 through mounting hole in the brake pedal and secure switch by tightening switch jam nut on the back side of the brake pedal 10 51 Section 10 Electrical System 3 Work the opening in the boot into the groove of the plunger so the metal of the plunger bears against the actuator plate not the boot Proper installation of the boot protects the sliding plunger from contamination 4 Install jam nut 1 on capscrew 4 and actua tor plate 2 on capscrew 5 Install jam nut 3 on capscrew and then install capscrew in brake pedal 6 Readjust brake pedal stop position as de scribed in para
213. cator Bulb oai n i aeie a a E a E a 1 GE 1893 or 53X Model 6036 S N 9B0499 and Before 10 83 SK YTRAK Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Customer Support Toll Free 877 554 5438 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47
214. circuit breaker Check and secure connections at light switch Check red wire terminal at light switch with test light if bulb doesn t light repair open wire circuit to battery See para 10 9 4 See para 10 4 and 10 9 4 If after a few minutes operation lights flicker ON and OFF and a thumping noise can be heard from the circuit breaker repair short to ground between light switch and headlights After repairing short check for flickering lights after one minute of operation If flickering occurs replace damaged circuit breaker Check red and yellow wire See para 10 9 4 terminals at light switch with test light If bulb lights at red wire terminal but not at yellow terminal replace light switch Windshield Washer Wiper for Enclosed Cab GENERAL Windshield wiper Inoperative probe to wiper or switch terminal H If lamp lights turn wiper switch to LOW leave wiring connected to wiper motor and connect jumper wire from motor to ground If lamp doesn t light circuit breaker 12 Fig 10 5 may be stuck in the open position it may be oscillating between open and closed due to a short in the circuit or it may be in its normally closed condition 10 78 1 Turn ignition switch to RUN and wiper switch clockwise to HIGH SPEED Ground a 12 Vdc test lamp and touch If lamp lights continue with See para 10 10 1 step 2 if lamp doesn t light continue with step 3 Se
215. ck and open the left rear engine access door 2 Remove fuel lift pump cover screw cover washer cover and strainer 3 Wash any sediment from lift pump and clean cover and strainer 4 Install strainer and cover making sure that cover seats on pump with NO leakage Model 6036 S N 9B0499 and Before Section 8 Engine 5 Remove air from the fuel system See para graph 8 4 8 How to Bleed to Fuel System 6 Close and lock access door a How to Test the Fuel Lift Pump in Position 1 Disconnect the outlet line from the lift pump to the fuel filter 2 Rotate the engine There should be a spurt of fuel from the outlet port once every two revolutions b How to Test Pressure with Pump in Place 1 Fita Oto 10 psi 0 to 0 7 bar pressure gauge to the outlet of the pump Ensure that there are no leaks at the connections between pump and gauge 2 Crank the engine for 10 seconds and note the maximum pressure on gauge If the pressure recorded is less than 75 percent of minimum production static pressure which is 4 5 psi 0 31 kgf cm or 31 kN m then repair or replace the pump NOTE Minimum production static pressure is 6 psi 0 42 kgf cm or 41 kN m Also observe the rate at which the pressure drops to half the maximum figure obtained when cranking has ceased If less than 30 seconds repair or replace the pump NOTE These figures apply to a 4 bolt type fuel lift pump If your engine has a 2 bolt type fuel l
216. ck valve poppet 12 from frame tilt section 7 5 Repeat steps 2 3 and 4 for the remaining valve sections 6 5 and 4 6 Remove nuts 1 and 13 and tie rods 9 and 10 at inlet section 2 Cleaning and Drying Clean all metal parts in an approved solvent such as trichlorethylene and blow dry Assembly 1 Thread nuts 1 Fig 9 26 onto ends of tie rods 9 and 10 until nuts are flush with the ends of the tie rods MA0671 Fig 9 26 Main Control Valve Sections Model 6036 S N 9B0499 and Before 9 48 d Install new O ring 3 in inlet section 2 Install tie rods 9 and 10 from the outside of inlet section 2 through the holes in the inlet section Install boom hoist section 4 over tie rods 9 and 10 Repeat steps 2 thru 4 for the remaining valve sections 5 thru 8 Install check valve poppet 12 and spring 11 into frame tilt section Install nuts 1 and 13 on the ends of the tie rods 9 and 10 and tighten the nuts so the rods protrude the same amount from both sides of the valve Torque nuts 1 to 48 4 8 lb ft 65 6 5N m Torque nuts 13 to 75 7 5 lb ft 102 10N m Repair of Main Control Valve Sections When repairing the main control valve first refer to paragraph b and repair the relief valveds It might be advisable to install seal and spring repair kits in all of the relief valves at this time Disassembly Remove two socket head capscrews 1 Fig 9 27 and spoo
217. cle can cause serious injury or death If axle assembly is still in the forklift be sure carrier differential and pinion assemblies are securely supported before they are separated from the axle housing A serious or fatal injury can occur if you lack proper training if you fail to follow recom mended procedures if you do not use proper Caution The use of non original equipment replacement parts is not recommended as their use may cause unit failure and affect vehicle safety An identification tag on the axle housing contains the axle assembly number the serial number and the build date Supply all of the informa tion on this tag when referring to components of the axle assembly Refer to Spicer Dana Maintenance Manual for Models PS PR 7036 for gear set identification instructions Be extremely careful when working on components using snap rings or spring loaded retention devices 5 11 Section 5 Wheel Assembly Tires and Axle front axle wheel ends contain service brakes If the forklift has a turbocharged engine both the front and rear axle wheel ends contain service brakes tools and safety equipment if you assemble components improperly if you use incompat ible components if you use worn out or damaged components or if you use compo nents in a nonapproved application Some manufacturers may require the assem bly of brake components on Dana axles that use materials containing asbestos fibers
218. ct the operator to extend or retract the frame tilt cylinder slowly until the base end eye is aligned with the frame mounting holes Secure the base end to the frame with pivot pin and snap rings 7 Remove blocking from between axle and frame 8 Using the fork and frame tilt control lever tilt the frame full right then full left at least five complete cycles or until operation of the frame tilt circuit is normal no jerking or spongy feeling 9 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual 10 Test frame tilt circuit operation as described in paragraph 9 1 4c 9 38 9 2 6 Steering Cylinder a Removal Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns Disconnect the hydraulic lines from the steering cylinder and cap and plug open connections Remove cotter pins 1 Fig 9 18 and nuts 2 securing the cylinder socket assemblies 3 to carrier 4 and knuckle 5 Cotter pin 2 Nut 2 Cylinder Socket Assembly
219. ctrical System 1 Cab Harness 16 2 Engine Harness 17 3 Battery 12 Volt 2 18 4 Battery Cable negative 19 5 Battery Cable positive 20 6 Starter Ground Cable 21 7 Horn 22 8 Wire Assembly 23 9 Male Terminal 4 24 10 Circuit Breaker 40 A 25 11 Circuit Breaker 10 A 26 12 Circuit Breaker 6 A 2 3 are required if forklift 27 has an enclosed cab 28 13 Circuit Breaker Bracket 29 14 Hex Nut 1 4 2 30 15 Lock Washer 1 4 2 10 6 Model 6036 S N 9B0499 and Before FOR WINDSHIELD WASHER WIPER 21 2 59 60 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Emergency Pump Oil Pressure Sender Street Tee 1 8 NPT Water Temperature Sender Fuel Run Solenoid Neutral Start Switch Starter Relay Starter Starter Solenoid Alternator Electric Motor for Brake and Steering Hydraulic Pump Solenoid for Electric Motor Fuel Level Sender Air Circulation Fan Windshield Washer Wiper Switch Park Lock Brake Light Section 10 Electrical System 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
220. curing the con verter housing to the flywheel housing 7 Remove the two guide studs and install the remaining two capscrews securing the con verter housing to the flywheel housing Torque all eleven housing capscrews to 25 to 30 lb ft 34to41N m 8 Using the access hole on the flywheel housing remove the drive plate locating stud and install a capscrew in its place Snug the capscrew but do not tighten it 9 Rotate the engine flywheel and individually install the remaining seven flywheel to drive plate capscrews through the access hole Snug the screws but do not tighten them 8 21 Section 8 Engine 10 After all eight capscrews have been installed rotate the engine flywheel again and individually torque all eight to 25 to 30 Ib ft 34 to 40 8 N m 11 12 8 22 Install the engine and transmission on the 13 Secure transmission drive shaft to transmis to to forklift frame as follows 14 a Attach a suitable engine hoist to the lifting tol lugs on the top of the engine a b Push the engine and transmission in through the rear of the forklift and rest it on b the frame aligning the engine mount hole c Secure both transmission mounts to the transmission and frame with capscrews c and locknuts Torque the 1 2 inch capscrew attaching the d mount to the frame to 68 to 72 lb ft 93 to 98 N h Torque the 3 4 inch capscrews attaching the mount to the transmission to 225 to 275 l
221. d Reach at maximum lift angle boom 26 0 in 66 0 cm 19 6 in 49 8 cm retracted Maximum reach at minimum boom 21 ft 2 5 in 6 5 m 21 ft 8 25 in 6 6 m angle boom extended Maximum boom lift angle 71 degrees 71 degrees 9 degrees 9 degrees Fork tilt angle at Minimum boom angle up 11 degrees 11 degrees Minimum boom angle down 101 degrees 101 degrees Maximum boom angle up 87 degrees 87 degrees Maximum boom angle down 25 degrees 25 degrees Model 6036 S N 9B0499 and Before 3 17 This Page Left Blank Intentionally Section 4 Operator s Cab SECTION 4 OPERATOR S CAB CONTENTS Par Title Page 4 1 SEAT 4 1 4 2 MECHANICAL HAND CONTROLS 4 1 4 2 1 Steering Wheel and Steering Unit 4 2 4 2 2 Travel Select and Range Select Lever 4 2 4 2 3 Boom Control and Grille and Frame Tilt Joystick 4 4 4 3 MECHANICAL FOOT CONTROLS 4 5 4 3 1 Service Brake Pedal 4 5 4 3 2 Throttle Pedal and Cable 4 6 4 4 REAR VIEW MIRRORS 4 8 4 4 1 Mirror Head Adjustment 4 8 4 4 2 Mirror Cleaning and Inspection 4 8 4 1 SEAT The seat Fig 4 1 is mounted on an adjustable suspension unit The seat assembly consists of a seat cushion and two slides One of the slides has a forward backward adjustment lever A seat belt is attached to the seat a Adjustment You can adjust the seat for your weight and height and position it horizontally and vertically Position the seat for your height by simply pulling u
222. d IMPORTANT DO NOT operate any boom or steering functions during pump test 6 Start the engine and operate the pump at least two minutes at no load and at a speed of over 400 rpm but below 1500 rpm During this break in period the unit should run free and not develop and excessive amount of heat If the unit operates properly speed and pres sure can then be increased to normal operat ing settings 9 66 9 4 2 Steering and Emergency Brake Pump S N 7P0013 and Before a Removal 1 Engage the park lock place the travel selector lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Slowly loosen the fittings on the steering and emergency brake pump as required to relieve any trapped pressure 3 Tag and disconnect yellow ground wire from ground terminal of motor 15 Fig 9 44 4 Tag and disconnect wire from switch terminal on solenoid 10 1 Supply Hose 2 Connector 3 Pump Outlet Hose 4 Elbow 5 Capscrew 2 6 Lock Washer 2 7 Terminal Cable 8 Screw 2 9 Washer 2 10 Solenoid 11 Capscrew 4 12 Washer 4 13 Pump 14 Coupling 15 Motor 16 Ground Strap Section 9 Hydraulic System 5 Disconnect red electrical cable from power terminal on solenoid Warning Wait for the hydraulic fluid to coo
223. d It follows that any open ports of high precision components such as fuel system equipment exposed by removal or disassembly will be covered until reassembled to prevent the entry of foreign material Use a suitable sealant such as Loctite when installing screws into through holes into the interior of the engine NOTE Screw threads which have been sealant coated can be identified by their red or blue etc color Unified Threads All threads used on the engine are Unified Series and American Pipe Series Unified threads are not interchangeable with BSF and although BSW have the same number of threads per inch as Unified Coarse Series inter changing is not recommended due to a difference in thread form FUEL FILL ACCESS DOOR 0A1130 Fig 8 1 Fuel Fill Access Door 8 2 8 1 ENGINE PREVENTIVE MAINTENANCE 8 1 1 Daily Before Operation 1 Open fuel fill access door with a key Fig 8 1 2 Remove fill cap on fuel tank and fill with No 2 Diesel Fuel as required Tank capacity is 24 gallons 90 liter 3 Install fill cap and lock access door 8 1 2 First 50 Hours and 250 Hours Thereafter NOTE Refer to paragraph 8 1 9 for 25 or 50 hour Post Delivery Check Fan Belt Tension 1 Lower carriage to ground shut off engine and engage park lock 2 Unlock and open left rear engine access door 3 Inspect the fan belt Replace a cracked or frayed belt FAN PULLEY on ALTERNATOR _ PULL
224. d retract end of the grille tilt and slave cylinders The extension of the slave cylinder is fixed by the position of the boom so that only the grille tilt cylinder is retracted to tilt the grille down This supply pressure also pilots open the counterbal ance valve Fig 9 4 The open check valve allows return oil from the base end of the cylinder to return through ports A to D Fig 9 4 of the directional control valve to the return filter and reservoir Fig 9 4 If the supply pressure reaches 2650 psi 182 6 bar the grille tilt down relief valve Fig 9 2 will open allowing hydraulic oil to return to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar b Grille Tilt Cylinder Slave Cylinder and Hoist Cylinder Interaction The slave cylinder is mounted to the boom in a way that is similar to the hoist cylinders Fig 9 4 When the boom is raised or lowered the move ment of the slave cylinder follows the movement of the hoist cylinders The slave cylinder shares a common extend hydraulic line with the grille tilt cylinder and also a common retract line The movements of the cylinders are interactive 9 9 Section 9 Hydraulic System When the boom is raised the slave cylinder is extended which causes pressure buildup on the rod end of the piston This pressure pilots open the counterbalance valve Fig 9 4
225. d Using one hand to support the starter remove the nuts 8 and lock washers 9 and lift the starter 10 from the forklift c Disassembly Disassemble starter only as required by the periodic maintenance recommendations in para graph h d Cleaning and Drying 1 While the starter is out wipe away any grease or dirt that has accumulated around the starter hole MA0981 1 Starter negative ground cable 5 Wire5 10 Starter 2 Positive cable 6 Wire 19 11 Battery terminal 3 Wire 29 7 Starter solenoid 12 Starter motor terminal 4 Wire 27 8 Hex nuts 13 Ignition switch terminal 9 Lock washers Fig 10 15 Starter Removal Model 6036 S N 9B0499 and Before 10 15 Section 10 Electrical System 2 Ifthe starter is to be reinstalled clean the exterior of the starter with an approved solvent without submerging the starter or allowing the solvent to contact the bushings 3 Dry the starter using a clean lint free cloth e Inspection and Replacement You can bench test a starter by using battery jumper cables Connect the negative cable to the starter housing and touch the positive cable to the positive connection on the starter motor The motor should spin if it is good f Starter No Load Test General Information 1 The No Load Test is done with the starter removed from the forklift 2 Ifthe starter drive doesn t slide freely on the armature shaft clean and repair as required 3 Ifthe armature
226. d coat the metal parts that are to be reused with a good preservative and place in protective storage Refer to specific instructions for removal rebuilding and installation of each cylinder a General Disassembly Instructions A Warning Take care when applying heat to parts to prevent severe burns Avoid the use of exces sive heat which will damage parts and make them unusable Some parts of cylinders are sealed with a special organic sealant and locking compound Before you attempt to disassemble these parts remove any accessible seals from the area of the bonded joint Wipe off any hydraulic oil and heat the joint uniformly to break the bond A temperature of 300 to 400 F 149 to 204 C will destroy the bond strength of the sealant Avoid overheating or the parts may become distorted or damaged Apply sufficient torque or pressure for removal while parts are still hot Breakdown of sealant will leave a white powdery residue on threads and parts which must be removed by brushing with a soft brass wire brush prior to reassembly Do not attempt to salvage cylinder seals or sealing rings Any hydraulic component must always be serviced with a complete seal kit during a compo nent rebuild Repair kits are available b General Cleaning Instructions Clean all reusable metal parts thoroughly after disassembly and prior to inspection Use an approved solvent such as trichlorethylene c General Assembly Instructions
227. d fan unit 7 forward to provide access to the cab heater motor and hose connections Tag and disconnect wiring from motor Open valve 13 at the left corner of the engine just above the alternator Place a clean container under the engine drain plug Drain the coolant by venting the radiator and removing the engine drain plug At the cab heater loosen clamps 14 and disconnect hoses 20 Remove heater and fan unit 7 from forklift and place it on a clean bench Disassembly Disassembly of the heater unit is not required However if you intend to clean the heater core remove four sheet metal screws 21 Fig 10 67 and the fan mounting bracket 22 IMPORTANT Handle core 23 with care to avoid damaging the delicate fins 2 Remove four sheet metal screws 21 from the front of the heater and lift the heater core from the heater 10 60 Cleaning and Drying Clean the interior of the heater core by con necting a hose to the inlet and flushing the core with water Soak the exterior of the heater core ina detergent solution and then flush the coil with water from a hose Allow the core to air dry Clean all parts of the heater housing with detergent in water rinse and dry using a clean lint free cloth Inspection and Replacement Straighten bent fins using a duckbill pliers Test the heater fan motor for free rotation of the shaft If the shaft is binding lubricate bushing area using a few drops o
228. d in B ABNORMAL CHARGING SYSTEM OPERATION If a defect has been found and corrected at this point no further checks need be made B Abnormal Charging System Operation 1 Check that discharged batteries weren t caused by accessories left ON for extended periods 2 Check alternator drive belt for proper slack adjustment 3 Ifa battery defect is suspected refer to Section 10 6 2 Battery 4 Inspect the wiring for defects Check all connections for tightness and cleanliness including the slip connectors at the alternator and connections at the batteries 5 With ignition switch ON and all wiring harness leads connected connect a voltmeter from a Alternator BAT TERMINAL to ground b Alternator NO 1 TERMINAL to ground c Alternator NO 2 TERMINAL to ground A zero reading indicates an open between voltme ter connection and batteries Repair wiring harness if required 6 With all accessories turned off connect a voltmeter across the batteries Operate engine at moderate speed If voltage is 15 5 V or more on a 12 V system remove alternator for repair INSERT SCREWDRIVER IN THIS HOLE TO GROUND TAB TO END FRAME MA1101 Fig 10 27 Grounding Alternator Field Winding Wiring Connections Are Not Shown 10 23 Section 10 Electrical System 1 Screw 4 Bolt 8 Self locking Nut 2 LockWasher 5 Lock Washer 9 Washer 3 Washer 6 Lever 10 Screw 7 Spacer 11 Sleeve 12 13 14
229. d pressure 10 Place the ignition switch in RUN position so that steering and emergency brake pump will run Check the pressure gauge reading output of pump Pressure should be 1500 psi minimum 11 Turn off the ignition Repeat step 2 12 If the steering or emergency pump does not work properly locate the cause of the problem and correct before putting the vehicle into service 13 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 14 Start the engine Operate the steering wheel several times to purge the system of air step 6 15 Install the transmission cover after adjustment or repair 9 1 7 Optional Auxiliary Circuit a Description Hydraulic pressure is applied in the optional auxiliary circuit by the 30 gpm section of the tandem pump which draws its fluid through a suction strainer in the reservoir Fig 9 8 Supply pressure is directed to either a male or female quick connect at the front of the boom by the shifting of a spool in a directional control valve found in the main control valve assembly The spool is shifted by an auxiliary control lever and its associated control cable The auxiliary circuit supplies hydraulic pressure for use on various hydraulically operated attachments Auxiliary control lever positions are as follows 9 20 Center Position When the auxiliary control lever is placed in the center or neutral position the directional control valv
230. d with oil or rust preventive to protect them from corrosion c Inspection and Replacement 1 Replace all bearings cups and cones if they are worn pitted or damaged 2 Replace all gears that are worn pitted scored orchipped d Assembly 1 Secure the spindle assembly to the steering knuckle with locknuts and washers 2 Referto page 31 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for assembly instructions 5 2 4 Axle Steering Joints If removing the entire axle assembly from the forklift refer to paragraph 5 2 1 A suitable holding stand is desirable but not necessary If the axle is to remain on the forklift use support stands under machine and axle Steam clean the axle assembly prior to disassem bly Seal all openings before steam cleaning Refer to wheel and tire removal instructions in paragraph 5 2 1 Except when servicing the planetary gear assem bly raise axle until pressure is relieved from wheel end and rest axle on support stands A Warning Wear safety glasses at all times when assem bling and disassembling the axle The smallest eye injury may cause loss of vision Model 6036 S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle 1 Shaft and Joint Assembly 8 2 Shaft outer 9 3 Cross Assembly 10 4 Bearing Race Assembly 11 5 Ring retaining 12 6 Yoke center 13 7 Shaft inner yoke left Model 6036 S N 9B0499 and Before Shaft i
231. dealer Reference See para 10 6 2 See para 10 7 1 See para 10 5 1 and 10 5 2 See para 10 6 2 See para 10 5 1 and 10 6 2 See para 10 5 3 See para 10 5 3 and 10 5 4 Section 8 See para See para See para See para See para See para Section 8 See para See para 10 67 Section 10 Electrical System Trouble Starter doesn t run or doesn t run correctly No voltage at starter solenoid when ignition key switch is in the START position Starter operates continuously without ignition key in the START position 10 68 Probable Cause Remedy Starting System STARTER Discharged batteries Bad connections wires cables or other parts in the starting circuit Using the wrong engine oil for cold weather operation Worn teeth on the starter drive pinion or the flywheel ring gear Hex nuts that fasten the starter to the flywheel housing are loose Worn or damaged parts inside the starter Damaged coils or contacts in the starter solenoid See corrections for problem of discharged batteries See troubleshooting the Starting system General Refer to paragraph 8 1 Engine Lubrication instructions Remove the starter to check the teeth Repair as necessary Tighten the hex nuts Refer to paragraph 10 5 3 e DO NO LOAD TEST Perform starter solenoid tests Starting System STARTING MOTOR RELAY
232. death or serious injury if the recommended precautions or practices are not taken The signal word Caution signifies that a potentially hazardous situation to a person on or near the forklift exists which may result in minor or moderate injury if the recommended precautions or practices are not taken IMPORTANT The information in this manual does not replace any safety rules used in your area Before operating this forklift learn the rules and laws for your area Make sure the machine has the correct equipment according to these rules and laws Your safety and the safety of others in the work area depend on your knowledge of correct operating procedures for the machine Section 1 Safety Practices 1 3 PERSONAL CONSIDERATIONS Item Clothing Eye Protection Breathing Protection Hearing Protection Foot Protection Lifting What to do Do not wear loose clothing or jewelry Always wear appropriate eye protection when chiseling grinding discing welding painting when repairing hydraulic sys tems or checking testing or charging the battery Wear respiratory protection if grinding or painting Always wear ear protection if noise is excessive Wear protective footwear with reinforced toe caps and oil resistant soles Make sure you are capable of lifting an object Get help or use a sling on large components 1 4 EQUIPMENT CONSIDERATIONS 1 2 Item Operator s Cab
233. dentified by a wire number on the electrical schematic and on both ends of each wire a Removal 1 Remove a wiring harness only if damaged or unusable 2 You may prefer to install the new harness as you remove the old harness 3 Tag the terminal locations of all wires harness clips and tie wraps as you remove the old harness as required to permit identical installa tion of the new harness b Disassembly When replacing wires it is important that the correct gage size be used Never replace a wire with one of a smaller gage size c Cleaning and Drying Clean a wiring harness using a natural bristle brush and the same detergents you would use to clean the forklift Allow to air dry with surface tempera tures not to exceed 300 F 149 C d Inspection and Replacement Replace a harness only if damaged or unusable If you must splice a wire or repair one that is broken always use rosin core solder to bond the splice Use insulating tape to cover all splices or bare wires 10 5 Section 10 Electrical System e Installation The harnesses are held securely in place by clips or other devices to prevent chafing or wearing of the insulation due to vibration Be careful to install harness clips and tie wraps in the locations tagged on the forklift and the old harness in step a 10 4 CIRCUIT BREAKERS Circuit breakers 1 thru 6 Fig 10 6 protect the electrical system The breakers are mounted inside the righ
234. doesn t rotate freely disas semble the starter and repair as required before doing the No Load Test Test Equipment 1 A Sun Electric VAT 33 Tester an equivalent tester or separate pieces of test equipment A hand held tachometer A remote starter button to actuate the starter A fully charged 12 V battery Test Procedure Connect the test equipment according to this procedure and the manufacturer s instructions If the VAT 33 tester is being used 1 Select the 0 to 100 A range Select the 18 to 40 V range Move the volt lead switch to the EXT position PF ND Turn the load control to the OFF position Warning Fasten the starter in a vise or use another method to prevent the starter from moving this is essential to prevent personal injury 10 16 POSITIVE BATTERY CABLE NEGATIVE BATTERY CABLE MA0991 Fig 10 16 Positive and Negative Battery Cables with End View of Starter Solenoid 5 Connect the positive battery cable to the battery terminal on the starter solenoid and the negative battery cable to the mounting flange of the starter Fig 10 16 POSITIVE LOAD CABLE CABLE cee A in NEGATIVE LOAD w l 1 MA1001 Fig 10 17 Positive and Negative Load Cables 6 Connect the positive load cable to the positive post of the battery Connect the negative load cable to the negative post Fig 10 17 RED VOLTMETER LEAD MA1011 Fig
235. e A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 4 Support the slave cylinder with a sling or other suitable device 5 Remove the capscrew and locknut securing the slave cylinder rod to the outer boom Start engine and fully retract slave cylinder Disconnect the hydraulic lines from the cylinder and cap or plug open connections 8 Remove the retaining ring and pin securing the slave cylinder tube to the frame 9 Remove the cylinder from the forklift using a strap sling and hoist or other suitable lifting equipment Model 6036 S N 9B0499 and Before b Disassembly 1 Remove all dirt and grease from cylinder 2 Fasten the cylinder in a soft jawed vise or other acceptable holding equipment Do not damage the tube 3 If necessary to replace remove grease fittings 13 and 14 Fig 9 13 NOTE It may be necessary to apply heat to break the bond of the sealant between bushings 1 and rod 12 and tube 2 before the bushings can be removed Refer to paragraph 9 2a 4 Carefully press or drive out the bushings 1 5 Using a pin spanner wrench unscrew the gland 4 from the cylinder tube 2 IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure
236. e on Three Piece Wheel 5 1 12 Mounting Optional Tire on Single Piece Wheel 5 1 13 Connecting Core Ejector Tool to Tire Valve Stem 5 1 14 Filling a Tire with Hydrofill a Calcium Chloride Solution 5 1 15 Installing a Wheel on the Forklift 5 1 16 Care of Core Ejector 5 1 17 Care of Pump 5 1 19 Care and Storage of Tires Model 6036 6036T S N 9B0499 and Before Tire Speed and Road Surface Limitations 5 1 1 Removing Hydrofill from Tire or Tube within Tire Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 If tire or tube within tire is on the forklift use a jack to raise the forklift until the tire is slightly deflected and the valve is at the bottom in the valve drain position Fig 5 1 Use jack stands to support the forklift in the raised position Connect core ejector tool 1 Fig 5 4 to valve stem as described in paragraph 5 1 10 With the pump control in the CHECK position unscrew and retract core housing into ejector body Start pump and turn pump control to EVACUATE position and run until tire is completely evacuated Check to determine if the valve stem is plugged by removing the core ejector tool Run a piece of wire through the stem to make sure it is not plugged Turn pump control to CHECK position stop pump replace core housing in valve stem stop pump and disconnect core ejector If there is no tube within the tire unseat beads and demo
237. e Tilt Joysticks The Boom Control Joystick raises lowers re tracts and extends the boom The Grille Frame Tilt Joystick tips the carriage up or down and tilts the frame left or right See the Owners Operators Manual for operational descriptions A control cable attached to each joystick assem bly Fig 4 5 terminates at a valve section on the main control valve Fig 4 6 a Joystick Assembly Removal 1 Remove the lower panel which is located below the side console 2 Remove the covers from the joystick assem bly Fig 4 5 3 Loosen the lock screws until the control cables with lock screws and cable bushings can be removed from the sliders 4 Remove the joystick assembly from the side console panel Installation 1 Install joystick assembly in side console panel Install the control cables in the sliders Tighten the slider lock screws holding the sliders in position with a 5 8 inch open end wrench IMPORTANT Do not exceed 55 lb ft 75 N m DO NOT let slider rotate during this step It could damage other internal parts of the joystick MAIN CONTROL VALVE BRACKET CLAMP CLEVIS COTTER PIN CLEVIS PIN MA0171 Fig 4 6 Boom Control and Grille and Frame Tilt Control Lever Connections 4 4 Model 6036 S N 9B0499 and Before 4 Install the covers on the joystick assembly Install the lower panel b Joystick Control Cables Removal 1 Remove the lower panel which is below the side console 2
238. e fuel pump 6 Remove the fuel pump from the timing case ensuring that when the fuel pump gear leaves the shaft it stays in mesh with the idler gear otherwise fuel pump timing will be affected b Fuel Injection Pump Disassembly IMPORTANT Unless the necessary equipment and experienced personnel are available disman tling of the fuel injection pump should not be attempted Refer to your Perkins Engine Distributor for disas sembly and servicing of your fuel injection pump c Cleaning and Drying Clean the exterior of the fuel injection pump with an approved solvent and dry with a clean lint free cloth d Inspection and Replacement Refer to your Perkins Engine Distributor if fuel injection pump requires component replacement or repair 8 16 e Fuel Injection Pump Installation IMPORTANT Instructions and specifications in the Perkins Workshop Manual for the Perkins 4 236 Series Engine are required for fuel injection pump installation Do not remove pump from engine unless you have this information which is essential to correct fuel injection pump installation f Maximum Engine Speed Setting IMPORTANT The maximum speed screw seal of the original fuel pump must not be broken or tampered with in any way unless authorized by JLG Failure to do so may void engine and forklift warranties When installing a replacement fuel injection pump refer to paragraph 8 4 7 e or in the event of the maximum speed screw havin
239. e fuel run solenoid valve 2 Fig 10 42 lets fuel enter the injection pump when the ignition key is turned to START or RUN 10 35 Section 10 Electrical System TRAVEL PARK STEERING SELECT LOCK SELECT LEVER LIGHT SWITCH RANGE PARK WINDSHIELD SELECT LOCK WASHER WIPER LEVER SWITCH CONTROL OA0031 Fig 10 43 Control Panel a Removal 1 Engage the park lock place the travel select lever in neutral and turn the ignition switch to OFF 2 Disconnect negative cable 2 Fig 10 38 from the batteries 3 Unlock and open the right engine access door to gain access to the fuel injection pump Tag and remove electric wires A plunger and spring may fall from the sole noid when it is removed from the fuel injection pump Be prepared to catch these parts when you remove the solenoid Use an appropriate wrench to turn the solenoid counterclockwise 6 Discard the O ring b Disassembly Do not disassemble the fuel run solenoid c Cleaning and Drying Without submerging the electrical components clean the fuel run solenoid using a approved solvent and dry using a clean lint free cloth d Inspection and Replacement 1 Prepare to test the fuel run solenoid by assembling the valve at a bench 2 Inspect the rubber tip on the plunger and replace plunger if tip is worn 3 Lubricate valve core and plunger using clean fuel oil 10 36 4 Place the spring and plunger
240. e gear e Apply a thin film of LU3001 grease to the portion of the housing that contacts the drive gear Apply two or three drops of SAE 10 oil to the felt packing surrounding the armature shaft bearing Lubricate the gear and shaft assembly 7 Fig 10 63 by applying a thin film of Electro Systems TSE52115 to the cam and recessed portion of the gear face Apply a thin film of Electro Systems LU3001 grease to both sides of the nylon spacing washer 8 GREEN LEAD LARGE LEAD RED LEAD SMALL LEAD MA1421 Fig 10 65 Soldering of Coil Leads and Cable Assembly to Windshield Wiper Parking Switch Model 6036 S N 9B0499 and Before g Reassembly 1 Solder the coil leads and cable assembly to the parking switch as shown in Fig 10 65 2 Assemble the spacing washer 8 Fig 10 63 to the drive shaft and the gear and shaft assembly 7 to the gear housing with the flats on the drive shaft coinciding with the horizon tal center line of the motor Complete step 1 of paragraph f Lubrication 3 Assemble the bowed washer 29 Fig 62 to the drive shaft with the convex surface facing the gear housing Assemble the drive arm 28 and nut 27 to the drive shaft IMPORTANT Hold the drive plate in a vise to prevent placing a strain on the gear teeth when tightening the nut 4 Tighten the nut to a torque of 50 to 70 Ib in 5 6to7 9N m h Testing 1 Connect the negative terminal of a fully charged 12
241. e if at all possible before performing any service Place a warning sign on forklifts that are dangerous to start Disconnect battery leads if leaving the unit unattended Model 6036 S N 9B0499 and Before To prevent serious injury and or death To prevent serious injury and or death 1 3 Section 1 Safety Practices 1 6 OPERATIONAL CONSIDERATIONS cont Item What to do Why 1 7 FINAL WORD 1 4 Ventilation Radiator Cap Soft Ground Supports and Straps Oil Pressure Pressure Testing Leaving Forklift Parking Wheels and Tires Avoid prolonged running of the engine in a closed area with inadequate ventilation Always turn the radiator cap slowly to the first stop to relieve pressure Never work on a forklift on soft ground Check for additional ballast Seek assistance and install suitable supports if necessary Make sure safe and stable supports or straps are installed beneath or around a component or structural member that may fall before commencing work Before loosening hoses or tubes turn off the engine and operate the controls several times to relieve pressure Make sure all test equipment is in good condition Use only gauges specified Comply with test procedure specified Lower carriage to the ground Do not park or attempt to service forklift on an incline If unavoidable block all wheels Keep tires inflated to correct pressure Do not over inflate tires
242. e inside of the piston 9 Carefully push the piston 6 onto the rod to avoid damage to the O ring 6 Apply Loctite Primer T and Threadlocker 271 to the threads on the nut 8 in accordance with the manufacturer s instructions Install the nut on the rod and torque to 575 to 625 lb ft 782 to 850 N m Stake the nut in four places Allow the Threadlocker to cure Install a new piston seal 10 on the piston Fasten the tube 7 in a soft jawed vise or other acceptable holding equipment Be careful not to damage the tube Model 6036 S N 9B0499 and Before 9 Lubricate the inside of the tube outside of the piston seal 10 and O ring 12 with clean hydraulic oil 10 Apply a compression sleeve or other suitable tool to the gland in order to compress the O ring 12 on the gland Insert the assembled piston rod and gland into the tube 7 Using a pin spanner wrench thread the gland into tube Remove the compression tool IMPORTANT When sliding the rod and piston assembly into the tube be careful so that gland threads in the tube do not damage the piston seal Keep the rod in line with the tube barrel to prevent binding 11 Install new O rings 2 and backup rings 3 on counterbalance valve 1 Use new valve if the valve was removed for replacement Lubricate outside of the valve with clean filtered hydraulic oil Install the valve and torque to 45 lb ft 61 2 N m 12 If removed for replacement install new plug
243. e of the tube 7 for scoring and other damage If the tube is damaged replace with new tube 3 Remove small scratches on the rod or inside the tube with emery cloth of very fine grit Use the emery cloth with a rotary motion 4 Remove staking burrs from the nut 8 and the bottom of piston 9 with a fine file Clean parts with trichlorethylene after repair e Assembly NOTE Follow general assembly instructions in paragraph 9 2c 1 Apply Loctite Primer T and Retaining Com pound 609 to the outside diameter of the bushing 18 Fig 9 10 in accordance with the manufacturer s instructions Press the bushing into position in the eye of rod so that the bushing is located an equal distance from each side of the rod eye Allow the compound to cure 2 Install a new rod seal 15 wiper 16 backup ring 13 and O ring 12 on the gland 14 as shown in Fig 9 10 NOTE The wiper lips should be toward the outer end of the gland and the rod seal lips toward the inner end of the gland Use tools that will not damage the seal or wiper If the backup ring is not flat on both sides the side with the arc must be toward the O ring 3 Fasten the rod eye in a soft jawed vise Puta padded support below and near the other end of the rod to prevent damage to the rod 4 Push the assembled gland onto the rod 17 If necessary use a soft hammer to drive the gland onto the rod 5 Install new O ring 8 into internal groove on th
244. e or other acceptable holding equipment Do not damage the tube 3 If necessary to replace remove the grease fittings 5 Fig 9 10 and plugs 4 and 6 4 Remove the counterbalance valve 1 with O rings 2 and backup rings 3 from the tube 7 SLAVE CYLINDER MA0501 HOIST CYLINDER EXTEND CYLINDER FRAME TILT CYLINDER IMPORTANT Do not attempt to reset the boom hoist cylinder counterbalance valves If replace ment is necessary replace both left and right hoist cylinder cartridges at the same time with new ones 5 Using a pin spanner wrench unscrew the gland 14 from the tube IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure 6 Pull the rod 17 and attached parts straight out of the tube IMPORTANT When sliding the rod and piston assembly in the tube be careful so that gland threads in the tube do not damage the piston 9 Keep the rod in line with the tube barrel to prevent binding 7 Remove the piston seal 10 from the piston 8 Fasten the eye end of the rod 17 in a soft jawed vise and put a padded support below the rod near the piston to prevent damage to the rod NOTE It may be necessary to apply heat to break the bond of the sealant between nut 8 and rod 17 before the piston can be removed Refer to paragraph 9 2a 9 Remove the nut 8 piston 9 and gland 14 from the rod 10 Remove the O r
245. e para 10 10 1 and 10 10 3 If wiper runs repair open in ground strap if wiper doesn t run problem is in motor refer to paragraph 10 10 3 If open replace circuit See para 10 4 breaker If oscillating check for high amperage draw due to a short in wiring or motor If circuit breaker is closed repair open in line 32 between circuit breaker and wiper motor or repair or replace wiper motor 33 Fig 10 62 Model 6036 S N 9B0499 and Before Trouble Probable Cause Section 10 Electrical System Remedy Windshield Washer Wiper for Enclosed Cab GENERAL cont d Windshield wiper has low speed only and is inoperative in high speed Windshield wiper has high speed only and is inoperative in low speed Wiper has one speed which is the same in both low and high 1 Remove connector from terminal H of wiper motor and connect a 12 Vdc source to this terminal If wiper runs in high check for open in red wire from switch to motor If wiper is inoperative look for a hung or grounded high speed brush in the wiper motor Remove connector from terminal L of wiper motor and connect a 12 Vdc source to this terminal If wiper runs in low check for open in black wire from switch to motor If wiper is inoperative look for a hung or grounded low speed brush in the wiper motor Remove connectors from terminals H and L of wiper motor and connect a 12 Vdc source first
246. e piston and rod are moving freely in both directions Model 6036 S N 9B0499 and Before 13 14 Increase the operating pressure to the maxi mum 4000 psi or 275 6 bar for the cylinder and check for external leakage and free movement in both directions Prepare the cylinder for installation by retract ing the piston and capping and plugging the ports Installation Lubricate the pivot pin with multi purpose lithium based grease Using suitable lifting device install the slave cylinder Fig 9 9 on the forklift securing the base end to the frame with a pin and snap rings Remove all plugs or caps from the hydraulic lines and securely tighten the lines to the cylinder A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Have a helper start the forklift engine Position the slave cylinder so that the rod is aligned with the rod end mounting holes as much as possible Instruct the operator to extend or retract the cylinder slowly until the rod end eye is aligned with the outer boom mounting holes Secure the slave cylinder to the outer boom with its locking capscrew and locknut Tilt grille forks up fully then down fully and then approximately level Raise the boom as far as it will go then lower it as far as it will go five times while observing the grille The grille should hold in the same position during boom raising and l
247. e spool is positioned so that supply pressure is applied through ports F to C Fig 9 8 to the return filter and reservoir If the filter becomes clogged hydraulic oil will bypass the filter when the pres sure reaches 10 to 15 psi 0 7 to 1 03 bar MAIN CONTROL VALVE ee BACKWARD Toauxiiany MALE y ATTACHMENTS EEMALE FORWARD TO FRAME TILT CYLINDER Lh o Goi lt O TO GRILLE TILT AND SLAVE CYLINDERS TO BOOM EXTEND RETRACT CYLINDER TO BOOM HOIST CYLINDERS r 0 4000 psi PRESSURE GAUGE MA0491 Section 9 Hydraulic System Forward Position When the auxiliary control lever is placed in the forward position the directional control valve spool is positioned so that pump applied pressure is directed through ports E to A Fig 9 8 to the female auxiliary quick connect coupler Return pressure is directed through ports B to D to the return filter and reservoir If the filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar DIRECTIONAL CONTROL VALVE POSITIONS FORWARD BACKWARD ABC ABC ABC DEF DEF DEF CENTER RESERVOIR STRAINER RETURN x FILTER cto T 1 Fig 9 8 Optional Auxiliary Circuit ee 9 21
248. e sure to flush the gauge with clear water after checking a tire inflated with hydrofill and air Before you remove a tire from a wheel use an ejector tool to remove the valve core and use ejector tool and pump to remove calcium chloride 5 3 solution from the tire These instructions cover tire removal and installa tion for the standard three piece wheel and for the optional single piece wheel Instructions in italics refer to a tire with an optional tube You may use a tube if the tire doesn t provide an air tight seal Model 6036 6036T S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle Tire and wheel maintenance is covered in the FIXED SIDE FLANGE AND TIRE SEAT N EMBOSSED VALVE HOLE TR618A ARWATER 1 TYPE VALVE O RING SEALING RING RIM BASE LOOSE SIDE FLANGE AND TIRE SEAT LA LOCK RING C MA0221 Fig 5 2 Standard Wheel Assembly with T Type Rim and Fixed Back Flange following paragraphs 5 1 1 5 1 2 5 1 3 5 1 4 5 1 5 Removing Hydrofill from Tire or Tube within Tire Demounting Tire Removing Wheel from Forklift Demounting Standard Tire from Three Piece Wheel Demounting Optional Tire from Single Piece Wheel Wheel Cleaning Wheel and Tire Inspection and Replacement Tire and Wheel Lubrication Mixing Hydrofill Solution 5 1 10 Filling Tire or a Tube within Tire with Hydrofill a Calcium Chloride Solution 11 Mounting Standard Tir
249. e switch if open Defective horn 7 Fig Remove horn from forklift and See para 10 5 test horn using short heavy gauge wires connected to a fused or protected 6 A minimum output 12 Vdc power supply Horn sounds Defective horn switch 49 Test horn switch for continuity See para continuously Fig 10 5 without horn button pressed without horn replace switch if closed Dutton pressan Short circuit in wiring Determine and repair cause of See para short circuit Warning Devices BACKUP ALARM AND REVERSE SWITCH Backup alarm No voltage at backup Replace wiring and circuit See para doesn t sound alarm 16 Fig 10 5 breaker as required and 10 4 with travel select broken wire or circuit lever in REVERSE breaker 11 doesn t reset Defective reverse switch Replace reverse switch See para 53 Fig 10 5 Backup alarm Short circuit in wiring Determine and repair cause of See para sounds with travel short circuit select lever in NEUTRAL AND FORWARD Defective reverse switch Test and replace reverse See para 53 Fig 10 5 switch as required Warning Devices PARK LOCK WARNING LIGHT Park lock warning Park lock warning bulb 45 Replace park lock warning See para bulb doesn t light Fig 10 5 is burned out bulb when park lock brake switch is UP 2 Loose or broken wiring Repair or replace wiring See para engaged Defective park lock brake Test park lock brake sw
250. e the O ring 6 backup ring 7 wiper 10 and rod seal 9 from the gland Model 6036 S N 9B0499 and Before Section 9 Hydraulic System NOaPon gt 12 A A gA Baten Cylinder Tube Nut Piston Seal Piston O ring O ring Backup Ring MA0562 Gland Rod Seal Wiper Rod Bushing Counterbalance Valve Grease Fitting Grease Fitting 90 O ring 3 Backup Ring 3 Fig 9 15 Grille Tilt Cylinder Exploded View If the bushing 12 needs replacement support the rod 11 in a soft jawed vise or other acceptable holding device Carefully press the bushing from the rod Cleaning Discard all seals and backup rings Replace them with a complete new seal kit Clean all metal parts in an approved cleaning solvent such as trichlorethylene Be sure to clean all cavities and grooves Inspection Repair and Replacement Check that the rod 11 Fig 9 14 is straight If the rod is bent install new rod Inspect inside of the tube 1 for scoring and other damage If there is any damage to the tube replace it with a new tube Model 6036 S N 9B0499 and Before 3 e Remove small scratches on piston rod or inside of tube with emery cloth of very fine grit Use the emery cloth with a rotary motion Remove staking burrs from the nut 2 and bottom of the piston 4 with a fine file Clean parts with trichlorethylene after repair Assembly NOTE Follow general assembly instructions in pa
251. ected through ports B to C in the park lock release valve Fig 9 6 With no pressure on the park lock piston the park lock springs force the discs together this engages the park lock With the park lock release valve solenoid in the de energized position pressurized hydraulic oil is blocked at port D The park lock light on the dash will illuminate whenever the park lock is engaged and the ignition switch is in RUN position When the park lock switch on the instrument panel is placed in the disengaged down position the park lock release valve solenoid is energized and the valve spool is positioned so that the hydraulic flow is directed through ports D to A in the park lock release valve Fig 9 6 to the park lock With hydraulic pressure being applied to the park lock piston the park lock springs are compressed Which disengages the park lock discs IMPORTANT Never engage the park lock while the machine is in motion The park lock is not designed to be used as a means to slow or stop machine travel and could be damaged as a result b Pressure Checks and Adjustments Sequence Valve 1 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 9 15 Section 9 Hydraulic System 2 Operate the hydraulic controls after the
252. ed whenever repairs or adjustments are made to components of the circuit 1 Start the engine park the forklift on level ground and level the frame 2 Check for signs of leakage of hydraulic oil from circuit hoses and other components Correct any leakage problem before testing 3 Extend and retract the boom several times to purge the system of air 4 Starting with the boom fully retracted and level extend the boom at full engine speed The time required for full extension should be 12 to 15 seconds no load 5 Starting at the fully extended position retract the boom at full engine speed The time required to retract the boom fully should be 10 to 13 seconds no load Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Repeat steps 4 and 5 to recheck performance 7 If the boom extend retract circuit test does not meet performance requirements locate the cause of the problem and correct before putting the vehicle into service 9 1 3 Grille Tilt and Slave Circuit a Description Hydraulic pressure is applied in the grille tilt and slave circuit by the 30 gpm section rear half of the tandem pump which draws its fluid through a suction screen in the reservoir Fig 9 4 Pressure is directed to either side of the grille tilt and slave cylinder pistons by the shifting of a spool ina directional control valve found in the main control valve assembly The spool is shifted by the grille and frame tilt con
253. ed during re moval Install cotter pin 1 in pivot Check for smooth operation of travel select lever 8 Connect negative cable 2 Fig 10 38 to batteries 9 Place travel select lever in REVERSE and turn ignition switch to ON the backup alarm should sound 10 Install lower panel 7 Fig 10 40 10 7 7 Steering Select Switch The steering select switch Fig 10 43 has three positions up for 4 wheel steer center for 2 wheel steer and down for crab steer The switch is a single pole double throw toggle switch with three screw terminals a Removal 1 Disconnect negative cable 2 Fig 10 38 from batteries 2 Prepare to remove steer select switch Fig 10 43 by removing lower panel 7 Fig 10 40 Tag and disconnect the wires from the switch Remove hex nut which secures switch to right front console panel b Disassembly Do not disassemble the switch c Cleaning and Drying Without submerging the switch clean switch with an approved solvent and dry with a clean lint free cloth d Inspection and Replacement 1 Inspect switch terminals for continuity in the up and down positions and shorting in the middle position 10 39 Section 10 Electrical System 2 Replace switch if it fails tests in step 1 e Installation 1 Connect the wires as they were tagged during switch removal 2 Position the switch from under the right front console panel 3 Install the switch and ca
254. eering cylinders and bleed the system 7 On an axle without service brakes a Using lifting device install hub assembly 21 Fig 5 9 on spindle assembly 30 b Install bearing cone 20 c Install locknut 18 tighten to 200 to 250 ft Ibs 272 to 340 N m Back the nut off 1 8 5 20 turn and align any hole in the nut with a major spline on the spindle Mark the end of the aligned spline on the edge of the spindle Make sure the hub rotates freely g Install roll pin 19 on the back face of planetary ring gear 17 and mark its location on the front face of the gear Install planetary ring gear making sure roll pin is locked into locknut hole Align mark on the edge of the spindle with the mark on the front face of the planetary ring gear f Install spacer 16 sun spur gear 15 and retaining ring 14 on the axle shaft 8 On an axle with service brakes a Using a suitable lifting device install the hub assembly onto the spindle b Install the planetary ring gear piston retainer unit on the spindle assembly being sure oil passage hole in ring gear is to the bottom of the axle at 6 o clock c Gradually increase torque on retainer screws 25 Fig 5 8 using a crossing pattern until 45 Ib ft 61 N m is achieved on each screw d Install lining stop plates 14 and 17 Fig 5 8 and Fig 5 12 and discs 18 9 Install the planetary gear assembly as de scribed in
255. efore Section 9 Hydraulic System Extend Position When the joystick is placed in the extend position the directional control valve spool is shifted so that supply pressure is directed through ports E to A Fig 9 3 to the base end of the boom extend cylinder piston If supply pressure reaches 2650 psi 182 6 bar the boom extend port relief valve Fig 9 2 will open allowing hydraulic oil to return to the reservoir Return oil from the rod side of the extend cylinder piston is directed back to the directional control valve through ports B to D Fig 9 3 to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar Retract Position When the joystick is placed in the retract position the directional control valve spool is shifted so that supply pressure is directed through ports E to B Fig 9 3 to the rod side of the boom extend cylinder piston This supply pressure also pilots open the counterbalance valve Fig 9 1 The open counterbalance valve allows return oil from the base end of the cylinder to return through ports A to D Fig 9 1 of the directional control valve to the return filter and reservoir If supply pressure reaches 2650 psi 182 6 bar the boom retract port relief valve Fig 9 2 will open allowing hydraulic oil to return to the reservoir If the return filter becomes clogged hydraulic oil will b
256. elect lever in R reverse The vehicle should not move when full throttle is applied 4 Ifthe park lock test does not meet perform ance requirements locate the cause of the problem and correct before putting the vehicle into service 9 16 9 1 6 Power Steering Circuit a Description 1 Hydraulic pressure is applied in the power steering circuit by the 15 gpm section front half of the tandem pump which draws its fluid through a suction strainer in the reser voir Fig 9 7 2 When the steering wheel is turned the se quence valve Fig 9 7 opens permitting supply pressure to be directed to the power steering unit If the supply pressure reaches 2475 25 psi 170 5 1 7 bar the steering relief valve will be piloted open to allow hydraulic oil to flow to the return filter and reservoir 3 The power steering unit consists of control valve and metering sections Fig 9 7 e The control valve section contains a mechanically actuated linear spool which is torsion bar centered and is of the open center type It directs fluid to and from the metering section and steering cylinders and regulates the pressure supplied to the steering cylinders e The metering section consists of a commutator and a bidirectional gerotor element It meters measures the amount of fluid sent to the steering cylinders Forklifts S N 8F0235 and before may have a counterbalance valve Fig 9 7 4 The steering and emergenc
257. eling the battery case If spewing occurs or temperature exceeds 125 F 52 C the charging rate must be reduced or tempo rarily halted to permit cooling Model 6036 S N 9B0499 and Before 10 C 18 C Below 15 F 0 F 0 F e lalala wee oe e The battery is sufficiently charged when the green dot in the built in hydrometer is visible No further charging is required Shake or tilt the battery at hourly intervals during the charging to mix the electrolyte and see if the green dot appears e Battery charging consists of a charge current in amperes for a period of time in hours Thus a 25 ampere charging rate for 2 hours would be 50 ampere hour charge to the battery In most cases batteries whose load test values are less than 200 amperes see Battery Testing Procedure will have the green dot visible after at least a 50 ampere hour charge Most batteries whose load test values are greater than 200 amperes will have the green dot visible after at least a 75 ampere hour charge In the event that the green dot does not appear after this amount of charging continue charging for another 50 or 75 ampere hours If the green dot still does not appear replace the battery The time required for a charge will vary due to the following conditions e Size of Battery For example a com pletely discharged large heavy duty battery requires more than twice the recharging as acompletely discharged small passenger car batter
258. ell rims start bead on rim nearest deep well Fig 5 3 6 Partially inflate tube with air and insert in tire casing with valve located near valve hole in rim Attach valve retrieval tool to valve and thread tool through valve hole inserting the 5 9 Section 5 Wheel Assembly Tires and Axle tube and attaching the tool may be facilitated by placing a block under the tire 7 Starting opposite the valve use tire irons to lever top bead over the rim flange and down into rim well Be careful to avoid pinching tube with tire irons Locking pliers may be used to keep your place When bead is well started lubricate remaining unmounted portion of tire bead and rim flange Taking small bites spoon tire bead over rim flange until final section drops over at valve 8 Thoroughly lubricate tire beads and rim bead seats on both sides of tire 9 Center tire on rim and inflate to fully seat bead do not exceed 35 psi 2 4 bar using an extension hose with clip on chuck and gauge to permit operator to stand clear of tire Then remove valve core and completely deflate Reinsert valve core and reinflate to recom mended pressure as described in paragraph 5 1 10 NOTE If either bead should fail to seat at 35 psi 2 4 bar inflation the tire may be pinched between tire bead and rim or something else is interfering with proper mounting Do not increase pressure to seat beads but remove valve core and completely deflate Break both
259. els PS PR 7036 for assembly instructions 5 2 3 Wheel End Without Service Brakes If removing the entire axle assembly from the forklift refer to paragraph 5 2 1 A suitable holding stand is desirable but not necessary If the axle is to remain on the forklift use support stands under machine and axle Steam clean the axle assembly prior to disassem bly Seal all openings before steam cleaning Refer to wheel and tire removal instructions in paragraph 5 2 1 Except when servicing the planetary gear assem bly raise axle until pressure is relieved from wheel end and rest axle on support stands A Warning Wear safety glasses at all times when assem bling and disassembling the axle The smallest eye injury may cause loss of vision a Disassembly 1 Remove the planetary gear assembly Refer to page 13 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for removal instructions 5 17 Section 5 Wheel Assembly Tires and Axle Support the hub assembly with a lifting device Refer to page 15 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for disassembly instructions b Cleaning and Drying 1 Clean all parts with an approved petroleum based cleaner 2 Use clean lint free towels to dry components after cleaning DO NOT dry bearings by spinning with compressed air This can damage mating surfaces due to lack of lubrica tion 3 After drying components should be lightly coate
260. em from the rear support and engine as follows Model 6036 S N 9B0499 and Before Section 8 Engine Removal from Naturally Aspirated Engine 10 11 12 a Loosen clamp that secures the elbow to the engine inlet manifold b Loosen clamp that secures the elbow to the air cleaner assembly c Remove the nuts lock washers washers and capscrews that secure the air cleaner mounting band to the forklift frame Removal from Turbocharged Engine a Loosen clamp that secures hose to hose reducer at the air inlet to the turbocharger b Loosen clamp that secures hose to hump hose at the air cleaner assembly c Remove the nuts lock washers washers and capscrews that secure the air cleaner mounting band to the forklift frame Detach the exhaust system from the engine at exhaust manifold as follows a Remove the parts attaching tail pipe to engine and muffler Fig 8 23 and 8 24 b Loosen and remove the T Bolt that secures the muffler to the engine c Remove the parts attaching the exhaust pipe to the exhaust manifold or turbo charger as applicable Drain the radiator as follows a b Remove the radiator cap Place a container under the radiator petcock at the bottom left corner of the radiator c Open the petcock and allow the coolant to drain from the radiator Disconnect radiator overflow bottle and radiator hose connections at engine Remove the radiator hoses and sh
261. emedy Defective counterbalance valve or cylinder seals Boom Hoist or Extend Function Drifts Grille Tilt Slow or Malfunctioning External fluid leakage at tubes hoses or fittings Faulty relief valve setting Internal leakage in cylin ders Internal leakage in control valve Defective tandem pump Grille Tilt Drifts Defective grille tilt or slave cylinders Frame Tilt Slow or Malfunctioning External fluid leakage at tubes hoses or fittings Faulty relief valve setting Internal leakage in cylin ders Internal leakage in control valve Defective tandem pump Defective check valves or frame tilt cylinder Frame Tilt Drifts Service Brakes Grab Excessive hydraulic pres sure Low disc brake oil Brake pedal not adjusted correctly Service Brakes Air in brake line Spongy Insufficient hydraulic pres sure Model 6036 S N 9B0499 and Before Repair or replace cylinders seals and or counter balance valves as required para 9 2 1 or 9 2 2 Check and tighten connections at valves pumps and cylinders Repair or replace faulty hose s Check and set relief valve para 9 1 3 Repair cylinders as required para 9 2 3 and 9 2 4 Repair control valve as required para 9 3 1 Repair tandem pump para 9 4 1 Repair or replace cylinder para 9 2 3 and 9 2 4 Check and tighten connections at valves pumps and cylinders Repair or replace faulty hose s Check and set relief valve para 9 1 4
262. emergency steer pump will resume operation for as long as the battery retains a sufficient charge Model 6036 S N 9B0499 and Before Section 10 Electrical System PA0562 1 Motor 6 Coupling 2 Pump 7 Washer 3 Screw 8 Screw 4 Solenoid 9 Washer 5 Terminal Cable 10 Ground Strap Fig 10 68 Steering and Emergency Brake Pump and Motor S N 7P0013 and Before a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Unlock and open right engine access door 3 Tag and disconnect wires from terminals of emergency pump oil pressure switch 4 Remove the switch b Disassembly Do not disassemble the engine emergency pump oil pressure switch c Cleaning and Drying Without submerging the switch clean the switch as required by using a fiber bristle brush and an approved solvent d Inspection and Replacement 1 Test the switch for continuity It should close when oil pressure falls below 4 psi 0 3 bar It should open when oil pressure rises above 4 psi 0 3 bar 2 Replace the switch if it fails to pass the tests in step 1 e Installation 1 Install the emergency pump oil pressure switch 2 Connect the wires to the terminals of the emergency pump oil pressure switch 10 61 Section 10 Electrical System 3 Connect negative cable 2 Fig 10 38 to the batteries 4 Start the engine and inspect for oil leaks 5 Close and lock right engine acce
263. emove the remaining two capscrews and lock washers attaching the drop box to the frame 8 Use hoist to lift drop gear box from forklift 9 Clean the exterior of the drop gear box and move it to a clean work area b Installation 1 From above and below the frame secure the drop gear box to the frame with four capscrews and lock washers Torque capscrews 67 5 to 82 5 lb ft 91 8t0112 2N m 2 Remove the vent and level plugs 3 Using vent plug opening fill housing with tractor drop box fluid meeting specifications in paragraph 6 3 until it flows from the fluid level plug 4 Install each plug securely Secure drive shaft cross assembly to drop box input shaft yoke with a U bolt assembly or bearing strap Torque U bolt assembly to 20 to 24 lb ft 27 to37N m orthe bearing strap to 55 to 60 Ib ft 75to82N m 6 Secure the drive shaft cross assemblies to the drop box output shaft yokes with a U bolt assembly Torque U bolt assembly to 20 to 24 Ib ft 27to37N m 7 Install transmission and hydraulic tank covers on frame 6 3 SPECIFICATIONS Transmission and Drop Box Use a Tractor Fluid which meets the requirements of any of the follow ing specifications John Deere J20 A Detroit Diesel C 3 C 2 Ford Tractor M2C134B White Farm UTHF Q1766 Q1722 Products known to meet these requirements include Texaco THD Oil ARCO Tractor Fluid or equivalent CAPACITIES Drop Box 2 0 quarts 1 9 liter Transmission
264. en seams holes loose connections and other dete rioration which could permit exhaust fumes to seep into the operators cab Any damaged areas must be corrected immediately Periodic maintenance of the exhaust system is not required however it is advisable to check the con dition of the system when performing other main tenance on the forklift PA0392 1 Muffler 6 Flat 2 Pipe exhaust 7 Capscrew hex head 3 Clamp T Bolt 8 Nut 4 Clamp muffler 9 Pipe tail 5 Gasket exhaust manifold Fig 8 24 Exhaust System for Turbocharged Engine Model 6036 S N 9B0499 and Before MA0371 a Plate 5 Screw 2 6 Screw 2 3 2 Washer 2 4 Washer 2 Plate NOTE Normally the engine and transmission are re moved as a unit by suspending both units from these plates The combined weight is 1 400 Ib 635 kg 7 Fig 8 25 Engine Lifting Plates 8 6 ENGINE REMOVAL A Warning To avoid severe burns DO NOT attempt this 8 procedure when the engine cooling and hydraulic systems are hot Wait until they have cooled before proceeding 1 Remove the transmission cover and open both engine access doors Lower the boom to the ground 3 Remove the counterweight from the rear of the 9 frame 4 Remove the radiator cover Remove oil cooler from the rear support and detach the lines Catch any excess oil that drains from cooler and lines Cap the lines 6 Detach and remove the air cleaner syst
265. en the upper plates of the inner and intermediate booms to the front boom opening Make sure chains are not twisted Route the chains over the chain sheave and attach the chains to the front yoke with a shoulder screw and locknut Tighten the locknut completely then back off 1 4 turn Secure the rear of the chain to a block at the upper rear of the inner boom with a flat washer and locknut The elastic collar on the locknut must engage the chain clevis by at least one full thread Be sure locknuts are tightened equally Check the position of the chain yoke at the front of the outer boom The front of the yoke must be parallel to the front face of the outer boom If not adjust the locknuts accordingly Model 6036 S N 9B0499 and Before Section 3 Boom Refer to paragraph 3 1 5 and lubricate the chain Refer to paragraphs 3 1 6 and 3 1 7 and check and adjust the chains Retract Chain Removal Fully retract the boom Remove the rear boom cover Remove the inner boom retract chain locknut and flat washer Fig 3 11 securing the retract chain to a block at the lower rear of the inner boom Remove the outer boom retract chain locknut and flat washer attaching the retract chain clevis to a chain support plate at the bottom of the outer boom From the rear outer boom cover opening pull the retract chain from the space between the outer and intermediate booms Remove a chain clevis from each end of the chain Installat
266. eriod they should be wrapped in wax paper PERIODIC OPERATION REQUIREMENT EV ERY TWO WEEKS drive the forklift far enough to cause the drivetrain components to make several complete revolutions This procedure will help assure that all internal components receive ad equate lubrication to minimize component deteriora tion caused by an undesirable environment such as high humidity SUBMERSION OR DEEP WATER FORDING If the vehicle is exposed to water deep enough to cover the hubs disassemble the wheel ends and inspect for water damage and contamination If you submerge the carrier housing in water particu Model 6036 S N 9B0499 and Before larly over the breather drain the hypoid gear lubricant and inspect internal parts for water damage and contamination Before you assemble and refill the unit with the specified lubricants clean examine and replace damaged parts Clean examine and replace damaged parts if necessary NOTE If the hubs are exposed to deep water it is possible that water could enter the carrier at the point the inner axle shaft enters the axle housing This could also necessitate the draining of the hypoid lubricant as described above Whenever you remove bearings replace them with new bearings regardless of mileage Use suitable pullers for bearing removal Clean inspect and lubricate all bearings just prior to reassembly If replacement of a damaged bearing cup or cone is necessary replace the cup and c
267. ervice 6 Drain the cooling system as described in paragraph 8 1 8 To give protection against corrosion it is better to fill the cooling system with a coolant that has a corrosion inhibitor see paragraph 8 2 1 If frost protection is needed use an antifreeze mixture If no frost protection is needed use water with an ap proved corrosion inhibitor mixture 7 Run the engine for a short period to send the lubricating oil and coolant around the engine 8 Clean outthe engine breather pipe where fitted and seal the end of the pipe 9 Remove the atomizers and spray POWER PART Lay Up 2 into each cylinder bore If this is not available clean engine lubricating oil will give a degree of protection Spray into cylinder bores 1 4 pint 140 ml of lubricating oil divided evenly between the four cylinders 11 Remove the air filter and any pipe installed between the air filter and induction manifold Spray POWERPART Lay Up 2 into the induc Model 6036 S N 9B0499 and Before Section 8 Engine tion manifold Seal the manifold with water proof tape 12 Remove the exhaust pipe Spray POWER PART Lay Up 2 into the exhaust manifold Seal the manifold with waterproof tape 13 Remove the lubricating oil filler cap Spray POWERPART Lay Up 2 around the rocker shaft assembly Replace the filler cap 14 Disconnect the batteries and put them into safe storage in a fully charged condition Before the batteries are put into storage
268. ervice and park lock brake circuits by the 15 gpm The steering and emergency brake pump is section front half of the tandem pump which controlled by a oil pressure switch on the engine draws its fluid through a suction strainer in the which senses the engine oil pressure When the reservoir Fig 9 6 A pressure of 575 25 psi ignition switch is in RUN position and the pressure 39 6 1 7 bar is maintained on the service switch is closed at oil pressure below 4 psi 0 3 brakes and park lock by the sequence valve This bar the steering and emergency brake pump is pressure is reduced to 525 25 psi 36 2 1 7 energized and the pump will run Output of the bar at the pressure reducing valve prior to pump is 3 gpm at approximately 1500 psi 104 entering the solenoid operated park lock release bar When the pressure rises above 4 psi 0 3 valve and pedal operated service brake valve bar engine running the oil pressure switch Steering and Emergency Brake Pump opens to stop the steering and emergency brake ump The steering and emergency brake pump Fig i 9 6 provides limited backup hydraulic supply Service Brake Valve pressure to the steering and brake circuits in the When the brake pedal in the operator s cab is event of engine stoppage or tandem pump failure not depressed the brake valve spool is spring 0 1000 psi PRESSURE GAUGE INSTALLED IN EN aii PARK LOCK BLEEDER l i i i L i i D
269. es from the wiring harness 5 Remove the shifter assembly from the control console Model 6036 S N 9B0499 and Before COTTER PIN AND WASHER Maintenance Prepare to clean and lubricate the spring disk and ball in each travel and range select lever mechanism by removing the cotter pins washers and clevis pins that secure each lever to the shifter assembly Remove the levers from the shifter assembly Clean each lever spring disk and ball with an approved solvent Replace defective or damaged parts as required Apply a multi purpose grease to each disk spring and ball Install the spring disk and ball in the shifter assembly Installation Install the shifter assembly on the control console Connect the reverse switch wires to the wire harness by connecting the red switch wire to red harness wire 24 and the black switch wire to yellow harness wire 31 Use washers and cotter pins to connect the specific cable with swivels to the appropriate bellcranks Secure the control cables to their respective angle brackets with clamps Install the lower panel on the control console BELL CRANK TRANSMISSION CONTROL VALVE SPOOL AND PLUG ASSEMBLIES BRACKET Section 4 Operator s Cab Transmission Cable Removal Remove lower panel below control console Remove the clamp that secures control cable to angle bracket Fig 4 3 Remove cotter pin and washer that attach the swivel to the shifter assembly bel
270. ess than 0 5 13 mm thick The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert the ends must range from flush to 0 19 5 mm recessed in the wear pad insert refer to Fig 3 3 When you install a wear pad on one side including top or bottom of boom replace the corresponding wear pad on the other side of the boom Usually shimming will remain the same when installing new wear pads on correspond ing sides of the boom e e e Apply Loctite 242 to all wear pad screws and torque them to 28 to 34 lb ft 38 to 46 N m a Inner Boom Wear Pads Fig 3 3 1 All inner boom wear pads can be removed by working through the rear boom cover opening 2 The bottom pad may be removed by first removing the top pads Use a wooden wedge between the inner and intermediate boom to provide clearance for removing the bottom pad 3 Inspect the wear pads removed as described in the preceding IMPORTANT notice b Intermediate Boom Wear Pads Fig 3 5 and 3 6 1 The rear wear pads can be removed by working through the rear boom cover opening 2 The rear bottom pad may be removed by first removing the top pads by using a wooden wedge between the inner and intermediate boom thereby providing clearance for removing the bottom pad 3 Front pads can be removed at the front of the boom 4 The front bottom pad may be removed by first removing the top pads Lower the gooseneck end of the inne
271. est switch for continuity and replace switch if closed in the released position Determine and repair the cause of the short circuit Test switches for continuity under the appropriate conditions and replace as required CIRCUIT BREAKERS No voltage at these operations caused by a broken wire or switch or a circuit breaker which doesn t reset to its closed position Check the system for shorts grounds or defective electrical components Circuit breaker remains closed during an overload condition or is illegally bypassed with a jumper Important Never jumper a circuit breaker without providing an equivalent protective devise in the jumper Replace wiring switch and circuit breaker as required Repair or replace as required Correct the cause of the overload and replace damaged wiring components and circuit breaker Reference See para 10 8 4 See para 10 7 4 See para 10 8 4 See para 10 4 See para 10 8 5 thru 10 8 8 See para 10 8 4 See para 10 8 4 See para 10 8 5 thru 10 8 8 See para 10 4 See para 10 4 See para 10 4 Model 6036 S N 9B0499 and Before Trouble Engine will not crank and starting motor relay or solenoid does not engage Starter relay closes and solenoid engages but engine will not crank Starting motor turns but does not crank engine Engine cranks slowly Engine turns over but fails to start Probable Cause Section
272. ever use an iron or steel hammer to tap parts Never hammer bushings into bores use an arbor press 9 62 Disassembly Instructions Prepare to disassemble the pump by placing it in a vise with the drive shaft pointing down Use a socket wrench to remove four hex nuts 1 Fig 9 42 studs 3 and washers 2 Lift off port end cover 4 If prying is neces sary be careful not to damage the machined surfaces Dowel pins 5 will remain in either port end cover or gear housing Do not remove dowel pins unless damaged Remove seal 7 and thrust plate 8 Section 9 Hydraulic System Carefully remove drive and driven gear set 9 Avoid tapping the gear teeth together or against other hardened surfaces to avoid possible chipping Keep the matched gears in a set together Remove seal 11 Lift gear housing 12 from the bearing carrier If prying is necessary take care not to damage machined surfaces Lift or pry off the bearing carrier housing 13 Take care not to damage contact face and edges Dowel pins will remain in either the bearing carrier or the gear housing Do not remove dowel pins unless damaged aes 1 Hex Nut 4 Connecting Shaft 2 Washer 4 11 Sp R Gasket Seal 4 3 Stud 4 12 Gear Housing 4 Port End Cover 13 Bearing Carrier Housing 5 Dowel Pin 8 14 Gear Shaft Set 6 Plug 4 15 Gear Housing 7 Channel Seal 4 16 Shaft End Cover 8 Thrust Plate 4 17 Lip Seal 9 Gear Set
273. f an ap proved oil for small electric motors Manually turn the shaft to work the oil into the bushings Test the motor by connecting a fused or protected 6 A minimum output 12 Vdc power supply to the motor terminals using short heavy gauge wires If the motor doesn t run prepare to replace it by removing the nuts and lock washers which secure the motor to the heater Position the new motor on the heater and install the lock washers and nuts which secure it to the heater Pressure test the heater core for leakage and replace core if defective or in marginal condi tion Assembly Position core 23 Fig 10 67 in the heater and install four sheet metal screws 24 Position fan mounting bracket 22 on heater and install four sheet metal screws 21 Installation If negative cable 2 Fig 10 38 had been reconnected to the batteries disconnect this cable Position the heater and fan unit in the forklift Connect hoses 20 Fig 10 67 and install and tighten clamps 14 Open valve 13 Replace coolant in engine and heater lines connect the ground cable 2 Fig 10 38 to the negative terminals of the batteries start the Model 6036 S N 9B0499 and Before engine allow engine to idle for several min utes and check for leakage at the heater connections 6 Disconnect battery ground cable 2 Fig 10 38 from the negative terminals of the batteries Connect wiring to motor Prepare to elect
274. f the tandem pump Fig 9 4 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 5 Start the engine Operate the grille tilt control several times to purge the system of air 6 Depress the accelerator to full throttle Place the grille and frame tilt control lever in the up position and hold until the grille tilt cylinder has fully extended Continue holding the lever in the up position until the pressure readings are taken 7 Check the pressure gauge reading It should read 2650 50 psi 182 6 3 4 bar If not adjust the grille tilt up relief valve Fig 9 2 turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m after adjustment 8 Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 9 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 10 Start the engine Operate the grille tilt control fully several times to purge the system of air 11 Install the transmission cover after adjustment Grille Tilt Down Relief Valve 1 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure
275. from the forklift 1 Start the forklift engine and run at idle 2 Turn the steering wheel fully left to right and back lock to lock several times in all three steering modes until they operate smoothly This should purge the steering system of air 3 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual Model 6036 S N 9B0499 and Before CARTRIDGE WITH SEALS MAO761 Fig 9 35 Valve Cartridge for Pressure Relief Valve 9 3 7 Pressure Reducing Valve a Removal NOTE On forklifts with S N 8F0235 and before refer to paragraph 9 3 8 and remove counterbal ance valve before you begin 1 Engage the park lock place the travel selector lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Slowly loosen the fittings at the pressure reducing valve as required to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Tag and disconnect hydraulic hoses and tube assemblies 16 and 17 Fig 9 33 from run tees 11 and 12 on pressure reducing valve 4 4 Remove two hex nuts 21 lock washers 19 and capscrews 18 to detach pressure reducing valve 4 from valve mounting plate 3
276. from the forklift the counterbalance valve cartridges were disabled for emergency boom lowering or any unauthorized adjustments are ever made to these cartridges remove and replace both cartridges with new parts Failure to replace these cartridges with new 5 Start the engine Raise and lower the boom fully several times to purge the system of air parts may alter the holding characteristics of the 6 Depress the accelerator to full throttle Place counterbalance valves creating an unsafe condi the joystick in the lower position and hold tion for machine operation until the hoist cylinders have fully retracted Continue holding the joystick in the lower b Pressure Checks and Adjustments position until the pressure readings are taken Main Relief Valve 7 Check the pressure gauge reading It should 1 Engage the park lock place the travel select read 3 000 50 psi 206 7 3 4 bar If not lever in neutral and stop the engine adjust the main relief valve Fig 9 2 by turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease 7 pressure Torque nuts on relief valve to 10 A Warn I n g 1 5 lb ft 13 5 2 N m after adjustment Relieve hydraulic pressure before servicing any 8 Stop the engine Operate the hydraulic hydraulic component Escaping hydraulic fluid controls after the engine has stopped to under pressure can penetrate the skin causing relieve any trapped pressu
277. g been moved check and reset the maximum no load speed The maximum no load speed will vary according to application For details refer to code number stamped on fuel injection pump data plate The last four numbers in the code indicate the speed required In the case of the following example this would be 3130 rev min Code Example AS62 800 0 3130 NOTE If the fuel pump data plate is damaged or defaced so as to make it impossible to read the code or if the code is not stamped on the plate contact your nearest Perkins Distributor or C A V dealer to obtain the correct setting IMPORTANT Under no circumstances should the engine be allowed to operate at a higher speed than specified or severe damage to the engine may result 8 4 8 How to Bleed the Fuel System See paragraph 8 1 5 500 Hour Intervals Bleeding Fuel System for procedures to remove air from the fuel system 8 4 9 Atomizers Fuel Injectors Atomizers should be taken out for examination at regular intervals refer to paragraph 8 1 7 When replacing atomizers in the cylinder head it is essential that a new correct type copper washer is installed between the nozzle cap and cylinder head Earlier engines have a one piece collar type dust seal later engines have an improved two piece arrangement which consists of a soft rubber sealing ring or sleeve and a rigid plastic spacer which presses down onto the rubber sealing ring The rubber sealing ring is always
278. ge The fuel gauge indicates the liquid level in the fuel tank It consists of a resistance float type fuel level sender Fig 10 51 mounted in the top of the fuel tank and a fuel level gauge in the control console The resistance range of the submerged coil type fuel sender is 0 30 ohms The pointer of the fuel gauge is moved by the magnetic field of two coils The coils are at right angles to each other Battery voltage is applied to the E coil and the circuit divides at the opposite end of this coil One path continues to ground through the F coil Another goes to ground through the variable resistor of the fuel level sender Model 6036 S N 9B0499 and Before When the tank is low the resistance of the sender is low A large flow of current passes through the E coil and the fuel level sender resistor This moves the pointer toward E on the scale When the tank is full the sender resistance is high More current flows through the F coil moving the pointer toward F on the scale With two coils operating the pointer the gauge is not affected by changes in the voltage of the system a Fuel Gauge Testing 1 With five gallons of fuel in the fuel tank fuel gauge needle must be at approximately 1 4 full 2 Use a jumper wire to jump across the two wires at the fuel level sender on the fuel tank Fuel gauge needle must be at FULL mark 3 Switch ignition key OFF needle must drop below EMPTY
279. ght console panel 5 and overlay to the cab and lift and tilt panel to gain access to the back side of the fuel gauge Tilt and lift the socket from the fuel gauge Press and turn bulb 16 counterclockwise to release it from socket 5 To install a new bulb align pins on bulb with channels in socket push bulb into socket turn it clockwise to lock pins in detents and release it bulb should be securely anchored in socket 6 Position and push socket until it seats in gauge 7 Lower right console panel 5 into position and secure the panel with four bolts 12 c Removal of Fuel Gauge and Sender Removal of Fuel Gauge 1 Refer to paragraph 10 8 1 for the removal of the gauge cluster 2 Remove the nut and wire from the right IGN terminal post Fig 10 52 IMPORTANT Do not touch this wire to the left SEND terminal post on the fuel gauge or the sender capsule will be damaged 3 Remove the nut and wire from the left SEND terminal post of the fuel gauge 4 Remove the nut and ground wires from the center GND terminal post of the fuel gauge 10 46 Loosen the nuts on the clip which secures the gauge to the gauge mounting plate Lift the gauge from the gauge mounting plate Connect negative cable to batteries Removal of Sender Disconnect negative cable 2 Fig 10 38 from the batteries Remove the nut and wire from the center terminal on the sender Remove the screw which
280. ging Light 10 8 8 Transmission WARNING DEVICES 1073 High Temperature Sender Hor Lites 10 8 9 Fuel Gauge Backup Alarm and Reverse Switch 10 4 10 9 OPTIONAL LIGHTING SYSTEM Park Lock Warning Light 10 4 10 9 1 Directional and Warning Lights 10 5 Emergency Flasher Switch 10 9 2 Momentary Brake Light WIRING HARNESSES 10 5 Stop Light CIRCUIT BREAKERS 10 5 10 9 3 Momentary Brake Light Switch 10 9 4 Headlight and STARTING CIRCUIT 10 9 Rear Work Light Switch Testing Starter in Forklift 10 10 Se as 10 10 WINDSHIELD WASHER WIPER How to Check Voltage Loss j in the Starting Circuit 10 12 10 10 1 Windshield Washer Wiper Switch a La 10 10 2 ma seis tt t d 10 indshie asher Motor an plaiting MORT BBIE 10543 Reservoir Enclosed Cab Only Thomo rare Pug 10 10 3 Windshield Wiper Motor for Cold Weather Starting 10 20 Enclosed Cab Only CHARGING CIRCUIT 10 21 1011 FAN SWITCH AND Alternator ie FAN MOTOR OPTIONAL Batteries 10 29 10 12 CAB HEATER SWITCHES AND SOLENOIDS 10 33 ENCLOSED CAB ONLY Ignition Key Switch 10 33 10 12 1 Cab Heater Switch Neutral Start Switch 10 35 Enclosed Cab Only Fuel Run Solenoid 10 35 10 12 2 Heater Fan Motor and Coil Park Lock Switch 10 36 Enclosed Cab Only P ang Lock Malons 10 13 EMERGENCY BRAKING Valve Solenoid 10 37 AND STEERING SYSTEM Reverse Switch 10 39 10 13 1 Low OP Switch Steer Select Switch 10 39 10 132 ania a aw Steer Select Valve Solenoid 10 40 Emergency Hydraulic Pum
281. ging the Thermo Start plug clean the exterior of the plug in an approved solvent and dry using a clean lint free cloth d Inspection and Replacement 1 Examine the bore of the fuel channel for any contamination and clean as required 2 Test the coil of the Thermo Start plug using short heavy gauge wires connected to a fused or protected 6 A minimum output 12 Vdc power supply If the coil doesn t heat replace the Thermo Start plug e Installation 1 Install the Thermo Start plug Connect fuel line 4 Fig 10 24 Connect wire at electrical terminal 3 Model 6036 S N 9B0499 and Before 10 6 CHARGING CIRCUIT The charging circuit Fig 10 26 is described in paragraph 10 6 1 a 10 6 1 Alternator The alternator Fig 10 25 has a rotating field system inside a stationary generating winding When the rotor rotates inside the stator the output produced is alternating current ac This is unsuitable for charging the battery which requires direct current dc so it is rectified by means of diodes which convert it to unidirectional flow to the battery BAT TERMINAL NO 1 ERMINAL NO 2 TERMINAL TEST MA1081 HOLE DRIVE END FRAME SLIP BEARING RINGS BEARING STATOR ASSEMBLY MA1082 Fig 10 25 Typical 12 SI Series Alternator Model 6036 S N 9B0499 and Before Section 10 Electrical System The alternator
282. gland O ring 9 with clean hydraulic oil 10 Apply a compression sleeve or other suitable tool to the gland in order to compress the O ring 10 on the gland Insert the assembled piston rod and the gland into the tube 3 Using a pin spanner wrench thread the gland into the tube Remove the compression tool IMPORTANT When sliding the rod and piston assembly into the tube be careful so that gland threads in the tube do not damage the piston seal Keep the rod in line with the tube barrel to prevent binding 11 Install new O rings 15 and backup rings 16 on check valves 1 Use new valve if either Model 6036 S N 9B0499 and Before valve was removed for replacement Lubri cate outside of the valves with clean filtered hydraulic oil Install the valves and torque to 30 to 35 Ib ft 40 8 to 47 6 N m 12 If removed install grease fittings 14 IMPORTANT When sliding the rod and piston assembly into the tube be careful so that gland threads in the tube do not damage the piston seals Keep the rod in line with the tube barrel to prevent binding 13 Following reassembly test the cylinder at low operating pressure 100 psi or 6 9 bar to be sure the piston and rod are moving freely in both directions 14 Increase the operating pressure to the maxi mum 1750 psi or 120 bar for the cylinder and check for external leakage and free movement in both directions 15 Prepare the cylinder for installation by retract
283. graph 4 3 1 7 With brake pedal in its normal adjusted position the plunger must be depressed approximately 0 12 3 mm Adjust the plunger by loosening the switch jam nut and adjust by turning the boot as required to obtain this dimension 8 Tighten the switch jam nut to maintain this adjustment 9 Reconnect negative cable to the batteries LIGHT SWITCH OA0611 Fig 10 59 Headlight and Work Light Switch 10 9 4 Headlight and Rear Work Light Switch The headlights and rear work light are controlled by a three position push pull switch Fig 10 59 on the instrument panel This switch also controls the headlights directional signal lights tail lights and a light in the fuel gauge e Switch In Lights OFF e Switch Halfway Out Headlights Tail Lights and Panel Lights ON e Switch Fully Out Headlights Tail Lights Panel Lights and Rear Work Light ON a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Prepare to remove the light switch by remov ing the lower panel which is located below the steering wheel 10 52 Tag and disconnect the wires from the switch 4 Remove the hex nut which secures the switch to the right front console panel b Disassembly Do not disassemble the switch c Cleaning and Drying Without submerging the switch clean the switch with an approved solvent and dry with a clean lint free cloth d Inspection and Replacement 1
284. h Installation 1 Place a new gasket 15 Fig 9 37 and main tandem pump 14 in position on the transmis sion and secure using two hex head capscrews 12 and lock washers 13 Torque capscrews to 75 Ib ft 101 7 N m 2 Fill the pump inlet port and outlet ports with hydraulic oil to provide initial lubrication 3 Install elbow 11 and connector 10 to the pump outlets 4 Install small pump outlet hose assembly 8 and large pump outlet hose assembly 9 5 Install O ring 7 in elbow 5 Position clamp halves 6 and elbow 5 on pump inlet and secure with four lock washers 4 and four hex head capscrews 3 Torque capscrews to 75 Ib ft 101 7N m 6 Check hose clamp 1 to be sure it is secure i Recommended Test Procedure Perform pump testing in accordance with proce dures in SAE Handbooks Refer to Hydraulic Pump Test Procedure SAE J745c 1 Be sure to run the pump in the clockwise direction from the drive end Driving the pump in the wrong direction will build up pressure behind the shaft seal damaging it and requiring replacement 2 Be sure there is an adequate supply of oil for the pump at least one gallon of oil for each gpm of pump capacity 3 If one section of the tandem pump is being tested make sure that the other section which is not being tested is adequately supplied with oil If any of the sections run dry or if plugs are left in ports serious and permanent damage will result 4
285. h a lifting device b Insert a small screwdriver under retaining knuckle ring 14 Fig 5 9 on the axle shaft and remove it by rotating around the shaft b Cleaning and Drying c Remove the sun spur gear 15 and spacer 16 from the axle shaft based cleaner d Remove planetary ring gear 17 Usea suitable puller if necessary remove two crosses 3 and center yoke 6 11 Refer to pages 20 through 22 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for disassembling the axle steering 1 Clean all parts with an approved petroleum 2 Use clean lint free towels to dry components after cleaning DO NOT dry bearings by spinning with compressed air This can IMPORTANT Do not use a pilot puller on the axle damage mating surfaces due to lack of lubrica shaft because it may damage the inboard axle tion seal 3 After drying components should be lightly e Remove roll pin 19 Fig 5 9 from locknut coated with oil or rust preventive to protect 18 or ring gear 17 them from corrosion f Remove the locknut using a three pin c Inspection and Replacement spanner wrench i 1 Replace any bearing race assembly 4 Fig g Remove bearing cone 20 5 10 if it is worn pitted or damaged h Using a suitable lifting device remove hub 2 Replace cross assemblies 3 that are worn or assembly 21 from spindle assembly 30 damaged 4 Remove the spindle assembly mounting nuts 3 Replace axle shafts 2 7
286. h the bearing assembled into the end frame as shown in Fig 10 34 Install a new retainer plate if the felt seal in the retainer plate is hardened or excessively worn Fill the cavity between the retainer plate and bearing with 1948791 Lubricant The bearing in Figure 10 34 is sealed on both sides lubrication is not required Replace the bearing in the slip ring end frame if its grease supply is exhausted No attempt should be made to lubricate or reuse the bearing To remove the bearing from the slip ring end frame press out with a tube or collar that just fits inside the end frame housing Press from the outside of the housing towards the inside To install a new bearing place a flat plate over the bearing and press in from the outside towards the inside of the frame until the bearing is flush with the outside of the end frame Support the inside of the 10 27 Section 10 Electrical System frame with a hollow cylinder to prevent breakage of the end frame Be extremely careful to avoid misalignment or otherwise placing undue stress on the bearing If the seal is separate from the bearing it is recommended that a new seal be installed when ever the bearing is replaced Press the seal in with the lip of the seal toward the rotor when assembled that is away from the bearing Lightly coat the seal lip with oil to facilitate assembly of the shaft into the bearing l Alternator Reassembly Reassembly is the reverse of disassembl
287. hand feels too hot to keep against the reservoir the oil temperature is acceptable 2 7 TORQUES 2 7 1 Fasteners All fasteners are plated and equal to SAE grade 5 PC8 8 unless otherwise specified 2 7 2 Bolts and Nuts Unless otherwise specified the following grade 5 PC8 8 torque values 10 apply Torque Torque Inch lb ft Nm mm Nm lb ft 1 4 9 12 6 0 10 7 5 16 18 24 8 0 25 18 3 8 31 42 10 0 50 37 7 16 50 68 zs 1 2 75 105 12 0 80 59 9 16 110 150 14 0 130 95 5 8 150 200 16 0 200 146 3 4 250 340 20 0 360 263 7 8 380 515 22 0 510 372 1 0 585 790 24 0 650 475 2 7 3 Flared Fittings 37 steel 1 Align tube and fitting 2 Tighten nut to the following torque Nm 4 8 12 11 16 6 19 23 26 31 8 38 46 52 63 10 50 58 68 79 12 84 92 114 125 14 100 108 136 147 16 117 129 159 175 20 176 200 239 271 24 251 283 340 384 Model 6036 S N 9B0499 and Before Section 2 General Instructions 2 7 4 Straight Thread O ring Fitting non adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Lubricate O ring with light coating of oil 3 Torque as follows Nm 4 22 26 30 35 6 46 54 63 73 8 95 105 129 143 10 125 135 170 183 12 165 175 224 237 16 245 255 332 346 20 270 290 366 393 24 365 385 495 522 2 7 5 Straight Thread O ring Fitting adjustable 1 Inspect and correct both mating parts for burrs nicks scratches or any f
288. harge current of the battery is very low because of the resistance values of R2 R3 R5 TR1 and TR When the ignition switch is closed current from the battery flows through the indicator lamp to alternator TERMINAL NO 1 through resistor R1 and transistors TR3 and TR1 to ground and then back to the battery Also current flows through the alternator field coil and TR2 back to the battery The indicator lamp then turns on Resis tor R6 carries some of the indicator lamp current With the alternator operating ac voltages are generated in the stator windings and the stator supplies dc field current through the diode trio the field coil TR1 and then through the grounded diodes in the rectifier bridge back to the stator Also the six diodes in the rectifier bridge change the stator ac voltages to a dc voltage which appears between ground and the alternator BAT terminal 10 21 Section 10 Electrical System REGULATOR D1 Eo n AAA oe ae r FIELD ROTOR QQQ0000000 STATOR 2 gt gt gt ot RECTIFIER BRIDGE IGNITION SWITCH o ALTERNATOR oh hh q RMW T BAT NOT CHARGING l WARNING LIGHT K q l 4 R2 R5 RI p2 DIODE TRIO Doaa aaa STARTER SOLENOI
289. he fluid temperature exceeds 250 5 F 99 3 C and the bulb lights a Removal 1 Disconnect negative cable 2 Fig 10 38 from batteries 2 Remove transmission cover 3 Tag and disconnect wire from high tempera ture sender terminal Fig 10 50 4 Remove high temperature sender b Disassembly Do not disassemble the transmission high tem perature sender c Cleaning and Drying Without submerging the sender clean the sender as required by using a fiber bristle brush and an approved solvent Model 6036 S N 9B0499 and Before HYDRAULIC FUEL LEVEL PUMP CASE SENDER GROUND Section 10 Electrical System TO LIGHTING SYSTEM FOR OPTIONAL FUEL GAUGE LIGHT BACK SIDE OF FUEL GAUGE MA1312 Fig 10 51 Fuel Lever Sender and Fuel Gauge Schematic d Inspection and Replacement Test the sender by suspending its probe in hy draulic fluid which is at least 10 F 5 C below 250 F 99 C The sender should remain open Increase the temperature of the fluid until it exceeds this temperature by 10 F 5 C The sender should close e Installation 1 Install the transmission high temperature sender 2 Connect wire to terminal of transmission high temperature sender 3 Connect negative cable 2 Fig 10 38 to batteries 4 Operate engine and check transmission for fluid leaks 5 Install transmission cover 10 8 9 Fuel Gau
290. he frame tilt control fully several times to purge the system of air 11 Install the transmission cover after adjustment c Testing The frame tilt circuit should be tested whenever repairs or adjustments are made to components of the circuit 1 Start the engine park the forklift on level ground and level the frame 2 Check for signs of leakage of hydraulic oil from circuit hoses and other components Correct any leakage problem before testing 3 Operate the frame tilt control several times to purge the system of air if necessary 4 Starting with the frame tilted fully to the left tilt the frame fully to the right at full engine speed The time required for frame tilt right should be 8 to 12 seconds no load 5 Starting with the frame tilted fully to the right tilt the frame fully to the left at full engine speed The time required for frame tilt left should be 7 to 11 seconds no load Repeat steps 4 and 5 to check performance If the frame tilt test does not meet perform ance requirements locate the cause of the problem and correct before putting the vehicle into service Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 9 1 5 Brake Circuits and during initial start up before the tandem pump E is fully operational This pump is driven by an a Description electric motor it also draws fluid through the Hydraulic pressure is normally applied in the suction strainer in the reservoir s
291. he hydraulic controls after the engine has stopped to relieve any trapped pressure 9 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 10 Start the engine Operate the grille tilt control fully several times to purge the system of air 11 Install the transmission cover after adjustment d Testing The grille tilt and slave circuit should be tested whenever repairs or adjustments are made to components of the circuit 1 Start the engine park the forklift on level ground and level the frame 2 Check for signs of leakage of hydraulic oil from circuit hoses and other components Correct any leakage problem before testing 3 Operate the grille tilt control several times to purge the system of air if necessary 4 Starting with the grille down fully tilt the grille up fully at full engine speed The time re quired for full tilt up should be 4 to 6 seconds no load 9 10 5 Starting at the full tilt up position tilt the grille down fully at full engine speed The time required for full tilt down should be 3 to 5 seconds no load Repeat steps 4 and 5 to recheck performance If the grille tilt circuit test does not meet performance requirements locate the cause of the problem and correct before putting the vehicle into service 9 1 4 Frame Tilt Circuit a Description Hydraulic pressure is applied in the frame tilt circuit by the 30 gpm section rear half of the t
292. hen TR1 turns off Resistor R2 is a thermistor which causes the regulated voltage to vary with the temperature thus providing optimum voltage for charging the battery b Troubleshooting Procedures Close adherence to the following procedures in the order presented will lead to the location and correction of charging system defects in the shortest possible time Only a portion of these procedures need to be performed It will never be necessary to perform all the procedures in order to locate the trouble Either of two methods may be used to trou bleshoot the charging system One method uses alternator tester Model J 26290 available from the Kent Moore Corporation Tool Division 29784 Little Mack Roseville MI 48066 Model 6036 S N 9B0499 and Before The other method follows A basic wiring diagram showing lead connections is shown in Fig 10 26 To avoid damage to the electrical equipment always observe the following precautions e Do not polarize the alternator e Do not short across or ground any of the terminals in the charging circuit except as specifically instructed herein e Make sure the alternator and batteries have the same ground polarity e When connecting a charger or a booster battery to the forklift batteries connect negative to negative and positive to positive The correct jump start procedure is covered in paragraph 10 6 2 g Trouble in the charging system will show up as one or more of the following
293. her 8 Plate 3 Hex Nut 6 Capscrew 9 Transmission Shifter Fig 10 45 Reverse Switch 6 Slide the solenoid from valve cartridge stem e Installation 7 If the valve cartridge 4 is leaking or malfunc 1 Clean the exterior of the park lock release tioning remove the cartridge from the park valve on the valve plate Fig 10 44 to prepare lock release valve by turning the cartridge it for installation of the park lock release valve counterclockwise then plug the opening in the solenoid cartridge part locerslease Valve 2 Install three new O ring seals on the valve 8 Remove the three O ring seals from the valve cartridge canndge and discard Ihe seals 3 Thread the park lock release valve solenoid b Disassembly cartridge into the park lock release valve on the valve plate by turning the cartridge clock ee the park lock release valve wise until it firmly seats against the valve 4 Slide the solenoid 3 and nameplate 2 over c Cleaning and Drying the cartridge 4 stem and secure these 1 Carry the park lock release valve solenoid to a components with the jam nut 1 clean working area 5 Refer to the tags attached during removal and 2 Without submerging the solenoid clean the connect the wires to the solenoid solenoid in an approved solvent and dry using 6 Connect negative cable 2 Fig 10 38 to a lint free cloth the batteries d Inspection and Replacement Prepare to test the park lock release valve solenoid cartridge by
294. higher than 170 F 77 C Stop the engine and remove the cylinder head cover Check the torque of the cylinder head nuts and capscrews in the correct sequence as shown in Fig 8 29 The correct torque is 100 Ib ft 136 N m for 1 2 studs and capscrews 60 lb ft 84 N m for7 16 studs e Ifa nut or acapscrew turns when checked tighten it to the correct torque e lf anutoracapscrew does not turn when checked loosen it by 30 to 60 and then tighten to correct torque ont U 0 4 13 OA a KR state 2 oK 2200 QO E X a O15 7Q Os 3 O10 16 f 22 9 o MA0411 Fig 8 29 Cylinder Head Torque Sequence After all the nuts and capscrews have been checked check the first 10 positions again to ensure that they are still to the correct torque During this last check do not loosen the nuts and capscrews 8 24 MA1451 Fig 8 30 Valve Stem Tip Clearance Check 8 10 STEM TIP TO ROCKER ARM CLEARANCE CHECK The correct clearance between the top of the valve stem and the rocker lever is 0 012 0 30 mm with the engine cold NOTE No 1 cylinder is at the front of the engine To adjust this clearance 1 Turn the crankshaft in the normal direction of rotation until the inlet valve of No 4 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed Check the clearances of No 1 cylinder valves and adjust if necessary Fig 8 30 With No 2 cylinder
295. hough ports A to D Fig 9 5 to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar Pilot operated check valves Fig 9 5 in the frame tilt cylinder permit free flow on both ends of the cylinder piston when supply pressure is applied to open either pilot operated check valve When the grille and frame tilt control lever is not activated no supply pressure is applied The two check valves prevent any back flow of hydraulic oil and the frame tilt cylinder is locked in position b Pressure Checks and Adjustments Frame Tilt Left Relief Valve 1 Engage the park lock place the travel select lever in neutral and stop the engine AL Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury Model 6036 S N 9B0499 and Before 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar at the 30 gpm section outlet of the tandem pump Fig 9 5 A Warning Before starting the engine be sure all hydraul
296. i 2 4 bar may break the bead or even the rim with explosive force sufficient to cause serious physical injury or death 4 To fill a tire 75 percent with water solution first inflate tire to 35 psi 2 4 bar after the beads have been fully seated in the mounting procedure Jack up the wheel if done ona forklift and turn the wheel to bring valve to top position Model 6036 6036T S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle 5 Inspect both sides of the tire to be sure beads are evenly seated If not completely deflate tire unseat beads and repeat entire mounting procedure 6 Lower jack until tire is slightly deflected With pump not running and the pump control handle at CHECK position connect ejector and remove core housing as described in paragraph 5 1 1 7 After connection is made bleed pressure down to about 5 psi 0 35 bar by moving pump control to EVACUATE This is sufficient pressure to keep the beads seated on the rim 8 When this point is reached start pump and move pump control to the FILL position and start hydroinflating the tire 9 Check pressure in tire periodically with pump gauge by placing pump in NEUTRAL or CHECK position 10 If pressure exceeds 20 psi 1 4 bar move pump control to EVACUATE until pressure is bled back to not less than 5 psi 0 35 bar 11 After pressure is lowered continue pumping Repeat above steps as often as may be necessary until water or solu
297. ic connections are tight and all tools are removed from the forklift 5 Start the engine Operate the frame tilt control several times to purge the system of air 6 Allow engine to run at idle Place the fork and frame control lever in the left position and hold until the frame tilt cylinder bottoms out Continue holding the lever in the left position until the pressure readings are taken 7 Check the pressure gauge reading It should read 1200 50 psi 82 7 3 4 bar If not adjust the frame tilt left relief valve Fig 9 2 turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m after adjustment 8 Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 9 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 10 Start the engine Operate the frame tilt control fully several times to purge the system of air 11 Install the transmission cover after adjustment Frame Tilt Right Relief Valve 1 Engage the park lock place the travel select lever in neutral and stop the engine 9 12 AL Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engi
298. ich bulbs fail to light NOTE If forklift has an optional lighting system turn on headlights momentarily to see if bulb 16 Fig 10 47 in fuel level gauge lights You may have to move the forklift to a dark environment to observe if this bulb lights If it doesn t light refer to paragraph 10 8 9 for fuel level gauge instructions Then continue with step 4 of this procedure 2 Disconnect negative cable 2 Fig 10 38 from the batteries 3 Remove the four bolts 12 Fig 10 47 which secure the right console panel and overlay to the cab and lift and tilt the panel to gain access to the back side of the panel 4 Grasp and turn the appropriate bulb socket 13 a few degrees counterclockwise and remove socket from gauge 5 Press and turn bulb counterclockwise to release it from socket 6 Inspect socket contact areas for corrosion and clean and brighten any corroded areas replace components as required 7 To install a new bulb align pins on bulb with channels in socket push bulb into socket turn it clockwise to lock pins in detents and release it bulb should be securely anchored in socket 8 Position socket in gauge and turn socket a few degrees clockwise to lock in place 9 Lower the right console panel into position and install the four bolts 12 which secure the panel to the cab 10 Connect negative cable to the batteries 11 Turn ignition key to RUN and press TEST button 10 All four
299. ift pump contact your Perkins Engine Distributor for pump pressure specifications a Fuel Lift Pump Removal 1 Disconnect lines from fuel pre filter and to the fuel filter 2 Remove four capscrews and lock washers that secure the fuel lift pump to the engine b Disassembly and Assembly Refer to your Perkins Engine Distributor for disassembly and servicing of the fuel lift pump c Cleaning and Drying Clean the pump as described in paragraph 8 1 5 Fuel Lift Pump Sediment Chamber Clean the exterior of the pump with an approved solvent and dry with a clean lint free cloth d Inspection and Replacement Refer to your Perkins Engine Distributor if fuel lift pump requires component replacement or repair 8 13 Section 8 Engine e Fuel Lift Pump Installation Position the fuel lift pump on the engine and install the four capscrews and lock washers that secure the fuel lift pump to the engine MA0351 1 Fuel Filter 5 Filter Element 2 Filter Element Kit 6 Screw 2 3 Seal 7 Washer 2 4 Gasket 2 8 Washer 2 Fig 8 21 Fuel Filter 8 14 8 4 6 Fuel Filter Change element 5 Fig 8 21 every 500 hours of operation 1 Unlock and open the right rear engine access door 2 Loosen hex screw in top of filter Fig 8 9 and lower filter bowl cover Remove and discard element and gaskets Before you put new filter element into lower cover clean top and bottom filter covers a
300. ig 9 14 with a pin and snap rings 3 Remove all plugs or caps from the hydraulic lines and securely tighten the lines to the cylinder A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Have a helper start forklift engine Position the grille tilt cylinder so that the rod is aligned with the rod end mounting holes in quick attach as much as possible 6 Instruct the operator to extend or retract the cylinder slowly until the rod end eye is aligned with the quick attach mounting holes Secure the rod end of the cylinder to the quick attach with pin capscrew and locknut 7 Raise the boom up so that you can observe the grille Tilt the grille all the way back then all the way forward Repeat this cycle at least five times or until the operation of the grille tilt circuit is normal no jerking or spongy feel 8 Tilt grille forks up fully then down fully and then approximately level Raise the boom as far as it will go then lower it as far as it will go five times while observing the grille The grille should hold in the same position during boom raising and lowering in the last two cycles 9 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual 10 Test grille tilt circuit operation as described in paragraph 9 1 3c Model 6036 S N 9B0499 and Before Section 9 Hydraulic System
301. ill does not run after you do these checks check the starting circuit Starter Circuit Checks Test 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 Model 6036 S N 9B0499 and Before BATTERY TERMINAL STARTER MOTOR TERMINAL END VIEW OF STARTER SOLENOID Section 10 Electrical System BATTERY POSITIVE NEGATIVE BATTERY BATTERY TERMINAL TERMINAL STARTER SOLENOID BATTERY TERMINAL STARTER MAO911 Fig 10 8 Positive and Negative Battery Cables with End View of Starter Solenoid starter now cranks the problem is in the wiring circuit If the solenoid fails to click the starter is probably defective 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 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 The starter is usually bad if it does nothing at all even when jumped if it cranks very sluggishly or if it makes grinding noises while cranking Model 6036 S N 9B0499 and Before Starter Circuit Checks Test 2
302. in both directions 10 Prepare cylinder for installation by retracting piston and capping and plugging the ports 9 2 1 Boom Hoist Cylinder a Removal 1 Support the boom Fig 9 9 in a horizontal position with blocking A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Engage the park lock place the travel select lever in neutral and stop the engine 3 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 4 Support the cylinder with a sling or other suitable device Model 6036 S N 9B0499 and Before Section 9 Hydraulic System A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 5 Remove pin and its locking capscrew and lock nut securing the boom hoist cylinder rod to the outer boom Start the engine and fully retract cylinder Disconnect the hydraulic lines from the cylinder and cap or plug the open connections 8 Remove the pin and snap rings securing the boom hoist cylinder to the frame 9 Remove the cylinder from the forklift using a strap sling and hoist or other suitable lifting equipment b Disassembly of Boom Hoist Cylinder with TJB Stamping 1 Remove all dirt and grease from the cylinder 2 Fasten the cylinder in a soft jawed vis
303. inding has excessive resistance The specified resistance value can be determined by dividing the voltage by 4 2 and 5 0 A 4 Remember that the winding resistance and ammeter readings will vary slightly with winding temperature changes If the rotor is not defective but the alternator fails to supply rated output the defect is in the diode trio Fig 10 30 rectifier bridge stator or regulator 10 25 Section 10 Electrical System DIODE m S OHMMETER MA1141 Fig 10 31 Diode Trio Check f Diode Trio Check 1 The diode trio is identified in Fig 10 31 To check the diode trio remove it from the end frame assembly by detaching the three nuts the attaching screw and removing the stator assembly Note that the insulating washer on the screw is assembled over the top of the diode trio connector 2 Connect an ohmmeter having a 1 1 2 V cell and using the lowest range scale to the single connector and to one of the three connectors Observe the reading Then reverse the ohm meter leads to the same two connectors If both readings are the same replace the diode trio A good diode trio will give one high and one low reading MA1151 Fig 10 32 Rectifier Bridge Check 10 26 3 Repeat the same test between the single connector and each of the other two connec tors Also connect the ohmmeter to each pair of the three connectors not illust
304. ing 11 from the inside of the piston OPTIONAL SIDE TILT CARRIAGE CYLINDER IS SHOWN IN FIGURE 9 20 Fig 9 9 Hydraulic Cylinders Model 6036 S N 9B0499 and Before 9 24 11 Remove the O ring 12 backup ring 13 wiper 16 and rod seal 15 from the gland 12 If the bushing 18 needs replacement support the rod 17 in a soft jawed vise or other acceptable holding equipment Carefully press or drive bushing from the rod eye NOTE It may be necessary to apply heat to break the bond of the sealant between bushing 18 and rod 17 before the bushing can be removed Refer to paragraph 9 2a Counterbalance Valve O ring 3 Backup Ring 3 Plug Grease Fitting 2 ONDARWN gt O ring 12 O ring 13 Backup Ring 14 Gland 15 Rod Seal 16 Wiper 17 Rod 18 Bearing Plug Cylinder Tube C A Nut 7 Piston i 10 Piston Seal 11 Rar Section 9 Hydraulic System Cleaning Discard all seals and backup rings Replace with a complete new seal kit Clean all metal parts in an approved cleaning solvent such as trichlorethylene Be sure to carefully clean cavities and grooves Inspection Repair and Replacement Check that the rod 17 Fig 9 10 is straight the rod is bent install new rod f MA0511 Fig 9 10 Boom Hoist Cylinder Exploded View 9 25 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 2 Inspect the insid
305. ing a strap sling and hoist or other suitable lifting equipment b Disassembly 1 Remove any remaining dirt and grease from the cylinder 2 Fasten the cylinder in a soft jawed vise or other acceptable holding equipment Do not damage the tube Model 6036 S N 9B0499 and Before 3 Remove check valves 2 and three O rings 15 and backup rings 16 4 Using a pin spanner wrench unscrew gland 4 Fig 9 21 from the tube 1 IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure 5 Pull rod 5 and attached parts straight out of the tube IMPORTANT When sliding the rod and piston assembly from the tube be careful so that gland threads in the tube do not damage the piston Keep the rod in line with the tube barrel to prevent binding 6 Fasten the eye end of the rod 5 in a soft jawed vise and put a support below the rod near the piston to prevent damage to the rod MA0611 Side Tilt Carriage Cylinder Hose Assembly Hose Assembly Snap Ring Cylinder Rod Pin Cylinder Base Pin Side Tilt Carriage Pivot Base OANOaABRWN Fig 9 20 Side Tilt Carriage Cylinder Removal 9 42 OO SG G1 BO N 7 Tube Check Valve 2 Piston Gland Rod Piston Nut Self Aligning Bearing Rod Seal Wiper O ring Backup Ring O ring Piston Seal Grease Fitting 2 O ring 3 Backup Ring 3 Section 9
306. ing Lever 3 Unlock and open the left rear engine access door Operate the priming lever on the fuel lift pump Fig 8 12 until fuel free of air comes from both vents NOTE If the fuel lift pump cam is on maximum lift it will not be possible to operate the priming lever The engine should be turned over momentarily to reposition the lift pump cam 4 Continue to pump fuel and close the vents in the following order e Injection pump vent screw e Governor vent screw 8 6 INJECTOR HIGH PRESSURE LINE FITTINGS OA0342 Fig 8 13 Injector High Pressure Line Fittings 5 Loosen any two high pressure fittings Fig 8 13 that come from the fuel injection pump Loosen these fittings at the base of the injectors Also loosen the fitting of the Thermo Start fuel line in the intake manifold Fig 8 14 THERMO START FUEL LINE FITTING YX S INTAKE MANIFOLD OA0352 Fig 8 14 Thermo Start Fuel Line Fitting 6 Turn the ignition key to the START position and operate the starter until fuel free from air comes from the injector and Thermo Start fuel line fittings Turn ignition switch OFF Tighten all fittings 7 Close and lock both access doors The engine is now ready to start If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure system 8 1 6 1 000 Hour Interv
307. ing or heating in radiators and cab heater cores by coating and plugging the tubes It usually deposits in the cooler section of the cooling system such as the radiator bottom tank USE DISTILLED WATER OR DEIONIZED WATER to reduce the potential and the severity of silicate dropouts 1 Where frost protection will never be required use clean soft water with an approved corro sion inhibitor in soft water 2 If an antifreeze mixture is used to prevent frost damage it must have an ethylene glycol ethanediol base An antifreeze that con forms to one of the standards given below or to an equal standard is acceptable if the pH value is from 7 0 to 8 5 when diluted e U S A ASTM D3306 74 Ethylene Glycol Base Engine Coolant e U K BS 3151 1959 Ethanediol Anti freeze Type B with Sodium Benzoate and Sodium Nitrite Inhibitors e Australia AS 2108 1977 Antifreeze Compounds and Corrosion Inhibitors for Engine Cooling Systems Check the quality of the antifreeze coolant at least once a year for example at the start of the cold period 3 There is an advantage to using antifreeze even when frost protection is not necessary Model 6036 S N 9B0499 and Before Section 8 Engine An approved antifreeze as described in paragraph 2 protects against corrosion and also raises the boiling point of the coolant A 50 percent concentration of antifreeze is preferred but if there is a less likely chance that this much frost protect
308. inimum output 12 Vdc power supply 2 Replace backup alarm if it malfunctions e Backup Alarm Installation 1 While positioning backup alarm on mounting plate secure alarm to plate using two lock washers 6 and two capscrews 5 Connect alarm wiring Connect negative cable to the batteries Test backup alarm ap ON Reverse Switch Please refer to paragraph 10 7 6 for reverse switch instructions 10 2 3 Park Lock Warning Light The park lock warning light Fig 10 43 illuminates when the park lock switch is in the UP or FOR WARD position a Bulb Replacement You will find the number of the bulb in the Electri cal Specifications Table at the end of this section Model 6036 S N 9B0499 and Before To replace the bulb within the warning light remove the lower panel 7 Fig 10 40 which is secured by four capscrews 6 To gain access to the bulb pull straight downward on the lower part of the park lock warning light b Light Removal To replace the park lock warning light continue as follows 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Remove the lower panel 7 Fig 10 40 which is secured by four capscrews 6 Disconnect the wiring to the light 3 Remove the nut and locknut and lift the light from the console c Light Installation 1 Position the light in the console and install locknut and nut 2 Connect wiring to light 3 Connect negative
309. intake manifold A tube from the fuel injection pump returns surplus fuel to the fuel filter 22 Fig 8 18 for recirculation back to the fuel injection pump A tube from the fuel injectors returns surplus fuel from the injectors to the fuel filter 22 and into a line and hose which returns it to the fuel tank 8 4 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 8 10 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 When operating in temperatures above 20 F 6 7 C use diesel fuel No 2D with a minimum cetane rating of 45 When operating in tempera tures below 20 F 6 7 C use diesel fuel oil No 1D with a minimum cetane rating of 50 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 8 4 2 Fuel Tank The fuel tank 1 Fig 8 18 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 b
310. ion Be sure the boom is fully retracted Install a chain clevis on each end of the chain Secure the rear of the chain to a block at the lower rear of the inner boom with a flat washer and locknut Route the chain around the chain sheave The elastic collar on the locknut must engage the chain clevis by at least one full thread Using a long rod or other suitable tool route the chain between the lower plates of the outer and intermediate booms to the chain support plate opening Fig 3 11 on the bottom of the outer boom Secure chain clevis to the chain support plate using a flat washer and locknut Torque the locknuts to 35 to 40 lb ft 47 5 to54 2N m Refer to paragraph 3 1 5 and lubricate the chain Refer to paragraphs 3 1 6 and 3 1 7 and check and adjust the chain 3 9 Section 3 Boom 3 1 5 Chain Lubrication 250 Hour Intervals 1 Remove the rear boom cover from the outer boom 2 Extend and retract the boom several times applying multi purpose lithium based grease to the entire retract chain with a brush or grease gun 3 With the boom fully extended apply multi purpose lithium based grease to the extend chain using a brush or grease gun 4 Install the rear boom cover on the outer boom MAXIMUM CHAIN SAG WITH BOOM EXTENDED IS 3 4 19 mm CENTER SECTION OF INTERMEDIATE OA0491 Fig 3 12 Maximum Extend Chain Sag 3 1 6 Chain Tension Check 250 Hour Intervals Check tension
311. ion cover from the top of the frame 3 Place a receptacle under the transmission filter Fig 7 2 to catch fluid when the filter is removed 4 Remove the old filter element and discard the element 5 Apply a thin film of tractor hydraulic fluid to the new element gasket 7 1 Section 7 Transmission TRANSMISSION FILTER TRANSMISSION DIPSTICK OA0402 Fig 7 2 Transmission Filter and Dipstick 6 Turn the element on the transmission fitting Tighten the element to 20 to 25 lb ft 27 to 34 N m 7 Remove the receptacle Check the transmission level as instructed in the previous paragraph and add tractor hy draulic fluid as required 9 Install the transmission cover on the frame 7 1 3 1000 Hour Intervals Fluid Change 1 Level the forklift ground the carriage shut off the engine and engage the parking lock 2 Place a funnel with a flexible drain and a re ceptacle under the transmission sump hous ing TRANSMISSION ENGINE FLYWHEEL MOUNTING FLANGE PLUG AND SCREEN GASKET OA0412 Fig 7 3 Transmission Sump Plug and Screen 7 2 3 Remove sump plug and screen with gasket from housing Fig 7 3 Allow the transmission to drain completely 4 Clean the plug and screen thoroughly with an approved solvent 5 Install a new filter element as described in paragraph 7 1 2 DO NOT START ENGINE 6 Install the cleaned drain plug and screen and gasket into the transmission sump
312. ion is required a mixture of not less than 33 percent concentra tion can be used If antifreeze is not used add an approved corrosion inhibitor mixture to the water Change the water corrosion inhibitor every six months or check according to the inhibitor manufacturer s recommenda tions NOTE Some corrosion inhibitor mixtures contain soluble oil which can have an adverse effect on some types of water hose 8 2 2 Piston Cooling Jets Current turbocharged engines have piston cooling jets which direct cooled lubricating oil into the main pressure rail at the base of each cylinder liner onto the underside of each piston crown where it circulates dispersing heat from the combustion area The oil then drains back to the sump The lubricating oil feed to the jet nozzle is controlled by a pressure relief valve fitted into the main body of the piston cooling jet assembly and comes into operation at a pressure of approximately 30 psi 206 7 kPa MA0331 Filter Head 5 Connection 6 Washer 2 10 Oil Filter 7 Nut 2 9 Seal Gasket Connector 11 Hose Clamp Stud 2 8 Oil Cooler 12 Hose Fig 8 17 Oil Filter with Integral Oil Cooler Fons 8 9 Section 8 Engine 8 2 3 Integral Oil Cooler in Oil Filter The oil filter for a turbocharged engine Fig 8 17 has an integral oil cooler Whenever you change engine coolant drain the oil cooler by removing inlet or outlet connections flush the cooler and reconnect hose
313. ion of a pair of spring loaded brake shoes 16 bearing against a brake drum inside the intermediate bracket 7 If the pinion jams in mesh this may occur with an engine which fails to start there is sufficient slack in the engagement lever to solenoid plunger linkage to permit the solenoid switch contacts to open If the drive remains in mesh with the flywheel after the engine has run up to speed the starter motor armature is protected from over speeding by the plate clutch assembly This clutch allows torque to be transmitted from the starter motor to the engine but not from the engine to the starter motor The clutch is set to slip at between two and three times normal starting torque thus providing overload protection for the starter motor Section 10 Electrical System b Removal Remove the starter only if it fails the tests listed in paragraph 10 5 2 To remove the starter 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Tag and disconnect the negative ground cable 1 Fig 10 15 from the starter 3 Tag and disconnect the positive cable 2 and other wiring 3 4 5 and 6 from the starter solenoid 7 paying attention to the sequence in which the wires are installed on the termi nal 4 Loosen but do not remove the three hex nuts 8 that secure the starter to the flywheel housing Be careful when you remove the nuts because the starter is heavy and it will fall if not supporte
314. ire Inflate tire to manufacturer s recommended cold operating pressure Use only approved tire mounting lubricant never use antifreeze silicones or petroleum base lubricants Be sure rim diameter exactly matches rim diameter molded on tire Clean and inspect rim Inspect inside of tire for dirt foreign material loose cords cuts penetrating objects and other carcass damage discard tires with unreparable damage Model 6036 6036T S N 9B0499 and Before The forklift may have standard or optional wheels and tires e Standard 13 00 24 10 ply tires and three piece 8 00 24 TGF wheels e Optional 15 00 x 19 5 12 ply tires and single piece 12 5 x 19 5 wheels The tires are filled with air and hydrofill which is a calcium chloride and water solution Super large bore TR618A valve stems expedite inflation and deflation or evacuation A special core housing ejector tool is used for inflating and evacuating A hose connects the ejector tool to a pump and a barrel or reservoir of the calcium chloride solution and an air water pressure gauge IMPORTANT Mount tire so it will rotate in the direction of arrow on side wall of tire Fig 5 1 Position tire on wheel so tire will rotate in direction of arrow This mounting requirement produces Left Side and Right Side Tire and Wheel Assem blies When filling or evacuating a tire e position valve stem at its highest or top position when filling tire e position tire w
315. irror glass if broken damaged or missing the concave surface of the convex mirror has a 21 radius 5 Replace mounting hardware if damaged or missing Model 6036 S N 9B0499 and Before This Page Left Blank Intentionally Section 5 Wheel Assembly Tires and Axle SECTION 5 WHEEL ASSEMBLY TIRES AND AXLE CONTENTS Par Title Page Par Title Page 5 1 WHEEL ASSEMBLY AND TIRE 5 2 5 1 15 Installing a Wheel on the Forklift 5 10 5 1 1 Removing Hydrofill from Tire or Tube 5 1 16 Care of Core Ejector 5 10 within Tire 5 4 5 1 17 Care of Pump 5 10 5 1 2 Demounting Tire 5 5 5 1 18 Tire Speed and 5 1 3 Removing Wheel from Forklift 5 5 Road Surface Limitations 5 10 5 1 4 Demounting Standard Tire 5 1 19 Care and Storage of Tires 5 10 from Three Piece Wheel 5 5 5 2 AXLE ASSEMBLY 5 11 5 1 5 Demounting Optional Tire 5 2 1 Axle 5 12 oar mingle e eve dvnee ae 5 2 2 Wheel End With Service Brakes 5 15 Sas Wheel Cleaning a 5 2 3 Wheel End Without Service Brakes 5 17 A Sa Rien ares 5 7 5 2 4 Axle steering Joints 5 17 5 1 8 Tire and Wheel Lubrication 5 7 5 2 5 steering Cylinder and tie mod sak 5 1 9 Mixing Hydrofill Solution 5 7 52 65 RATK Lock Onl eal 5 1 10 Filling a Tire or a Tube within a Tire 5 2 7 Carrier Assembly 5 23 with Hydrofill 5 7 5 3 AXLE LUBRICATION 5 26 5 1 11 Mounting Tire 5 8 5 3 1 Grease 5 26 5 1 12 Mounting Standard Tire 5 3 2 Differential Housing Oil 5 26 on Three Piece Wheel 5 8 5 3 3 Wheel
316. is twisted Connections are too tight or cross threaded External fluid leakage at tubes hoses or fittings Faulty relief valve setting Internal leakage in cylin ders Internal leakage in control valve Defective tandem pump Lower load using Emergency Boom Lowering instructions in Owners Operators Manual Lower load using Emergency Boom Lowering instructions in Owners Operators Manual Repair main control valve para 9 3 1 Add fluid Refer to Owners Operators Manual Clean or replace filler oreather Using an oil can containing system fluid squirt a little fluid on each joint of the suction line and tighten any joint where fluid stopped the noise Double clamp if necessary Tighten mounting capscrews to 75 lb ft 101 7 N m Tighten hardware to 200 Ib ft 271 2N m Refer to para 9 4 1 Repair pump para 9 4 1 Replace hose and install without tight bends or twists Check and set the main relief valve para 9 1 1 Replace and make sure the hose does not turn as swivel fitting is tightened Repair hose fittings if possible or replace hose Check and tighten connections at valves pumps and cylinders Repair or replace faulty hose s Set relief valves para 9 1 1 and 9 1 2 Repair cylinders as required para 9 2 1 and 9 2 2 Repair control valve as required para 9 3 1 Repair tandem pump para 9 4 1 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Trouble Probable Cause R
317. itch See para switch 46 Fig 10 5 for continuity and replace switch if open in the engaged position Model 6036 S N 9B0499 and Before 10 65 Section 10 Electrical System Trouble Park lock warning bulb lights when park lock brake switch is DOWN disengaged Bulbs in warning lights gauge don t light when test button is pressed Bulbs in warning lights gauge light continuously when ignition key switch is in the RUN position Loss of electrical power for some but not all forklift operations Circuit breaker continuously trips Overheating and burnout of wiring and forklift electrical components 10 66 Probable Cause Remedy Warning Devices PARK LOCK WARNING LIGHT cont d 1 Short circuit in wiring Defective park lock brake switch 46 Fig 10 5 Determine and repair cause of short circuit Test park lock brake switch for continuity and replace switch if closed in the disengaged position Warning Devices WARNING LIGHTS Bulbs are burned out No voltage at warning lights gauge 51 Fig 10 5 loose or broken wiring or circuit breaker 12 doesn t reset Defective sender switches Defective test switch 47 Fig 10 5 Short circuit in wiring Defective sender switches Replace bulbs Replace wiring and circuit breaker as required Test switches for continuity under the appropriate conditions and replace as required Check t
318. ith valve stem at its lowest or bottom position when evacuating a tire Check tire inflation with valve at the bottom of a hydrofill or liquid filled tire when tire is cold and before forklift is operated A tire that has sufficient pressure when hot may be underinflated when it cools A Warning NEVER operate forklift without hydrofill in tires NEVER attempt to unseat the beads of an inflated tire NEVER reinflate a tire that has been run flat or seriously underinflated without removing tire from wheel and checking for tire and rim damage NEVER hit a tire or rim with a hammer or sharp object NEVER rework weld heat or braze a rim Section 5 Wheel Assembly Tires and Axle SOME TIRES HAVE THIS INSTRUCTION EMBOSSED IN SIDE WALL DRIVING TIRES MUST ROTATE AS THE ARROW POINTS K OTHER TIRES MUST ROTATE IN THE OPPOSITE DIRECTION VALVE POSITION FOR FILLING TIRE WITH HYDROFILL AND AIR WHEEL LUG NUT VALVE POSITION FOR CHECKING TIRE PRESSURE AND FOR DRAINING HYDROFILL FROM TIRE ARROW POINTS TO RIGHT gt gt gt ON BOOM SIDE OF FORKLIFT MAQ212 MA0214 NOTE DIRECTION OF TREAD PATTERN ARROW POINTS TO LEFT lt lt ON CAB SIDE OF FORKLIFT ree Fig 5 1 Tire Direction of Rotation and Valve Stem Positions for Tire Pressure Check Fill and Evacuate NOTE The calcium chloride hydrofill solution will corrode a standard tire pressure gauge Usea corrosion resistant tire pressure gauge B
319. ition pin with grease holes facing UP 10 Using grease fittings at the ends of the pin lubricate the quick attach pivot pin 11 Install the grille tilt cylinder as described in paragraph 9 2 4 f 12 Adjust hose tension as described in paragraphs 3 1 9 Model 6036 S N 9B0499 and Before Section 3 Boom CAPSCREW ENDS TO BE FLUSH TO 0 19 5 mm RECESSED IN WEAR PAD INSERT L lt lt lt PAD SPACER INSERT 2 IA LOCK WASHER 6 Z 7 Z j ZF FLAT WASHER 6 Thin 3 8 16 X 1 3 4 CAPSCREW 6 GAP MUST BE 0 07 TO 14 GA SHIM 0 13 1 8 TO 3 3 mm A i E 7 GAP MUST BE 0 07 TO _ r 1 ST YT L 0 13 1 8 TO 3 3 mm INTERMEDIATE _ 7 BOOM N ae INNER BOOM f lt CAPSCREW ENDS TO BE FLUSH SS TO 0 19 5 mm RECESSED IN d WEAR PAD INSERT F S PAD INSERT 1 LOCK WASHER 2 PAD 14 GA SHIM INSERT 2 FLAT WASHER 2 LOCK WASHER 4 3 8 16 X 7 8 FLAT WASHER 4 CAPSCREW 2 3 8 16 X 3 4 CAPSCREW 4 MA0031 Fig 3 3 Rear Wear Pads Attached to Inner Boom 13 Check and adjust chain tension as described in 3 Working from the rear boom cover opening paragraphs 3 1 6 and 3 1 7 record the number of shims beneath each wear pad as you remove the side and top wear pads
320. k or hoist 6 Remove the wheel lug nuts Fig 5 1 and wheel and tire assembly from the axle hub 5 1 4 Demounting Standard Tire from Three Piece Wheel IMPORTANT Always completely deflate tire as described in paragraph 5 1 1 before you attempt to demount a tire 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 Place the wheel and tire assembly on the floor on blocks with the loose side flange side up Fig 5 2 3 After deflating the tire as described in para graph 5 1 1 drive the hooked ends of two bead unseating tools between the tire bead and rim flange about 5 inches apart be careful that you don t damage the tire bead area Pry both tools down and out Leave one tool in position and place the second about 5 inches beyond Repeat the operation slowly in successive steps until tire bead is completely unseated Model 6036 6036T S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle CLIP ON CHUCK CORE EJECTOR BODY CORE REMOVER EJECTOR CHUCK __ PACKING NUT HANDLE VALVE CORE MA0241 Figure 5 4 Core Ejector Tool NOTE A mechanical bead unseating and seating tool may be purchased from the lowa Mold Tooling Company to facilitate step 3 4 After the tire bead is unseated stand on the flange and tire side wall to depress the flange down along the rim base then pry loose the lock ring Keep fingers out of the way 5 Ho
321. kup ring 6 from the relief valve poppet Cleaning and Drying Clean metal parts in an approved solvent such as trichlorethylene and blow dry Inspection and Replacement Inspect the poppet seating surfaces They must be sharp clean and free of nicks or excessive wear Replace the part if worn or damaged Install new O rings and backup rings Repair kits are available Clean out the channel in piston 8 Fig 9 25 through which fluid passes Make sure the piston moves freely in the relief valve poppet Assembly Lubricate with hydraulic oil and install new O ring 5 Fig 9 25 and backup ring 6 on relief valve poppet 4 Stretch O ring do not roll it to fit Lubricate poppet 4 with hydraulic oil and insert into check valve poppet 7 followed by piston 3 and piston spring 2 Lubricate with hydraulic oil and install new O ring 10 backup ring 11 and O ring 12 on plug 1 Stretch O rings do not roll them to fit Lubricate exterior of plug 1 and insert into poppet 7 9 47 Fig 9 25 COHDNOARWNM gt Section 9 Hydraulic System MAO661 Plug Pilot Spring Piston Relief Valve Poppet O ring Backup Ring Check Valve Poppet Housing O ring O ring Backup Ring O ring Pilot Poppet Pilot Spring Adjustment Screw O ring Jam Nut O ring Acorn Nut Relief Valve Exploded View Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Insert
322. l before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 6 Tag disconnect and plug the hydraulic supply hose 1 at the connector 2 Wire or otherwise secure the hose to the frame to hold it up and prevent oil from draining out of the reservoir Cap the connector 7 Tag disconnect and plug the pump outlet hose 3 at the elbow 4 Cap the elbow 8 Have an assistant support the pump and motor assembly while removing two capscrews 5 and lock washers 6 and remove from the forklift MA0841 Fig 9 44 Steer and Emergency Brake Pump and Motor S N 7P0013 and Before 9 67 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System b Disassembly 1 Remove connector 2 Fig 9 44 and elbow 4 from the pump 13 if necessary 2 Disconnect black electric terminal cable 7 from the solenoid cable terminal and the motor power terminal 3 Remove solenoid 10 from motor 15 by removing two screws 8 and washers 9 NOTE Normally the pump and motor assembly is replaced as a complete unit If the unit is under warranty do not disassemble further refer the unit to your JLG authorized dealer The pump 2 and motor 1 can be separated by removing four screws 11 and washers 12 c Cleaning and Drying Without submerging the motor 15 Fig 9 44 in the cleaning solvent clean the pump and motor assembly in an approved cleaning solvent and blow dry
323. l cap 2 Remove spool end 3 spring seat 4 spring 5 spring end 4 wiper 6 and O ring 7 Remove two round head machine screws 10 seal plate 9 wiper 6 and O ring 7 Cleaning and Drying Clean all metal parts in an approved solvent such as trichlorethylene and blow dry 1 Inspection and Replacement Inspect spool seating surfaces They must be sharp clean and free of nicks or excessive wear Replace entire section if worn or damaged Replace all O rings and backup rings with new ones Repair kits are available Make sure the piston moves freely in valve section Assembly Insert spool in the linkage end of the section IMPORTANT Take care during insertion to avoid damaging the valve s internal lands 2 Install O ring 7 Fig 9 27 wiper 6 and seal plate 9 and secure with two round head screws 10 9 49 ONDARON Section 9 Hydraulic System MA0681 Hex Socket Capscrew 2 Spool Cap Spool End Spring Seat Spring Wiper O ring Section Body with Spool body and spool supplied only as a complete assembly Seal Plate 0 Round Head Screw 2 Figure 9 27 Valve Section Exploded View Install O ring 7 spool end 3 spool cap 2 and secure with socket head capscrews 1 Main Control Valve Installation Position the main control valve 6 Fig 9 23 on the forklift and secure it to frame using capscrews 5 locknuts 3 and washers 4
324. l pressure sender 2 Connect wire to terminal of low oil pressure sender 3 Connect negative cable 2 Fig 10 38 to batteries 4 Start engine and inspect installation for oil leaks 5 Close and lock right engine access door a ENGINE COOLANT HIGH TEMPERATURE SENDER MA1291 Fig 10 49 Engine Coolant High Temperature Sender 10 43 Section 10 Electrical System 10 8 6 Engine Coolant High Temperature Sender The engine coolant temperature light warns the operator to discontinue forklift operation immedi ately when engine coolant is too hot When ignition switch is in RUN position current through the bulb can be grounded through the coolant high temperature sender The sender closes when the coolant temperature exceeds 210 F 99 C and the bulb lights a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Unlock and open right engine access door IMPORTANT Drain engine coolant below the level of the high temperature sender Fig 10 49 3 Tag and disconnect wire from high tempera ture sender terminal Fig 10 49 4 Remove high temperature sender b Disassembly Do not disassemble high temperature sender c Cleaning and Drying Without submerging the sender clean the sender as required by using a fiber bristle brush and an approved cooling system cleaner d Inspection and Replacement Test the sender by connecting a low voltage dc power
325. lag Replace hourmeter if See para 10 8 3 Inaccurate wheel defective Model 6036 S N 9B0499 and Before 10 73 Section 10 Electrical System Trouble Probable Cause Remedy Reference Gauges and Indicator Lights WARNING LIGHTS Bulbs in warning Bulbs are burned out Replace bulbs See para 10 8 4 lights gauge fail to light when test button is pressed No voltage at warning Test switches for continuity See para 10 8 4 lights gauge 51 Fig 10 5 under the appropriate thru 10 8 8 loose or broken wiring or conditions and replace as circuit breaker 12 doesn t required reset Defective sender switches Replace switches See para 10 8 5 thru 10 8 8 Bulbs in warning Defective test switch 47 Check test switch for See para 10 8 4 lights gauge light Fig 10 5 continuity and replace switch continuously if closed in the released when ignition key position switch is in RUN position Short circuit in wiring Determine and repair the cause of the short circuit Defective sender switches Test switches for continuity See para 10 8 5 under the appropriate thru 10 8 8 conditions and replace as required Gauges and Indicator Lights ENGINE LOW OIL PRESSURE SWITCH Oil Pressure If the oil level and oil pressure If there are no shorts to See para Indicator does not are good and voltage is zero ground install a new oil go out when the at wire 16 Fig 10 5 check for pressure switch
326. lcrank and remove the swivel with cable from the lever Remove the swivel from end of each cable Remove the transmission cover Remove the cotter pin and washer Fig 4 4 that attach the cable connecting the swivel to the bellcrank and remove the swivel with cable from the bellcrank Remove the swivel from the cable by turning it counterclockwise Installation Thread jam nut and swivel on rod end as shown and connect swivel to bellcrank using a washer and a cotter pin Fig 4 4 Tighten jam nut Place travel and range select levers in their middle positions N and 2 With transmission spools in center position install clamp into groove on cable and secure clamp to bracket CLAMP RANGE SELECT CONTROL CABLE TRAVEL SELECT CONTROL CABLE MAO151 Fig 4 4 Transmission Control Valve Cable Model 6036 S N 9B0499 and Before 4 3 Section 4 Operator s Cab JOYSTICK ASSEMBLY __ CABLE BUSHING SLIDER LOCK SCREW CONTROL CABLES MA0161 Fig 4 5 Joystick Assembly With Covers Removed 5 Assemble the other end of each cable Fig 4 3 by installing the swivel on the cable by turning it clockwise Position each swivel so it lines up with the hole in each bellcrank 6 Install the swivel by using a washer and a cotter pin Clamp the cable to the angle bracket Install the transmission cover and lower panel CONTROL CABLE Boom Hoist JAM NUT SPOOL 4 2 3 Boom Control and Grille and Fram
327. ld the side flange down with the hooked end of a bead unseating tool and remove the O ring from the O ring groove 6 Remove the side flange Turn tire and rim over and unseat second bead by inserting both bead unseating tools between the bead and rim flange as in step 3 Repeat step 3 until the tire bead is completely broken loose from the rim on the fixed flange side Lift rim base out of tire 7 Refer to paragraph 5 1 11 for tire mounting instructions Model 6036 6036T S N 9B0499 and Before 5 1 5 Demounting Optional Tire from Single Piece Wheel IMPORTANT Always completely deflate tire as described in paragraph 5 1 1 before you attempt to demount a tire 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 Place the wheel and tire assembly on the floor on blocks with the narrow ledge on the bottom Fig 5 3 NOTE A mechanical bead unseating and seating tool may be purchased from the lowa Mold Tooling Company to facilitate step 3 3 After deflating tire as described in paragraph 5 1 1 drive the hooked ends of two bead unseating tools between tire bead and rim flange about 5 130 mm apart be careful that you don t damage the tire bead area Pry both tools down and out Leave one tool in position and place the second about 5 130 mm beyond Repeat the operation slowly in successive steps until tire bead is completely unseated 4 Turn the tire and wheel o
328. le tool to the gland in order to compress the O ring 6 on the gland Insert the assembled piston rod and gland into the tube 1 Using a pin spanner wrench thread the gland into the tube Remove the compression tool IMPORTANT When sliding the rod and piston assembly into the tube be careful so that gland threads in the tube do not damage the piston seal Keep the rod in line with the tube barrel to prevent binding 11 Install new O rings 16 and backup rings 17 on the counterbalance valve 13 Use new valve if the valve was removed for replace ment Lubricate outside of the valve with clean filtered hydraulic oil Install the valve and torque to 45 lb ft 61 2N m 12 If removed install grease fittings 14 and 15 13 Following reassembly test the cylinder at low operating pressure 100 psi or 6 8 bar to be sure the piston and rod are moving freely in both directions 14 Increase the operating pressure to the maxi mum 4000 psi or 275 6 bar for the cylinder 9 35 Section 9 Hydraulic System and check for external leakage and free movement in both directions 15 Prepare the cylinder for installation by retract ing the piston and capping and plugging the ports f Installation 1 Lubricate the rod end pin with a good grade of multi purpose lithium based grease 2 Using a suitable lifting device install the grille tilt cylinder Fig 9 9 on the forklift securing the tube end to the gooseneck F
329. lunger 10 and spring replace the entire brake valve 12 from housing bore Retaining Ring Boot Piston Shims as required Spring Spring O ring Retaining Ring Washer Plunger Spring Housing O ring 7 a ae Valve and Ball Assembly 6 O ring 2 Guide ye Spring 5 y O 1 Sleeve Washer Cup 4 Backup Ring O Plug MA0701 Fig 9 29 Brake Valve Exploded View Model 6036 S N 9B0499 and Before Section 9 Hydraulic System REAR SERVICE BRAKES PRESSURE REDUCING VALVE 4 3 RESERVOIR _ p AQ F PARK LOCK RELEASE 4 VALVE FRONT SERVICE SERVICE BRAKES BRAKE 3 VALVE a MACHINE FRONT S N 8L0333 AND BEFORE 4 Q a 3 lt y A K 5 FRONT G 2 SERVICE Ta SERVICE BRAKES Poa BRAKE ee VALVE MACHINE FRONT Cap Used on Forklifts with Only Front Service Brakes ial Bulkhead Tee Connector Hydraulic Hose PON gt Fig 9 30 Brake Circuits With Park Lock and Two or Four Wheel Service Brakes Model 6036 S N 9B0499 and Before 9 52 Section 9 Hydraulic System 2 Remove small scratches in the bore using g Bleeding the Brake Lines emery cloth of very fine grit Use the emery cloth with a rotary motion Bleed the brake lines very carefully as soon as the brake valve is installed in the machine Air in the e Assembly system will not allow the brakes to release prop erly and may severely damage them Bleed the brakes whenever there is reason to su
330. mbly Model 6036 S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle PA1360 1 Differential Carrier Assembly includes 23 Screw differential bearing cap 4 nems A ihe 40 24 Washer differential bearing cap 4 2 Ring adjusting 2 25 Bolt hex 2 3 Cup roller bearing 2 26 Washer flat 2 Cone TONS bearing 2 27 Clip adjusting ring 2 5 Screw differential 12 28 Screw hex hd cap 14 6 Differential Case Assembly includes 29 Washer flat 14 items 7 thru 13 30 Spacer flat 7 Washer thrust 2 31 Shim adjusting AR 8 Gear differential side 2 32 Cup roller bearing 2 Washer pinion thrust 4 33 Cone roller bearing Gear pinion 4 34 Washer bearing thrust 11 Shaft differential 35 Seal oil 1 Case Ona ey 36 End yoke assembly includes items 37 and 38 13 Pin pinion bearing cage 37 Deflector 14 Gear and Pinion Assembly 38 End Yoke 15 Cone roller bearing 39 Washer pinion nut 16 Cup roller bearing AO Nut pinion 17 Shim bevel pinion bearing 0 003 AR 18 Shim bevel pinion bearing 0 005 AR 19 Shim bevel pinion bearing 0 010 AR 41 Housing axle 42 Fitting grease 2 43 Bushing axle pivot 2 20 Carrier Assembly includes items 21 thru 24 44 Pin dowel 2 21 Carrier i oe 22 Cap differential carrier 2 ee pipe lt 2 Fig 5 15 Front Axle Differential Carrier Assembly Model 6036 S N 9B0499 and Before 5 24 Section 5 Wheel As
331. mbly NOTE Follow general assembly instructions in paragraph 9 2c 1 If bearing 7 Fig 9 21 was removed for replacement press new bearing into eye of tube 1 The bearing should protrude the same distance from each side of the eye 2 Install new O ring 10 backup ring 11 wiper 9 and rod seal 8 on gland 4 as shown in Fig 9 21 NOTE The wiper lip should be toward the inner end of the gland and the rod seal toward the outer end of the gland Use tools that will not damage the seal If the backup ring is not flat on both sides the side with the arc must be toward the O ring 3 Fasten the rod eye in a soft jawed vise or other acceptable holding device Puta padded support below and near the end of the rod to prevent damage to the rod 4 Push the assembled gland onto the rod 5 If necessary use a soft hammer to drive the gland onto the rod 5 Install a new O ring 12 on the inside of the piston Carefully install piston 3 on the rod to avoid damage to O ring 6 Apply Loctite Primer T and Threadlocker 271 to the nut 2 in accordance with the manufac turer s instructions Install the nut on the rod and torque to 400 to 450 Ib ft 544 to 612 N m Stake the nut in four places Install new piston seal 13 on the piston Fasten the cylinder tube 3 in a soft jawed vise or other acceptable holding equipment Be careful not to damage the tube 9 Lubricate the inside of the tube piston and
332. mended for the applica tion Some service operations require the use of tools specifically designed for the purpose Use the special tools when and as recom mended Hammering on end yokes or flanges to remove or install them is not only destructive to the yoke or flange itself but can also cause serious internal damage Hammering on end yokes can close the bearing bores or misalign yoke lugs and result in early failures of journal needle bearings or other driveline compo nents Serious damage can also be done internally to the ring and pinion set or pinion bearings by hammering on external parts Remove and install end yokes by following recommended procedures e Do not reuse oil or grease seals CLEANING Clean parts with machined or ground surfaces such as gears bearings and shafts with emulsion cleaners or petroleum based cleaners Steam cleaning of internal components and the interior of the planetary hub and axle housing is not recommended Water can cause corrosion of critical parts Rust contamination in the lubricant can cause gear and bearing failure Clean all surfaces of old gasket material DRYING Use clean lint free towels to dry compo nents after cleaning DO NOT dry bearings by spinning with compressed air This can damage mating surfaces due to lack of lubrication After drying lightly coat components with oil or rust preventive to protect them from corrosion If components are to be stored for a prolonged p
333. mensions given must be applied in such a way that after servicing preventive maintenance or repairing the engine it does not contravene the local regulations when in use Model 6036 S N 9B0499 and Before contain asbestos Breathing asbestos dust is dangerous to health and may cause seri ous bodily harm Avoid creating dust and follow local directives for handling and dis posing of materials which contain asbestos Disconnect negative battery terminals before repairing electrical system Only one person must be in control of en gine forklift brakes must work Make only adjustments you understand Section 8 Engine IMPORTANT These instructions cover only the routine maintenance of the engine Refer to your Perkins Engine Distributor for engine diagnosis repair and component replacement A gradual running in of a new engine is not necessary Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F 60 C Extended light load operation during the early life of the engine is not recommended Do not run engine at high no load speeds Do not apply an overload to the engine Standard Maintenance Practices It is assumed that gaskets will be replaced and gasket faces will be cleaned where applicable It is understood that in reassembly and inspection all parts are to be thoroughly cleaned and where present burrs and scale are to be remove
334. ment A preset locates the home position for each mirror When you swing a mirror outward a detent locks the mirror in your preset viewing position This reduces the need for frequent mirror adjust ment You can swing the mirror assembly inboard to reduce overall vehicle width for parking in tight areas the mirror will also pivot inboard upon impact Adjust mirror preset as follows IMPORTANT Before attempting to reposition a mirror on a forklift which has just been received from the factory loosen the bottom nuts to permit loop and mirror adjustment MA1460 Fig 4 10 Position Loop 90 from Side of Forklift 1 Position the loops so they extend from the side of the forklift Fig 4 10 2 Adjust mirror heads for proper view Evaluate view from operator s seat change loop angle and readjust each mirror if necessary PIVOT BOLT 3 16 5 mm GAP yy TENSION WASHER I 7s Ba 4 at LOCK PINS LOCKPLATE BOTTOM NUT MA1470 Fig 4 11 Tighten Pivot Bolt to Provide a 3 16 5 mm Gap 4 8 3 Tighten preset pivot bolt to a 3 16 5 mm gap as shown in Fig 4 11 e PIVOT BOLT 7 Loop RETAINING CAP LockPLATE LOCK WASHER ___ TUBING SUPPORT TA Pa BRACKETS FLAT WASHER Sa BOTTOM NUT Fig 4 12 Tighten Bottom Nut While Holding Pivot Bolt Stationary MA1480 4 Be sure
335. n brake switch pedal is pressed Momentary brake Momentary brake switch Replace momentary brake See para bulbs remain ON 9 is closed when brake switch when brake pedal pedal is released Is released Short in wiring Remedy cause of short See para Optional Light Circuit HEADLIGHT AND REAR WORK LIGHT SWITCH One headlight or Loose connection Secure connections to See para rear work light is headlight including ground inoperative or wire black wire Intermittent Defective sealed beam Replace sealed beam unit See para unit One or more Open ground connection at Repair black wire connection See para headlights are headlight between sealed beam and dim body ground Black wire mislocated in Relocate black wire in See para headlight connector three connector wire hi lo connector only One or more Charge circuit problem Refer to charge circuit See para headlights have a troubleshooting short life Model 6036 S N 9B0499 and Before 10 77 Section 10 Electrical System Trouble Probable Cause Remedy Reference Optional Light Circuiit HEADLIGHT AND REAR WORK LIGHT SWITCH cont d All lights are inoperative or intermittent Tripped circuit breaker Loose connection Open wiring from light switch to battery Short to ground in circuit between light switch and lights 5 Defective light switch Determine cause of overload See para 10 4 and reset
336. n place Fig 3 16b and move aside to gain access to the lower capscrews and hose clamps Inner boom hose Pull hoses through hose clamps and capscrews clamps 1 further to tension hoses lt 180 Hose must have a S minimum of 180 A iksodo contact with pulley Fig 3 16a Cylinder Hose Tensioning Upper set of hose Pull hoses through hose clamps and capscrews clamps 1 further to tension hoses lt I 180 Lower set of hose clamps and stacking capscrews Hose must have a minimum of 180 of contact with pulley MA6050 When vehicle has auxilliary hydraulics option remove upper clamps in stack and tension lower hoses first and then tension top hoses Fig 3 16b Cylinder Hose Tensioning Model 6036 S N 9B0499 and Before 4 Loosen capscrews securing the hose clamps to the inner boom Fig 3 16a or Fig 3 16b 5 Manually remove all hose slack between the pulley and the inner boom hose clamps and the pulley and the outer boom tubes Pull the hoses through the hose clamps towards the front of the boom until there is 180 of hose in contact with the pulley 6 Pull the hoses 1 further into the hose clamps so the hose achieves more than 180 of contact with the pulley and at the same time tighten the clamp capscrews 7 Ifthe vehicle has auxilliary hydraulics replace the upper hoses and clamps onto the lower hose clamps Do not fully tighten the cap screws Repeat steps 4 through 6 for
337. nd install new gaskets 5 Position new filter element between base and head and install hex screw to secure parts 6 Remove air from the fuel system See paragraph 8 4 8 How to Bleed to Fuel Sys tem a Fuel Filter Removal 1 Disconnect lines from fuel pump to fuel injection pump from fuel injection pump to Thermo Start from fuel pipe and to fuel tank 2 Support fuel filter with one hand and remove capscrews and lock washers that secure fuel filter and bracket to engine 3 Remove filter from engine Hold filter upright until you pour fuel oil from filter into an ap proved container Dispose of the fuel in an approved manner b Disassembly Remove hex screw in top of filter Fig 8 9 remove filter base and discard element c Cleaning and Drying Clean the filter using an approved solvent and dry with a clean lint free cloth d Assembly Position new filter element between base and head and install hex screw to secure parts e Installation 1 Support fuel filter with one hand and install capscrews and lock washers that secure fuel filter and bracket to engine 2 Connect lines from fuel pump to fuel injection pump from fuel injection pump to Thermo Start from fuel pipe and to fuel tank Model 6036 S N 9B0499 and Before Fuel Injection Pump Sleeve Seal Wire Gasket Stud 3 Nut 3 Washer 3 Washer 3 Injection Pipe for No 1 Cylinder Injection Pipe for No 2 Cyli
338. nd Before c Testing The service brakes should be tested whenever repairs or adjustments are made to components of the circuit 1 Start the engine park the forklift on level ground and level the frame 2 Check for signs of leakage of hydraulic oil from circuit hoses and other components Correct any leakage problem before testing 3 Bleed the brake system as described in paragraph 9 3 2 if necessary 4 Drive the unloaded forklift down a paved road at road speed in third gear approximately 11 5 mph 5 Apply the service brakes The forklift should stop within 15 feet Repeat steps 4 and 5 to recheck performance Park the forklift on level ground and engage the park lock 8 Place the range select lever in 2nd gear With the service brakes applied the forklift should not move when the park lock is disengaged in either forward or reverse 9 If the service brakes do not meet performance requirements locate the cause of the problem and correct before putting the vehicle into service The park lock should be tested whenever repairs or adjustments are made to park lock components 1 Start the engine park the forklift on level ground and level the frame 2 With the park lock engaged place range select lever in 2nd gear and travel select lever in F forward The vehicle should not move when full throttle is applied 3 With the park lock engaged place range select lever in 2nd gear and travel s
339. nd Before Section 4 Operator s Cab BRAKE VALVE PUSH ROD JAM NUT Lee BRAKE VALVE SPRING SHAFT ADJUSTING NUT STOP SCREW CLEVIS PIN PEDAL Set stop screw for 2 51 mm clearance from wall with pedal released and 1 2 13 mm minimum clearance from wall with pedal depressed MAO181 Fig 4 7 Service Brake Pedal 4 3 MECHANICAL FOOT CONTROLS 4 3 1 Service Brake Pedal When you press the service brake pedal you activate a brake valve that applies the hydraulic service brakes The service brake pedal pivots on a shaft and is held in the raised position by a spring a Removal 1 Remove the lower panel below the control console 2 Remove the cotter pins and clevis Fig 4 7 that secures the brake valve yoke to the brake pedal NOTE Brake valve push rod will slip out of brake valve at this point Remove push rod with yoke attached 3 Remove the spring from the pedal 4 Remove one capscrew washer and nut that attaches pedal shaft to mounting frame Slide shaft out of pedal and remove pedal and flat washers b Installation 1 Lubricate the shaft Fig 4 7 with multi purpose lithium based grease Install shaft through mounting frame flat washer pedal flat washer and mounting frame Secure in place with capscrew and nut 4 5 Section 4 Operator s Cab LIMIT STOP SCREW ee LOCKNUT ___ WASHER CLAMP CABLE SUPPORT THROTTLE CABLE SPRING CAB
340. nd in good working order Always use the Special Service Tools recommended 1 5 GENERAL CONSIDERATIONS Item What to do Many cuts abrasions and or injuries are caused by defective or improper tools Well maintained tools work better and may prevent injury These tools will reduce the work labor and costs Why Solvents Housekeeping First Aid Cleanliness Use only approved cleaning fluids and solvents that are known to be safe Clean and remove all hazards from the area Do not overlook any cut abrasion or burn Have it cleaned and dressed properly Make sure you know the location of the First Aid Box Plug all hose ends and connections when removing components Clean exterior of all parts before repairing A high pres sure or steam cleaner is recommended Always wear eye protection when steam cleaning 1 6 OPERATIONAL CONSIDERATIONS Item What to do Certain types of fluid cause damage to components and may cause skin irritation To prevent accidents and injuries What appears at first trivial could become painful and injurious Quick application of first aid procedures To prevent dirt and foreign material from entering the system Dirt and abrasive dust can reduce the efficiency and working life of a component and lead to costly replacement Permanent eye damage can be caused if foreign matter enters the eye Why Engine Dangerous Start Stop the engin
341. nder S20 ONO OE ON O Model 6036 S N 9B0499 and Before Injection Pipe for No 3 Cylinder Injection Pipe for No 4 Cylinder Bridle 4 Plate 4 Screw 2 Nut 2 Atomizer 4 Holder Nozzle Washer 4 Pipe Fig 8 22 Fuel Injection Pump Section 8 Engine MA0361 Union Nut Ball Bolt 4 Washer 8 Gear Dowel Fuel Pipe Spacer 4 Seal 4 Screw 8 Fuel Run Solenoid 8 15 Section 8 Engine 8 4 7 Fuel Injection Pump The fuel injection pump Fig 8 22 is a distributor type pump with a mechanical flyweight type governor The pump is flange mounted and is driven from the engine timing case IMPORTANT Unless the necessary equipment and experienced personnel are available disman tling of the fuel injection pump should not be attempted a Fuel Injection Pump Removal IMPORTANT Instructions and specifications in the Perkins Workshop Manual for the Perkins 4 236 Series Engine are required for fuel injection pump installation Do not remove pump from engine unless you have this information which is essential to correct fuel injection pump installation 1 Remove the high and low pressure pipes from the fuel pump 2 Disconnect the stop and throttle controls and remove return springs Disconnect wiring to the fuel run solenoid Remove the timing case front cover inspection plate 5 Remove the three screws which secure the fuel pump gear to th
342. ndicates alternator is not charging Transmission Oil Temperature Indicates high transmission Oil oaozso Temperature Fig 10 48 Warning Lights Signal Dangerous Operating Conditions 10 8 4 Warning Lights Warning lamps indicate e low engine oil pressure e high engine coolant temperature e alternator is not charging e and high transmission oil temperature When ignition key is turned to RUN engine low oil pressure and alternator charge lamps will light This is normal When engine is running all lights should be OFF If a lamp lights an emergency condition exists stop forklift as soon as possible and correct the indicated condition At the right of the gauges is a warning bulb test button With ignition key in RUN position and engine OFF press this button to test all four warning lights If a bulb fails to light replace it immediately You will find the bulb number in the Specifications Table at the end of this section a How to Test the Warning Light Gauge Bulb Test Switch 1 Prepare to test the bulb test switch 10 Fig 10 47 by disconnecting the wiring at switch 10 42 2 Use an ohmmeter or a continuity tester to test switch for continuity in the depressed TEST position and for a short in the released OFF position Replace the switch if it fails the test in step 2 b How to Replace Bulbs in Warning Light Gauge 1 Turn ignition key to RUN and press bulb test button Fig 10 48 Note wh
343. ne has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns Remove the transmission cover from the frame Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar at the 30 gpm section outlet of the tandem pump Fig 9 5 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift Start the engine Operate the frame tilt control several times to purge the system of air Allow engine to run at idle Place the fork and frame control lever in the right position and hold until the frame tilt cylinder bottoms out Continue holding the lever in the right position until the pressure readings are taken Check the pressure gauge reading It should read 1200 50 psi 82 7 3 4 bar If not adjust the frame tilt right relief valve Fig 9 2 9 13 Section 9 Hydraulic System turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m after adjustment 8 Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 9 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 10 Start the engine Operate t
344. neutral the starter pinion engages the flywheel to start the engine If the key binds in the lock check for a sticky painted or bent key If key is sticky clean key If key is painted remove paint If key is bent straighten key If the key is straight and usable sprinkle some powdered graphite on the sides of the key and insert key in lock several times to distribute the graphite If the lock should fail to accept key or fail to turn due to freezing tempera tures warm the key switch using a hair dryer or use a liquid lock deicer to lower the freezing point and evaporate the moisture within the lock IMPORTANT Use only graphite or a liquid lock deicer within the lock Severe lock malfunctions may require the services of a locksmith a Removal 1 Prepare to remove ignition switch by removing lower panel 7 Fig 10 40 next to the switch 1 Seal Cap 4 Seal Cap 2 Horn Button 5 Steering Select Switch 3 Washer Wiper Switch 6 Capscrew hex hd 10 34 2 Disconnect negative cable 2 Fig 10 38 from the batteries 3 Remove the hex nut which secures the switch to the console 4 Carefully tilt the switch as required to reposition switch in lower panel opening 5 Tag and disconnect the wires from the switch b Disassembly Do not disassemble the ignition switch c Cleaning and Drying Without submerging the switch clean the exterior of the switch with an approved solvent and dry with a Clean lint f
345. new plugs are being installed coat threads with Loctite Threadlocker 242 5 If removed install new dowels 5 as needed Be sure dowel holes are clean and free of burrs Gently tap in new dowels with a soft hammer Assembly of bushings in shaft end cover 16 bearing carrier housing 13 and port end cover 4 a Install any new bushings in drive bores with groove to top of unit 12 o clock Assemble bushings in driven bores with the groove to bottom of unit 6 o clock b Press bushings into the bores one at a time using the special installation tool Fig 9 40 and an arbor press Be sure the grooves are positioned as stated in step 6a Bushings must be pressed into the bores flush with the casting face Be sure to support the castings so they are square and level c Repeat Steps 1 and 3 stone and rinse parts Before inserting a new lip seal 17 in the shaft end cover 16 coat the outer edge of the lip seal and its recess with Permatex Aviation Form A Gasket No 3 non hardening sealant or equivalent With the metal side of the lip seal up press it into the mounting flange side of the shaft end cover with an arbor press and special installation bar paragraph 9 4 2b Be careful not to damage the lip of the seal Press in until flush with the recess Wipe off excess sealant Lubricate new gasket seals 11 and insert them into the grooves in both sides of all gear housings Position the first gear h
346. ning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns Section 9 Hydraulic System 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar in the tandem pump outlet of the 30 gpm section Fig 9 3 5 Start the engine Extend and retract the boom several times to purge the system of air 6 Depress the accelerator to full throttle Place the joystick in the retract position and hold until the extend cylinder has fully retracted Continue holding the joystick in the retract position until the pressure readings are taken 7 Check the pressure gauge reading It should read 2650 50 psi 182 6 3 4 bar If not adjust the boom retract port relief valve Fig 9 2 by turning the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m after adjustment 8 Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 9 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 10 Start the engine Extend and retract the boom fully several times to purge the system of air 11 Install the transmission cover after adjustment c Testing The boom extend retract circuit should be test
347. nkage and lubricate or free up as required Disassemble control valve and replace broken parts para 9 3 1 Inspect valve body and spool and replace valve section if scored para 9 3 1 Disassemble valve and replace broken spring para 9 3 1 Clean and lubricate the linkage and make sure it operates freely Disassemble and clean control valve thoroughly par 9 3 1 Check all joints for faulty connections Replace applicable valve section 9 76 Section 9 Hydraulic System oO ice oO 1 eS OS Ee Se a a a 68 6Z E Pasiney I La SLO WHOS H3S avo INVA S YOLVYHSdO 3ONaNOAS 27 g UNN Oo ONIHSSIS anv amp o YSGNMAO LSIOH 1437 fra IEE I E a z S a i 2 Y de ox So So SO Ss SATA a I asvaisy D ot 27 i MOOT MW gt EE eee ee em mz Nn _ reuondo rs A9 ava x Wo avag E NAA anna 1N H4 1437 gt YY34 IIIT Amm Siva f LJ AONSOYSWA rs 3 ONIUSSLS BF Re ee ag epee ee ei ime in ge me Rr A ep A eo So i 13 4331S x lt q O a fa i t E C _ z E ll ame 5 So 2 niLa L 0 oO ofd in AD 42s aul o uL au puexal isioH oa 2 J puea eis woog woog Ld ar D o o o o LP an gE jeuondo _ YI0AH3S3H BS Bm ho DIVAA OMAVYGAH nig ata 2 53 e LNO 4 LH9IH gt jot YVSY THO Fg 5 29 O p YSGNITAD o 3WIS Q O CD e ISd 099Z 2 gt d P S
348. nner yoke right Deflector seal Seal oil Bushing spindle Knuckle Assembly Stud dowel 14 15 16 17 18 19 Locknut Washer flat Fitting grease Capscrew Washer flat Cap king pin Fig 5 10 Axle Steering Joints 20 21 22 23 24 25 26 PA0312 Shim formed Shim formed Seal oil Cone roller bearing Cup roller bearing Retainer grease Housing axle Section 5 Wheel Assembly Tires and Axle a Disassembly 5 Tap the spindle with a soft faced hammer to 1 Refer to page 13 through 16 of Spicer Dana Maintenance Manual for Axle Models PS PR Remove espindleassembly loosen the knuckle assembly 12 Fig 5 10 7036 for removing and disassembling the drive 6 Replace oil seal or bronze bushing 42 Fig flange and wheel end hub 5 8 or 31 Fig 5 9 in the spindle bore 2 Onan axle with service brakes 7 Holding shaft and joint assembly 1 Fig 5 10 a Remove lining stop plates 14 and 17 Fig 5 8 and disc assemblies 18 b Remove retainer screws 25 and plane tary ring gear 31 piston 19 and retainer 29 as a unit 9 Remove retaining rings 5 from the housing yoke bore level pull the assembly straight out to avoid damaging inner shaft oil seal 10 8 Remove oil seal 10 and spindle bushing 11 c Remove hub assembly 33 10 Press out bearing race assemblies 4 and 3 Onan axle without service brakes a Support the hub assembly wit
349. noid The 3 way 2 position park lock release valve solenoid is threaded into the park lock release valve The valve is located under the cab on the valve plate assembly a 1 Removal Engage the PARK LOCK place the travel select lever in NEUTRAL and turn ignition switch to OFF Model 6036 S N 9B0499 and Before Section 10 Electrical System Jam Nut 1 Name Plate va Park Lock Release Valve Solenoid ty Pai Valve Core Tee Run Connector Connector Hex Nut Lock Washer 10 Flat Washer 11 Capscrew 12 Valve Plate Assembly on mwm oND A MA1252 MA1251 Fig 10 44 Park Lock Release Valve Solenoid 2 Disconnect negative cable 2 Fig 10 38 from the batteries Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 3 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before serv icing any hydraulic component Hot hydraulic fluid can cause severe burns 4 Disconnect and tag the two wires attached to the solenoid valve 5 Remove the jam nut 1 Fig 10 44 and name plate 2 from the end of the solenoid valve 10 37 Section 10 Electrical System REVERSE SWITCH MA1261 1 Cotter Pin 4 Lock Washer 7 Spacer 2 Washer 5 Was
350. not visible and the center of the hydrometer has a DARK appearance it means the battery must be charged before the test procedure is performed In charging the appearance of the green dot means that the battery is sufficiently charged Charging can be stopped to prevent overcharging The hydrometer on some batteries may be CLEAR or light yellow refer to Fig 10 37 This means the fluid level may be below the bottom of the rod and attached cage This may have been caused by excessive or prolonged charging a broken case excessive tipping or normal battery wear out IMPORTANT Whenever this clear or light yellow appearance is present when looking straight down on the hydrometer always tap the hydrometer lightly with a small screwdriver to dislodge any gas bubbles that may be giving a false indication of low electrolyte level If the clear or light yellow appear ance remains and if a cranking complaint exists that is caused by the battery replace the battery Complete hydrometer information is printed on a label on top of the battery Refer to this label to accurately interpret hydrometer appearance d Battery LoadTest 1 Remove cable clamps and be sure parts are clean for a good connection Model 6036 S N 9B0499 and Before Minimum Voltage Section 10 Electrical System Relation of Battery Temperature to Minimum Voltage Temperature 21 C 1 C 70 F amp 30 F Above Attach voltmeter and battery load tester
351. ns replace if defective Charging System GENERAL Visual Check Check for loose or corroded connections Check the condition and adjustment of the alternator belts Check the condition of the batteries Check for voltage at the terminals on the alternator Repair as necessary Install a new set of drive belts if necessary refer to paragraph 8 1 2 for belt adjustment instructions Refer to Charging System Batteries Refer to paragraph 10 6 1 b for alternator troubleshooting procedures Charging System ALTERNATOR Noise coming Damaged or worn drive from the belt alternator Damaged or loose pulley on the alternator Worn or damaged bearings in the alternator Model 6036 S N 9B0499 and Before Install new drive belt Remove the pulley and check for damage to the rotor shaft and pulley install new parts as required Disassemble the alternator and replace bearings as required See para See para See para See para See para See para See para See para 10 6 See para 8 1 2 and 10 6 1 See para 10 6 2 See para 10 6 1 b See para 8 1 2 and 10 6 1 See para 8 1 2 and 10 6 1 See para 10 6 1 10 69 Section 10 Electrical System Trouble Probable Cause Remedy Reference Charging System BATTERIES Warning e Wear safety glasses when working near batteries e Keep batteries out of the reach of children e Ne
352. nual Clean or replace suction line and or tighten if loose 9 74 Trouble Probable Cause Section 9 Hydraulic System Remedy Tandem Pump Fails to Deliver Fluid Cylinder Fails to Move When Control Valve is Actuated Cylinder Movement is Jerky Cylinder Movement is Sluggish Cylinder Piston Rod Drifts or Creeps Relief Valve Doesn t Hold Pressure Setting Directional Control Valve Does Not Return 9 75 Fluid viscosity is too heavy to pick up prime Worn broken or stuck parts in pump Faulty hose Damaged cylinder Defective main control valve Air trapped in cylinder or in hydraulic line Binding of cylinder rod or piston Rod seal installed improp erly Binding of base end or rod end bearing Defective counterbalance cartridges Hoist cylinders Control valve not fully en gaged Internal leakage or binding in cylinder Worn piston seals Internal leaking in control valve Tube is out of round Spring broken or has taken a set Poppet stuck due to dirt or deposits Excessive clearances be tween valve body and pop pets Check working temperature and service and change fluid in system if necessary Repair tandem pump para 9 4 1 Repair or replace hose Repair or replace cylinder as required para 9 2 Inspect and repair as required para 9 3 1 Inspect fluid for foam and bubbles Check and tighten connections Bleed cylinder and lines as required
353. o that supply pressure is applied through ports F to B Fig 9 7 to the intake side of the power steering unit metering section 2 Ameasured amount of hydraulic oil is ex hausted from the metering section and routed back to the control valve section where it is channeled through ports C to D to port J in the steer select valve 3 Both steer select valve solenoids are de energized Oil is channeled through ports J to of the steer select valve to the rod retract end of the right front steering cylinder and the base extend end of the left front steer ing cylinder 4 Return hydraulic oil from the cylinders flows through ports A to E of the power steering control valve section to the return filter and reservoir Left Turn 4 Wheel Steer When a left turn is being made with the steering select switch in 4 wheel steer up position 1 The power steering control valve spool is shifted so that supply pressure is applied through ports F to B Fig 9 7 to the intake side of the power steering unit metering section 2 Ameasured amount of hydraulic oil is ex hausted from the metering section and routed back to the control valve section where it is channeled through ports C to D to port J in the steer select valve Model 6036 S N 9B0499 and Before Section 9 Hydraulic System LEFT REAR STEERING CYLINDER RIGHT REAR STEERING CYLINDER STEER SELECT VALVE l 1 RIGHT FRONT rt STEERING
354. of the axle housing and compare readings If necessary remove tie rod adjust the overall socket to socket length in or out reinstall the tie rod assembly and remeasure Repeat this procedure until equal measurements are attained for zero toe in A zero to 1 2 toe in is acceptable Retorque slotted nuts to 140 Ib ft 190 N m minimum Torque the tie rod clamp assembly bolts and nuts to 60 to 70 Ib ft 81 to 95 N m 5 If repairs were made to or the retracted length of the steering cylinder was inadvertently changed the retracted length of the assembly will require resetting as follows a Remove slotted nuts from and remove rod end socket assemblies from steer knuck les Push in or use air pressure to retract the rod into the barrel assembly of both cylinders b lt Turn steering knuckle to full inside turn position on either right or left hand side c Adjust the socket assembly position in or out on the rod end and also barrel end if required such that its retracted length matches the length required for assembly to its steer knuckle Reconnect the cylinder assembly as described in step 3 Torque the cylinder socket clamp bolts and nuts to 60 to 70 Ib ft 81 to 95N m IMPORTANT Protect the rod from damage while adjusting socket position d Turn the other steer knuckle to its full inside turn position Adjust its steer cylinder retracted as noted in step c 6 Connect the hydraulic hoses to the st
355. of the switch by removing two screws 2 Apply silicon lubricant to the switch lever pivot and mechanical contact areas 3 Replace top cover and two screws f Switch Installation 1 Make sure you disconnect the ground cable 2 Fig 10 38 from the negative terminals of the batteries and remove the flasher during installation and wiring 2 Refer to schematic Fig 10 54 and reconnect the wires Tape ends of unused wires to prevent shorts 4 Mount switch on steering column as shown in Fig 10 57 5 Insert screws into anchors RED PILOT LIGHTDEMERGENCY FLASHER GREEN PILOT LIGHTDRIGHT TURN TO CHANGE PILOT BULB REMOVE TWO SCREWS AND lt TOP COVER SEE FIGURE 10 56 MA1362 Fig 10 57 Directional and Emergency Flasher Switch Removal 10 50 Model 6036 S N 9B0499 and Before 6 Insert assembled anchor screws into slots in switch Do not tighten 7 Bend strap end through and around clip Engage clip between anchor and switch housing 8 Hold switch against steering column in desired position and bend strap around column Scrape paint from column under strap to make ground contact 9 Estimate strap length required and cut if necessary Insert unbent portion of strap through other clip and assemble as in step 7 10 Catch clip under anchor and tighten screws equally until switch is clamped firmly to steering column 11 Replace flasher and connect negative cable to the batteries 10 9 2 Momentar
356. on 2 3 2 9 7 After Engine Servicing 2 5 2 6 PRESSURE TESTING AND 2 9 8 After Boom Servicing 2 5 ADJUSTMENT 2 3 2 9 9 After Axle Servicing 2 5 2 7 TORQUES 2 3 2 10 FLUID LEVELS AND 2 7 1 Fasteners 2 3 LUBRICATION 2 5 2 7 2 Bolts and Nuts 2 3 2 10 1 Wheel Ends 2 5 2 7 3 Flared Fittings 37 steel 2 3 2 10 2 Hydraulic Reservoir 2 6 2 7 4 Straight Thread O ring Fitting 2 10 3 Engine Oil 2 6 non adjustable 2 4 2 10 4 Cooling System 2 6 2 7 5 Straight Thread O ring Fitting 2 10 5 Splines 2 6 adjustable 2 4 2 10 6 Drop Box 2 6 2 8 PAINTING 2 4 2 10 7 Grease Fittings 2 6 2 8 1 Orange Paint 2 4 2 8 2 Black Paint 2 4 2 8 3 White Paint 2 4 2 1 Model 6036 S N 9B0499 and Before Section 2 General Instructions 2 1 INTRODUCTION Appropriate service methods and proper repair procedures are essential for safe reliable opera tion of the forklift and safety of the individual doing the work This Maintenance Manual provides general directions for accomplishing service and repair work with tested effective techniques Following them will assure reliability There are many variations in procedures tech niques tools and parts for servicing vehicles as well as work skills This Manual cannot possibly anticipate all such variations and provide advice or cautions for each one Accordingly anyone who intends to depart from the instructions in this Manual must first consider his safety and the vehicle integrity 2 2 CLEANING Clean the exteri
357. one as a Set DIFFERENTIAL CARRIER ASSEMBLY FRONT AXLE WHEEL END WITH SERVICE BRAKES OR REAR AXLE WHEEL END AXLE STEERING MA0251 Fig 5 6 Axle 5 2 1 Axle a Removal 1 Engage the park lock place the travel select lever in neutral and stop the engine Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 5 12 Section 5 Wheel Assembly Tires and Axle A Warning from the mounting blocks Wait for the hydraulic fluid to cool before servicing any hydraulic component Hot hy draulic fluid can cause severe burns 10 Using the hoist remove the axle from the frame and place it on a support at three points of the housing A suitable holding stand is desirable but not necessary Refer to Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for internal servicing instructions 3 Place adequate support under the frame so that it will remain in place when the axle assembly is removed 4 Remove the wheels from the axle as described b Installation in paragraph 5 1 3 1 Using a suitable hoist remove the axle from its support or stand and position it under the frame so that pivot pin holes are aligned with hole in axle 5 Use floor jacks or install a suitable hoist at the ends of the axle
358. or place the rotor in a vise and tighten only enough to permit removal of the shaft nut 18 Fig 10 28 USE OHMMETER TO CHECK FOR SHORTS AND OPENS MA1121 Fig 10 29 Checking Rotor Winding Model 6036 S N 9B0499 and Before Section 10 Electrical System e Rotor Field Winding Checks 1 To check for opens connect the test lamp or ohmmeter to each slip ring refer to Fig 10 29 If the lamp fails to light or if the ohmmeter reading is high infinite the wind ing is open 2 Connect test lamp or ohmmeter from one slip ring to shaft If lamp lights or if reading is low the rotor winding is grounded not illustrated INSULATING WASHERS RESISTOR USED ON SOME MODELS CAPACITOR Y RECTIFIER BRIDGE ATTACHING NUTS MA1131 Fig 10 30 Inside View of 10 SI End Frame Assembly 12 SI Is Similar 3 Check the winding for short circuits or exces sive resistance by connecting a battery and ammeter in series with the edges of the two slip rings The field current ammeter reading at 80 F 26 7 C should be 4 2 to 5 0 A A reading above this range indicates shorted windings a reading below this range indicates excessive resistance An alternate method is to check the resistance of the field by connect ing an ohmmeter to the two slip rings If the resistance reading is below 2 4 to 2 8 ohms the winding is shorted if above this range the w
359. or engine cold start procedure 1 Check fluid levels 2 Start engine at idle Check for leaks from hydraulic components engine axles trans mission brakes and reservoirs 3 Purge systems of air by operating functions 4 Check for proper operation 5 Retract all cylinders Shutdown and check reservoir levels Recheck levels when oil is cold 6 Replace hydraulic filter if required 2 9 2 After Hydraulic Component Servicing 1 Check torque on fastening hardware of components being replaced 2 Check that hoses are in place and tightly connected 3 Check hydraulic fluid level and replenish as required 4 Start forklift and bleed systems of air 5 Check operation 2 9 3 After Brake System Servicing 1 Check level of TRAK wet disc brake oil in wheel ends and replenish as required 2 Bleed brakes 3 Check wheel end brake pressure 4 Check operation 2 9 4 After Fuel System Servicing 1 Bleed fuel system 2 Fill tank with clean fuel as required 2 5 Section 2 General Instructions 2 9 5 After Replacing Transmission 1 Check transmission fluid level and replenish as required 2 Replace transmission filter 3 Check torque on drive shaft yoke hardware 4 Refer to the Clark Maintenance Manual for Servicing Machine After Transmission Overhaul 2 9 6 After Tire Servicing 1 Check hydrofill mixture air pressure and weight of tire empty and full 2 Check wheel nut torq
360. or of all parts before repairing Dirt and abrasive dust reduce the efficient work life of the part and lead to costly replacement Use cleaning fluids and solvents which are suit able for cleaning parts and do not risk the safety of the user Certain types of fluids damage rubber parts and or cause skin irritation The following precautions must be observed to insure hydraulic cleanliness 1 Flush hose and tube assemblies with a solvent compatible with hose assemblies Blow out excess solvent with shop air 2 Cap hydraulic fittings and protect threads until installation 3 Cap hoses and tube assemblies until installa tion 4 Flush hydraulic reservoir fuel tank and gear housing with a suitable solvent to remove paint metal chips welding shot etc 5 Protect system components from airborne contaminants Plug all cylinder valve reser voir tank and pump openings until in stallation 6 Use clean filtered oil when filling the system 7 System cleanliness level must be a minimum ISO code 18 15 particle ratio count Model 6036 S N 9B0499 and Before 2 3 REPLACEMENT Replace O rings seals and gaskets whenever they are disturbed Never mix new and old seals or O rings regardless of condition Always lubri cate new seals and O rings with hydraulic oil before installation When replacing parts use the correct tool 2 4 HOSES AND TUBES 2 4 1 Inspection 1 Ifthe hose end fittings are damaged always
361. or operate as fast switches Both are accurate and sensitive They do not wear out and cannot be adjusted but because they are sensitive to voltage changes and high temperature the following precautions are vital to prevent them from being destroyed e Disconnect the ground cable first when you disconnect the battery cables from the battery connect the ground cable last when you connect the battery cables to the battery e Always connect POSITIVE TO POSITIVE NEGATIVE TO NEGATIVE e 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 e DO NOT disconnect a lead without first stopping the engine and turning all electrical switches to the OFF position e 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 e DO NOT connect a battery into the system without checking for correct polarity and voltage e DO NOT flash connections to check for current flow No matter how brief the contact the transistors may be ruined e f a battery caused cranking complaint exists with a clear or light yellow indication replace the battery In this case the charging system should be checked refer to charging system instructions in this manual Excessi
362. oreign par ticles 2 Lubricate O ring with light coat of oil 3 Back off locknut as far as possible 4 Screw fitting into the port by hand until the backup washer contacts the face of the port and is pushed all the way towards the locknut 5 To position the fitting unscrew by the required amount but not more than one full turn 6 Hold the fitting in the desired position and torque the locknut as follows SAE Torque Nm 4 14 5 17 5 20 24 6 37 43 50 58 8 75 85 102 115 10 115 125 156 170 12 155 165 210 224 16 225 235 305 319 20 260 280 353 380 24 340 360 461 488 Model 6036 S N 9B0499 and Before 2 8 PAINTING Unless otherwise specified paint all components as follows 2 8 1 Orange Paint Use orange paint on all components except as specified in paragraphs 2 8 2 and 2 8 3 P N 85280338 aaae 1 gallon service paint P N 8528034 naen 16 oz Spray can 2 8 2 Black Paint Use P N 8528036 0 0e 16 oz spray can Boom Angle Indicator Pointer Wheels Brake Pedal Radiator Seat Adaptor Plate Radiator Shroud Transmission Oil Cooler Axles Drive Shafts Drop Box Forks Mirrors and their Brackets Dash Panels Instrument Mounting Plate Air Cleaner Steering Column Joystick Panel Cab Door Handle 2 8 3 White Paint Use P N 8528040 naison 16 oz spray can Boom Extend Cylinder 2 4 2 9 AFTER SERVICE STARTUP AND CHECKS 2 9 1 Starting After Servicing NOTE Refer to Owners Operators Manual f
363. ottle or restricted 44 Choked oil filter movement 45 Piston seizure 24 Exhaust pipe restriction 46 Incorrect piston height 25 Leaking cylinder head gasket 47 Damaged fan 26 Overheating 48 Faulty engine mounting 27 Cold running 49 Incorrectly aligned flywheel 28 Incorrect tappet adjustment housing or flywheel 29 Sticking valves 50 Faulty thermostat 30 Incorrect high pressure pipes 51 Restriction in water jacket 31 Worn cylinder bores 52 Loose fan belt 32 Pitted valves and seats 53 Choked radiator 33 Broken worn or sticking piston 54 Faulty water pump ring s 55 Choked breather pipe 34 Worn valve stems and guides 56 Damaged valve stem oil 35 Overfull air cleaner deflectors if fitted 36 Worn or damaged bearings 57 Coolant level too low 37 Insufficient oil in sump 58 Blocked sump strainer 38 Inaccurate gauge 59 Broken valve spring 39 Oil pump worn 60 Exhauster or vacuum pipe leak 40 Pressure relief valve sticking 61 Turbo impeller damaged or open dirty 41 Pressure relief valve sticking 62 Turbo lubricating oil seal leak closed 63 Induction system leaks 42 Broken relief valve spring 43 Faulty suction pipe turbocharged engines Model 6036 S N 9B0499 and Before This Page Left Blank Intentionally Par CONTENTS Title Section 9 Hydraulic System SECTION 9 HYDRAULIC SYSTEM Page 9 1 9 1 1 9 1 2 9 1 3 9 1 4 9 1 5 9 1 6 9 1 7 9 2 9 2 1 9 2 2 9 2 3 9 2 4 9 2 5 9 2 6 9 2 7
364. ousing 15 over the shaft end cover 16 and dowels Tap it with a soft hammer until it rests tightly against the shaft end cover Be careful not to pinch the gasket seal 8 Also be sure the large rounded core is on the inlet side 10 Assemble new channel seals 7 into the grooves in all the thrust plates 8 with the flat side of the seal facing away from the thrust plate Fig 9 43 11 Gently slip thrust plate 8 with seal 7 through the gear housing and into place on the shaft end cover 16 The channel seal should face the shaft end cover The relief groove in the plate should face the outlet side of the pump 9 65 12 FLAT SIDE Section 9 Hydraulic System Slide the driven gear and shaft through the housing 15 and into the bushing in the shaft end cover 16 Coat the steel sleeve tool Fig 9 41 with hydraulic oil inside and out Place the lightly lubricated drive shaft inside the sleeve and slide both through the shaft end cover with a twisting motion until the integral gear rests against the thrust plate Avoid damaging the double lip seal 17 Squirt clean hydraulic oil over the gears Slip thrust plate 8 with seal 7 over gear journals and into housing bore The flat side of the seal should face up with the relief groove facing the outlet side Position the bearing carrier housing 13 over the gear housing 15 so that the bushings receive the journals of the drive and driven gears
365. ousing personal injury bore 7 Install washer 9 in the housing bore Carefully install retaining ring 8 in housing bore to avoid scratching the housing bore 9 Install new O ring 7 in housing bore 10 Install springs 5 and 6 shim or shims 4 and piston 3 in housing bore 11 Install boot 2 and retaining ring 1 in housing 16 Oe a f Valve Installation 1 Lower brake valve 9 Fig 9 28 into position on the mounting bracket 2 Install capscrews 6 lock washers 5 and jam nuts 4 to secure valve 3 Remove plugs or caps as required and connect the tagged hydraulic lines to the brake BRAKE valve BLEEDER 4 Install lower panel 2 with capscrews and lock T washers 1 after bleeding and checking brake MA0721 system Fig 9 31 Brake Bleeder 9 53 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 3 While holding the tubing firmly on the bleeder open the bleeder with a suitable small wrench Have an assistant depress the brake pedal Close the bleeder when air bubbles no longer appear in the oil Release the brake pedal and remove the tubing from the bleeder 4 Repeat steps 2 and 3 for the brakes on the other wheels 5 Discard the oil which was collected in the container 6 Check level in reservoir and fill as described in the Owners Operators Manual 9 3 3 Park Lock Release Valve a Removal 1 Engage the park lock place the travel selector
366. owering in the last two cycles Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual Test grille tilt circuit operation as described in paragraph 9 1 3c 9 32 9 2 4 Grille Tilt Cylinder a Removal 1 Remove any attachment from the quick attach assembly 2 Tilt the quick attach assembly fully forward and lower it face down to the ground 3 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 4 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns INNER BOOM BASE END PIN GOOSENECK GRILLE TILT ye CYLINDER QUICK ATTACHMENT LOCK PIN ROD END PIN MA0021 Fig 9 14 Grille Tilt Cylinder Gooseneck 9 33 Section 9 Hydraulic System 5 Remove the rod end pin Fig 9 14 and its locking capscrew and locknut securing the grille tilt cylinder rod to the quick attach 6 Start the engine and fully retract grille tilt cylinder 7 Disconnect the hydraulic lines from the cylinder and cap or plug open connections 8 Remove the pin and snap
367. p GAUGES AND S N 7P0013 and Before INDICATOR LIGHTS 10 40 10 13 3 Steering and Removal of the Gauge Cluster 10 40 Se ae Pump Installation of the Gauge Cluster 10 40 0014 and After Hourmeter 10 41 10 14 TROUBLESHOOTING Warning Lights 10 42 10 15 SPECIFICATIONS Page 10 43 10 44 10 44 10 44 10 45 10 49 10 49 10 51 10 51 10 52 10 52 10 52 10 53 10 55 10 58 10 58 10 58 10 60 10 61 10 61 10 62 10 63 10 64 10 83 Model 6036 S N 9B0499 and Before Section 10 Electrical System a A wo Pp MA0871 A The area around the base of the stud the outside diameter of lock washer 5 shall be free of paint Stud bolt or capscrew Hex nut or lock nut Tooth or slot type lock washer Flat washer Electrical ground or grounds Tooth type lock washer aroN B 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 rever
368. p on the seat until the desired level low middle or high is attained To return the seat to the low level raise the seat past the high level and allow it to return to the low level Adjust the seat to your weight by turning a suspen sion adjust knob on the front of the suspension unit until you see your weight in kilograms 2 2 pounds per kilogram on an indicator next to the knob Adjust the horizontal or forward backward position of the seat by using the forward backward lever on the slide to the left of the seat b Seat Removal The seat and seat slides may be removed from the suspension unit and mounting plate by remov ing four locknuts and flat washers that attach the seat slides to the suspension unit Model 6036 S N 9B0499 and Before SEAT CUSHION SEAT BELT FORWARD SUSPENSION BACKWARD ADJUST KNOB LEVER Fig 4 1 Seat 4 2 MECHANICAL HAND CONTROLS Mechanical hand controls in the operators cab are shown in Fig 4 2 TRAVEL RANGE STEERING WHEEL SELECT SELECT AND STEERING LEVER LEVER UNIT LOWER PANEL GRILLE AND FRAME TILT CONTROL LEVER OA0021A Fig 4 2 Mechanical Hand Controls 4 1 Section 4 Operator s Cab TRAVEL SELECT LEVER FOR FORWARD F ______ NEUTRAL N AND REVERSE R BELL CRANKS SHIFTER OSE EE SWIVEL LOCKNUT REVERSE SWITCH RANGE SELECT LEVER FOR LOW 1 ae MEDIUM 2 AND HIGH 3 GATE PLATE CLEVIS PIN WASHER AND COTTER PIN COTTER PIN A
369. p or plug the grille tilt cylinder tubing extend cylinder tubes and bulkhead fittings in support plate Fig 3 8 below the rear opening of the boom Loosen clamps that hold the tubing to the bottom of the outer boom and remove the tubing from the outer boom Attach slings and a suitable hoist to the approximate center of gravity of the outer boom and remove all slack from hoist cable NOTE The approximate center of gravity of the outer boom will be closer to the rear of the outer boom 9 10 11 12 13 3 6 Refer to Fig 3 7 and remove the locknut and capscrew that secures the hoist cylinder rod end pin Remove the pin Check the condition of the bearing in the cylinder rod end replace bearing if worn or damaged Refer to Fig 3 7 and remove the capscrews and lock washers securing boom pivot pins to the outer boom Remove both boom pivot pins and washer spacers from the outer boom and main frame Using the hoist remove the outer boom from the main frame of the forklift Check the condition of both boom pivot main frame bearings replace if worn or damaged 14 If the front outer boom wear pads Fig 3 9 are excessively worn temporarily replace them with new pads Use the same amount of shimming as used when the pads were re moved IMPORTANT The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert the ends must range from flush to 0 19 5 mm recessed in the wear
370. per 2 rod seal 3 and step seal 17 on the gland as shown in Fig 9 12 NOTE Wiper lip should be toward outer end of gland and rod seal lips 3 and the step of step seal 17 toward the inner end of the gland Use tools that will not damage the seals If the backup ring 11 is not flat on both sides the side with the arc must be toward O ring 10 2 Fasten the rod eye in a soft jawed vise Place a padded support below and near end of rod to prevent damage to rod 1 3 Slide the assembled gland and seals onto the rod If necessary use a soft hammer to drive the gland on the rod 4 Slide the stop tube 9 onto the rod Install new O ring 8 inside internal groove on inside of piston 5 6 Apply Loctite Primer T and Compound 609 to inside threads of piston in accordance with manufacturer s instructions Carefully screw piston completely onto the rod 7 Apply Loctite Threadlocker 242 to setscrews 6 and 7 and install them in the piston 8 Apply Loctite Primer T and Compound 609 to outside diameter of rod next to piston Slide stop tube 9 down the rod and against the piston Allow sealants to cure 9 Install new piston seal 4 on piston 10 Fasten cylinder tube 13 in a soft jawed vise or other acceptable holding equipment 11 If removed install two plugs 16 in the bottom of the cylinder tube 12 Lubricate inside of the tube and outside of the piston and gland with clean hydraulic oil
371. per outlet port fitting on the 15 gom pump section to relieve any trapped pressure Ay Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove hex head capscrews 5 lock wash ers 6 and both clamp halves 4 on the main pump inlet line Disconnect the hose elbow 3 from the pump inlet Remove and discard the O ring 7 from the elbow Disconnect small pump outlet hose 8 Disconnect large pump outlet hose 9 1 Remove connector 10 and elbow 11 from the pump outlets 7 Remove capscrews 12 and lock washers 13 that attach the main tandem pump 14 to the transmission Remove and discard the pump gasket 15 b Tools Required for Pump Repair The following tools are required for tandem pump disassembly and assembly 1 A bushing puller made from Collet 33863 of Blind Hole Puller Set 981 by Owatonna Tool Company or an equivalent puller from another supplier Modify this collet as shown in Fig 9 38 9 60 c k 0 015 R MAXIMUM Hose Clamp Inlet Hose Elbow Clamp Half 2 Capscrew 4 Lock Washer 4 O ring Small Pump Outlet Hose Large Pump Outlet Hose 10 Connector 11 Elbow 12 Capscrew 2 13 Lock Washer 2 14 Main Tandem Pump 15 Pump Gasket O NEO RO Section 9 Hydraulic System MA0781 Fig 9 37 Main Tandem Pump Installation 9 61
372. perature Replace bulb See para temperature indicator bulb is burned out indicator bulb fails to light when the test switch is pressed or the engine is overheated Coolant Remove the terminal at the If the indicator bulb goes out See para temperature coolant temperature switch install a new coolant warning bulb 15 Fig 10 5 temperature switch lights when the engine is running but not overheated If the indicator remains on If there is a short to ground See para check wire 15 and the remedy the cause of the ignition switch for a short to short ground Gauges and Indicator Lights ALTERNATOR WARNING LIGHT Alternator warning 1 Alternator not producing Replace bulb See para bulb doesn t light voltage or warning bulb is when alternator burned out isn t producing se ys voltage 2 Battery is discharged Charge battery See para 3 Circuit breaker is stuck in Replace circuit breaker See para open position Resistor R6 in alternator is Replace resistor R6 See para open Gauges and Indicator Lights TRANSMISSION HIGH OIL TEMPERATURE SWITCH Transmission Transmission high Replace bulb See para high temperature indicator bulb is temperature burned out indicator bulb fails to light when the test switch is pressed or the engine is overheated Transmission Remove the connector to If the indicator bulb goes out See para 10 8 8 temperature the transmission ins
373. pilot poppet 13 and spring 14 into the plug Install adjustment screw 15 into the plug Lubricate and install new O rings 16 and 18 on nuts 17 and 19 Stretch O rings do not roll them to fit Install jam nut 17 and acorn nut 19 on the adjustment screw Torque nuts on relief valve to 10 1 5 lb ft 13 5 2N m Install the relief valve cartridge in the housing The cartridge is a honed fit and may require gentle tapping to install IMPORTANT Care must be taken to avoid damaging the valve s internal lands 10 11 12 OMNOARWNM gt Spring Lubricate and install new O ring 9 on hous ing 8 Stretch O ring do not roll it to fit Install assembled relief valve in the control valve housing Torque all relief valves except main relief valve to 40 4 lb ft 55 5 5 N m Torque main relief valve to 60 to 80 lb ft 82 to 109N m Adjust relief valve pressure as instructed in paragraph 9 1 Special Nuts 4 Inlet Section O rings 5 Boom Hoist Section Boom Extend Section Grille Tilt Section Frame Tilt Section Outlet Section Tie Rods 2 Tie Rod Check Valve Poppet Special Nuts 2 c Repair of Main Control Valve Disassembly To replace seals between the sections of the main control valve 1 Remove nuts 1 and 13 Fig 9 26 at outlet section 8 2 Remove outlet section carefully to avoid losing spring 11 Remove O ring 3 and discard Remove spring 11 and che
374. pray YSINITAD 1SIOH Y3QNITA9 LSIOH LHOI 1Sa 0997 HANNAS GNALXA l l ALINY SST e ae t s 0008 5 ml IMOT DO 4 ISd 00Z LHO LL AWWH4 D me ISd 00Z 1457 IL AWS 10 g pue 667086 N S DILVINAHOS DIINVYCGAH 9 09 Model 6036 S N 9B0499 and Before 9 77 Section 9 Hydraulic System 9 6 SPECIFICATIONS HYDRAULIC SYSTEM System Capacity 38 gallons 143 8 liter Reservoir Capacity 24 gallons 90 8 liter Hydraulic Oil Level Oil level to be visible in reservoir sight gauge when oil is all cylinders retracted cold room temperature Fill and maintain system level with clean filtered hydraulic oil Type of Hydraulic Oil Anti wear hydraulic oil per ISO Grade 46 or ASTM Viscosity SSU 215 at 100 F 38 C including the following Amoco Rykon 46 Arco Duro AW S 215 Benz Petraulic 46 LC Chevron AW 46 Citgo Pacemaker XD 46 Gulf Harmony 46 AW Mobil DTE 25 Shell Tyllus 46 Sun Sunvis 821 WR Texaco Rando HD 46 Interval for Hydraulic Oil Change Annual Filter Capacity 1 quart 0 95 liter Interval for Hydraulic Filter Change After first 50 hours of operation every 1000 hours of operation thereafter or after any hydraulic component failure and repair Relief Valve Settings Steering Relief 15 gom pump 2475 25 psi 170 5 1 7 bar Main Hydraulic Relief 30 gpm pump 3000 50 psi 206 7 3 4 bar Boom Hoist Relief 2650 50 psi 182 6 3 4 bar Boom Extend Relief 2650 50 psi 182 6 3 4 bar
375. pressure 9 59 Section 9 Hydraulic System MACHINE FRONT 14 MA0771 Capscrew HOSE CONNECTIONS Elbow Counterbalance Valve N To front steering unit Elbow P To steering unit Hose Elbow Reducer 3 Nut 3 Run Tee Steer Select Valve Subplate Pressure Reducing Valve Lock Washer 2 Hex Nut 2 Valve Plate 0 ONO Ot dS GON nore ge arene PoeN gt oO Fig 9 36 Counterbalance Valve Installation A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Tag and disconnect hydraulic hoses to elbows 6 Fig 9 36 in counterbalance valve 3 4 Remove two hex nuts 13 lock washers 12 and capscrews 1 to detach the counterbal ance valve and pressure reducing valve 11 from valve mounting plate 14 5 Refer to paragraph 9 3 7 for maintenance information for the pressure reducing valve 6 Remove hydraulic fittings from valve as required Model 6036 S N 9B0499 and Before Section 9 Hydraulic System b Disassembly NOTE There are no serviceable parts in the counterbalance valve do not disassemble Remove the counterbalance valve cartridge Fig 9 34 c Cleaning Clean metal parts of valve in an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect valve cartridge Fig 9 34 for wear scoring damaged seals and other damage Replace cartridge if damaged 2 Discard
376. quired to relieve binding Check ground at mechanical support for presence of tooth type washer See para Cab Heater for Enclosed Cab HEATER FAN MOTOR AND COIL 1 Check circuit breaker 2 Check motor and fan for mechanical binding 3 Check continuity through blower switch in high and low positions 4 Open heater ground at mechanical support Replace circuit breaker if See para open Realign motor and fan as See para required to relieve binding Replace switch if defective See para Check ground at mechanical support for presence of tooth type washer 10 67 Hydraulic Pump for Emergency Braking and Steering GENERAL Low oil pressure switch is defective Circuit breaker is stuck in open position Defective hydraulic pump motor Hydraulic pump is defective or frozen Low oil pressure switch is defective Short circuit in wiring Refer to troubleshooting instructions for oil pressure switch Replace circuit breaker Repair or replace hydraulic pump motor or 10 13 3 Repair or replace hydraulic pump or 10 13 3 Refer to troubleshooting instructions for oil pressure switch Remedy cause of short circuit Model 6036 S N 9B0499 and Before Reference See para 10 12 2 and item 3 Fig See para 10 13 1 See para 10 4 See para 10 13 2 See para 10 13 2 See para 10 13 1 See para 10 3 Section 10 Electrical System
377. r T and Retaining Com pound 271 to the threads of the locknut 3 in accordance with the manufacturer s instruc tions Install the nut on the rod and torque to 450 to 500 lb ft 612 to 680 N m Stake the nut in four places and allow sealants to cure Install new piston seal 8 on the piston Fasten cylinder tube 2 in a soft jawed vise or other suitable holding equipment Be careful not to damage the tube Lubricate inside of the tube piston and gland O ring 6 with clean hydraulic oil Apply a compression sleeve or other suitable tool to the gland in order to compress the O ring 6 on the gland Insert the assembled piston rod and gland into the tube 2 Using a pin spanner wrench thread the gland into the tube Remove the compression tool IMPORTANT When sliding the rod and piston assembly in the tube be careful so that gland threads in the tube do not damage the piston seal Keep the rod in line with the tube barrel to prevent binding 10 11 12 Apply Loctite Primer T and Retaining Com pound 609 to outside diameter of bushings 1 in accordance with manufacturer s instruc tions Press bushings into both the eye of rod and eye of cylinder tube so that the bushing is located an equal distance from each side of the rod eye Allow the compound to cure If removed install grease fittings 13 and 14 Following reassembly test the cylinder at low operating pressure 100 psi or 6 9 bar to be sure th
378. r bent key Moisture within ignition switch is frozen Loose or broken wiring or circuit breaker 10 Fig 10 5 doesn t reset and remains open Trouble in the starting circuit Trouble in the THERMO START circuit Defective ignition switch Travel select lever is in FORWARD or REVERSE Model 6036 S N 9B0499 and Before Clean remove paint and straighten remove any burrs from surface of key and sprinkle powdered graphite on working surfaces of key as described in paragraph 10 7 1 IMPORTANT Use only graphite or a liquid lock deicer within the lock Severe lock malfunctions may require the services of a locksmith Warm the ignition switch using a hair dryer or use a liquid lock deicer to lower the freezing point and evaporate the moisture within the lock Replace wiring and circuit breaker Refer to starting circuit troubleshooting Refer to Thermo Start plug troubleshooting Repair or replace ignition switch Move travel select lever to NEUTRAL position Reference See para 10 6 2 d See para 10 6 2 i See para 10 6 2 i See para 10 6 1 See para 10 6 2 and 10 5 2 d See para 10 6 2 and 10 5 2 f See para 10 7 1 See para 10 7 1 See para 10 7 1 See para 10 7 1 See para 4 2 2 10 71 Section 10 Electrical System Trouble Probable Cause Remedy Reference Switches and Solenoids IGNITION KEY SWITCH cont d Ignition switch 1 Fuel run
379. r boom to the ground until the intermediate boom raises up to provide clear ance for removing the bottom pad 5 Inspect the wear pads removed as described in the preceding IMPORTANT notice c Outer Boom Wear Pads Fig 3 9 1 All outer wear pads can be removed working at the front of the boom 2 The front bottom pad may be removed by first removing the top pads Lower the gooseneck end of the inner boom to the ground until the 3 12 intermediate boom raises up thereby providing clearance for removing the bottom pad 3 Inspect the wear pads removed as described in the preceding IMPORTANT notice 3 1 9 Hose Tensioning 100 Hour Intervals Adjust grille tilt cylinder hose or auxiliary hydraulic hose tension whenever the boom is disassembled a hose is changed or whenever proper hose adjustment is in question Check hose tension as part of general maintenance every 100 hours IMPORTANT Before you begin tensioning the hoses make sure that the hoses are not twisted within the boom Keep the hose manufacturers marking in line as a guide 1 Park forklift on level surface engage park lock and fully retract and level the boom Remove the rear boom cover Fig 3 1 If the vehicle has auxilliary hydraulics there will be four hoses in hose clamps Fig 3 16b with the auxilliary hose clamps stacked on top of the grille tilt cylinder hose clamps Fig 3 16a Remove the capscrews and hose clamps holding upper hoses i
380. ragraph 9 2c 1 Press the bushing 12 Fig 9 15 into position in the eye of the rod 11 so that the grease groove runout is located toward the center of the eye Install new O ring 6 backup ring 7 wiper 10 and rod seal 9 on the gland 8 as shown in Fig 9 15 9 34 NOTE Wiper lip should be toward outer end of gland and seal lips toward the inner end of the gland Use tools that will not damage the seals If the backup ring is not flat on both sides the side with the arc must be toward the O ring 3 Fasten the eye of the rod in a soft jawed vise Put a padded support below and near end of rod to prevent damage to the rod 4 Push the assembled gland onto the rod 11 If necessary use a soft hammer to drive the gland onto the rod 5 Install new O ring 5 inside of piston 4 Carefully install the piston on the rod to avoid damage to the O ring 6 Apply Loctite Primer T and Threadlocker 271 to the nut 2 in accordance with the manufac turer s instructions Install the nut on the piston rod and torque to 450 to 500 lb ft 612 to 680 N m Stake the nut in four places Allow the compound to cure Install new piston seal 3 on the piston Fasten the tube 1 in a soft jawed vise or other acceptable holding equipment Be careful not to damage the tube 9 Lubricate inside of the cylinder tube piston and gland O ring 6 with clean hydraulic oil 10 Apply a compression sleeve or other suitab
381. rain completely into receptacle a Unlock and open the right rear access door 6 Remove the oil filter Fig 8 7 A strap or chain filter wrench may be required N Clean the filter sealing surface Apply a thin coat of engine oil to the seal on a new filter 9 Install new oil filter and tighten 1 2 turn after initial contact 10 Clean and install the oil pan drain plug 11 Remove oil fill cap Fig 8 7 and add 10W30 motor oil equal to API SE CC or SE CD specifications refer to paragraph 8 1 10 DO NOT overfill Crankcase capacity with filter is 9 4 quarts 8 9 liter 12 Start the engine and run for several minutes 13 Stop the engine and allow oil to drain back for a few minutes 14 Check dipstick and add oil as required 15 Check for leaks at the filter and drain plug Retighten either if necessary 16 Add oil to bring level to full mark on dipstick 17 Close and lock engine access door TOP BLEED SCREW J FILTER HEAD FUEL PRE FILTER DRAIN COCK OA0292 Fig 8 8 Fuel Pre Filter Fuel Pre Filter 1 Unlock and open right rear access door 2 Open top bleed screw of fuel pre filter Fig 8 8 Model 6036 S N 9B0499 and Before 3 Loosen drain cock on bottom of fuel pre filter and allow water to completely drain from it 4 Tighten the drain cock and top bleed screw after draining 5 Close and lock the right rear engine access door Fan Belt Tension
382. rated If any reading is zero on this test replace the diode trio g Rectifier Bridge Check To check the rectifier bridge connect the ohmmeter to the grounded heat sink and one of the three terminals as shown in Fig 10 32 Then reverse the lead connections to the grounded heat sink and same terminal If both readings are the same replace the rectifier bridge A good rectifier bridge will give one high and one low reading 2 Repeat this test between the grounded heat sink and the other two terminals and between the insulated heat sink and each of the three terminals This makes a total of six checks with two readings taken for each check 3 To replace the rectifier bridge remove the attaching screws and disconnect the capacitor lead Note the capacitor lead clip is attached with a screw or press fit OHMMETER CHECK FOR OPENS MA1161 OHMMETER OHMMETER CHECK FOR OPENS CHECK FOR GROUNDS Fig 10 33 Checking Stator Windings h Stator Checks 1 The stator windings may be checked with a 110 V test lamp or an ohmmeter refer to Fig 10 33 If the lamp lights or if the meter reading is low when connected from any stator lead to the frame the windings are grounded If the lamp fails to light or if the meter reading is high when successively connected between each pair of stator leads the windings are open Model 6036 S N 9B0499 and Before 2 A short circuit in the
383. rculation Fan Switch and Fan Motor for Enclosed Cab GENERAL Air Circulation Fan 1 Wire 30 from circuit Repair or replace wire Doesn t Run breaker 12 is broken Fan switch or motor is Replace air circulation fan broken assembly Cab Heater for Enclosed Cab GENERAL Heater doesn t Coolant shut off valve in Turn shut off valve to the ON See item 13 Fig produce heat with the OFF position position 10 67 coolant at Heater hoses clogged Repair or replace heater See para 10 12 2 operating kinked or crushed hoses temperature and heater fan Dirty heater core Disassemble heater and clean See para 10 12 1 running heater core as described in and 10 12 2 paragraph 10 12 1 amp 10 12 2 Model 6036 S N 9B0499 and Before 10 81 Section 10 Electrical System Trouble Blower fan motor doesn t run Blower fan motor doesn t run Hydraulic pump fails to operate when engine oil pressure is low Hydraulic pump operates when engine oil pressure is normal 10 82 Probable Cause Remedy Cab Heater for Enclosed Cab CAB HEATER SWITCH Check circuit breaker Check continuity through blower switch in high and low positions Check motor and fan for mechanical binding Open heater ground at mechanical support Replace circuit breaker if See para open See para Replace switch if defective Realign motor and fan as See para re
384. re serious injury 9 Remove the pressure gauge and tee from the tandem pump and reconnect the hydraulic line 2 Operate the hydraulic controls after the 10 Start the engine Raise and lower the boom engine has stopped to relieve any trapped fully several times to purge the system of air pressure A Warning 11 Install the transmission cover after adjustment Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 9 3 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System FRAME TILT GRILLE TILT BOOM RIGHT PORT UP PORT EXTEND RELIEF RELIEF VALVE PORT MAIN VALVE RELIEF RELIEF VALVE VALVE _ DO MA0431 T ILJJ J iB J Si J GRILLE TILT i BOOM HOIST DOWN PORT PORT RELIEF FRAME TILT RELIEF VALVE BOOM VALVE LEFT PORT RETRACT RELIEF VALVE PORT RELIEF VALVE Fig 9 2 Main Control Valve Relief Valves Boom Hoist Port Relief Valve 1 Engage the park lock place the travel select lever in neutral and stop the engine Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing
385. red safely to the ground by following the Emergency Boom Lowering procedures in your Owners Operators Manual IMPORTANT DO NOT attempt to reset the counterbalance valve cartridge In the event that the counterbalance valve cartridge was disabled for emergency boom lowering or any unauthorized adjustments are ever made to this cartridge remove and replace the cartridge with a new part Failure to replace this cartridge with a new part may alter the holding characteristics of the counterbalance valve creating an unsafe condition for machine operation b Pressure Checks and Adjustments Boom Extend Port Relief Valve 1 Engage the park lock place the travel select lever in neutral level the boom and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns Remove the transmission cover from the frame Install a tee and pressure gauge capable of measuring 0 4000 psi 275 6 bar in the tandem pump outlet of the 30 gpm section Fig 9 3 9 6 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are
386. ree cloth d Inspection and Replacement 1 Key should insert and turn freely in switch If the key binds in the lock check for a bent key If the key is straight sprinkle some powdered graphite on the sides of the key and insert key in lock several times to distribute the graphite IMPORTANT Use only graphite or a liquid lock deicer within the lock Severe lock malfunctions may require the services of a locksmith 2 Refer to the table below Using an ohmmeter or continuity tester check for continuity as follows SWITCH POSITION THERMO START START a X XxX X Switch Terminals MA1221 10 Park Lock Warning Light 11 Seal Cap 12 Park Lock Switch 7 Lower Panel 8 Switch Guard 9 Decal Fig 10 40 Removal of Switches and Indicators Model 6036 S N 9B0499 and Before 3 Replace the switch if it fails the tests in step 2 e Installation 1 Connect the wires as they were tagged during switch removal Position the switch from under the panel Install hex nut Connect negative cable 2 Fig 10 38 to the batteries 5 Install lower panel 7 Fig 10 40 10 7 2 Neutral Start Switch The neutral start switch Fig 10 41 prevents the engine from being started with the transmission in forward or reverse The switch is located on the transmission control valve assembly The switch is normally open and is closed when a switch actuating pin presses a spring loaded ball in the neutral start
387. refully tighten the hex nut 4 Connect negative cable 2 Fig 10 38 to the batteries 5 Test switch for proper operation e UP for 4 wheel steer e CENTER for 2 wheel steer e DOWN for crab steer If operation is not correct rotate switch or reconnect wires 1 3 Q i ag l B aA A e sJ d h f d 6 2 5 4 4 5 2 6 1 Housing oe 2 Solenoids 2 3 Control spool 4 Return springs 5 Push pin 6 Manual override 7 Steer Select Solenoid Operated Valve Fig 10 46 Typical Steer Select Solenoid Operated Valve 10 7 8 Steer Select Solenoid The steer select valve is a direct solenoid oper ated spool type directional control valve It controls the start stop and direction of fluid flow to the steering cylinders It is located on the valve plate assembly which is mounted under the operator s cab The valve consists of a housing 1 Fig 10 46 two solenoids 2 a control spool 3 and two return springs 4 10 40 In the de energized condition the spool 3 is held by the return springs 4 in the center position The spool is shifted by energizing wet pin sole noids 2 The force of the solenoid 2 pushes against push pin 5 on the end of spool 3 The spool is shifted from its normal position to
388. replace hoses and tubes Damaged dented crushed or leaking hose fittings restrict oil flow and the operation of the parts being served Fittings showing signs of movement from their original position have failed and must be replaced 2 Be sure hoses are in good condition If in doubt replace them 3 Replace hoses if the following occur e chafed outer cover e concealed corrosion of wire reinforcement e ballooning replace immediately e kinked crushed stretched or deformed 2 4 2 Installation 1 When installing a new hose loosely connect each end and make sure the hose takes up the designed position before tightening the connection Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing 2 Ifa hose is replaced on a moving part be sure it does not foul by moving the part through its complete range of travel 3 Be sure any hose which has been installed is not kinked or twisted 4 Free moving unsupported hoses must never touch each other or related work surfaces This causes chafing reducing hose life 2 2 2 5 BEARINGS 2 5 1 Removal 1 Bearings should never be removed unless absolutely necessary Always use the recommended puller to reduce the risk of bearing or related component damage 2 When bearings or bushings are removed check that the bearing is free from dis coloration nicks scuffing and signs of overheating If in doubt replace the bearing
389. ribed in the Owners Operators Manual Test steering circuit operation as described in paragraph 9 1 6c Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 9 2 7 Side Tilt Carriage Cylinder Optional a Removal 1 Place the boom in a horizontal position 2 Using the side tilt control lever tilt the carriage fully to the left to retract the side tilt cylinder 3 Support the side tilt carriage 7 Fig 9 20 in this position with blocking 4 Engage the park lock place the travel select lever in neutral and stop the engine A Warning Relieve hydraulic pressure before servicing any hydraulic component Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury 5 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 6 Remove all dirt and grease from side tilt carriage cylinder 1 and hydraulic lines 2 and 3 7 Disconnect the hydraulic lines from the cylinder and cap and plug the open connec tions 8 Remove snap ring 4 and cylinder rod pin 5 securing the side tilt carriage cylinder rod to side tilt carriage 7 9 Remove snap rings 4 and cylinder base pin 6 securing the side tilt carriage cylinder tube to pivot base 8 10 Remove the cylinder from the pivot base us
390. rically ground the heater unit by positioning tooth type ground washers 3 Fig 10 67 over the tapped holes in the coolant inlet outlet side of the heater Use a thin transparent tape to temporarily secure the washers to the heater unit 9 Slide heater and fan unit 7 into position under suspension support 12 without disturb ing the ground washers 3 which were taped into position during the previous step 10 Install two lock washers 5 capscrews 4 and spacers 6 at the other side of the suspension support 12 11 Install two lock washers 2 and capscrews 1 through the holes in the suspension support 12 and through the tooth type grounding washers 8 into the tapped holes in the heater 12 Connect negative cable 2 Fig 10 38 to the batteries 13 Test heater fan motor operation 10 13 EMERGENCY BRAKING AND STEERING SYSTEM 10 13 1 Low Oil Pressure Switch The emergency pump oil pressure switch 31 Fig 10 5 performs three functions e When starting the engine the switch energizes the emergency steer pump to supply oil pressure as the engine is being started e When oil pressure at the engine rises above 4 psi 0 3 bar the switch opens stopping the emergency steer pump because the engine is turning fast enough for the tandem pump to supply sufficient hydraulic oil pressure for forklift operation e f engine oil pressure again falls below 4 psi 0 3 bar the switch will close and the
391. rit Carborundum stone oil and grease snap ring pliers prick punch scale 1 32 or 1 64 graduations small screwdriver torque wrench vise with 8 minimum open spread General Repair Precautions To facilitate repair of the pump and before any work is done first read and understand all of the steps used in the disassembly and assem bly instructions The first requirement of good maintenance of hydraulic equipment is cleanliness Make sure you disassemble and assemble your hydraulic equipment in a clean area Model 6036 S N 9B0499 and Before THROUGH HOLE C RADIUS 0 015 X 45 CHAMFER m A 3 3 8 B 4 1 2 C 9 16 R D 1 065 PLUS 0 000 MINUS 0 002 E 1 002 PLUS 0 002 MINUS 0 000 MA0821 Fig 9 41 Special Steel Sleeve If prying off sections becomes necessary take extreme care not to mar or damage machined surfaces Excessive force while prying can result in misalignment and serious damage to parts Match mark exterior surface of housings before separating the parts Align match marks during assembly Gears are closely matched Gears must be kept together as sets when removed from a unit Handle with care to avoid damage to the journals or teeth Avoid touching gear jour nals Always replace matched parts as a set Do not grip machined surfaces in a vise to prevent damage to fine surfaces If parts are difficult to fit during assembly tap gently with a soft hammer N
392. rive shaft assembly in a bench vise 3 Pinch the ends of two retaining rings Fig 6 2 that secure the bearing cross assembly in the yoke with a pair of pliers and remove them from their grooves in the yoke NOTE If the retaining ring does not readily snap out of the groove in the yoke tap the end of the bearing cap lightly to relieve the pressure against the ring 4 Using a soft round pin with a flat face about 1 32 0 8 mm smaller than the hole diameter in the yoke drive on one end of the bearing assembly unit until the opposite bearing assembly comes out of yoke 5 Turn the yoke over and tap the exposed end of cross until the opposite bearing assembly falls free Remove the cross from the yoke Repeat steps 2 thru 6 to remove cross and bearings on other end of drive shaft 8 Mark the shaft and sleeve assembly so that it can be aligned properly when reassembled Yokes at both ends of the drive shaft must be in the same plane to prevent excessive vibration 9 Unscrew the dust cap and slide the sleeve assembly off the spline of the drive shaft 10 Remove the dust cap split retaining ring and felt seal from the shaft assembly 6 1 Section 6 Drive Shafts and Drop Box SLEEVE DUST CAP ASSEMBLY SHAFT ASSEMBLY SPLIT Fo RETAINING FELT RING SEAL DRIVE F4 SHAFT A QZ ne SLEEVE DUST OAK ASSEMBLY DROP BOX CAP Pa INPUT SHAFT SPLIT YOKE RETAINING
393. rk lock Be sure that the arrow on the wheel end housing is pointing down Fig 5 19 Clean the area around the magnetic drain plug and remove the plug Check the oil level and if necessary use only Special JLG Wet Disc Brake Oil P N 8522042 as required to bring the level up to the plug hole IMPORTANT Other brake oils must not be used If they are loss of braking force and squealing will occur 4 Clean and install the magnetic drain plug Oil Change 1000 hour intervals Level the forklift ground the carriage shut off the engine and engage the park lock Be sure that the drain plug on the wheel end housing is pointing down Fig 5 15 Remove the vent plug Clean the area around the magnetic drain plug and remove the plug Allow the oil to drain Move the forklift so that the arrow on the wheel end housing is pointing up Fill the wheel end using only Special JLG Wet Disc Brake Oil P N 8522042 as required to bring the level up to the drain plug hole Capacity for the front wheel end is 54 0 ounces 1 6 liter and for the rear wheel is 56 0 ounces 1 7 liter Clean and install the drain and vent plug 5 4 SPECIFICATIONS Oil Capacity of Differential Housing 18 qts 17 liters Gear oil MIL L2105C API classification GL 5 90W or multi grade 80W 90 with EP properties Amoco MP Gear Lube 80W90 Benz Multi Purpose 80W90 Mobil Mobilube HD 80W90 Shell Spirax 80W90 Texaco Multi Gear Lube 80W90
394. rn key to the Thermo Start position and hold it there for fifteen to twenty seconds With the throttle pedal fully depressed turn the key to the START position to engage the starter motor If the engine doesn t start within fifteen seconds return the switch to the THERMO START position for ten seconds and then reengage the starter motor by turning key to the START position As soon as the engine starts allow key to return to the RUN position If the engine should fail to start check the electri cal connection to the Thermo Start plug In the event of difficult starting check that fuel is reaching the Thermo Start plug by unscrewing the inlet fuel connection If fuel is reaching the Thermo Start plug the plug itself may not be working correctly This can be checked by remov ing the air cleaner and watching the cold starting aid while the equipment is used When the starting switch is turned to the THERMO START position the element should become red hot and on engagement of the starter motor ignition of the fuel should take place 10 20 The engine is fitted with an efficient cold starting aid and no responsibility can be accepted for any damage caused by unauthorized starting aids a Removal 1 Tag and disconnect wire at electrical terminal 3 Fig 10 24 2 Disconnect fuel line 4 3 Remove Thermo Start plug b Disassembly Do not disassemble the Thermo Start plug c Cleaning and Drying Without submer
395. roud Disconnect the wiring to the backup alarm Fig 8 26 Remove the rear support which is above the engine between the side frame members along with the backup alarm 8 19 Section 8 Engine 13 Disconnect the engine wire harness at the following components Fig 8 26 e Starter e Starter Ground Cable e Starter Relay e Neutral Start Switch on transmission e Transmission Temperature Switch e Low Oil Pressure Sender e Emergency Pump Oil Pressure Switch e Water Temperature Sender e Fuel Run Solenoid e Alternator e Thermo Start Plug Pull harness off of engine and forward on forklift so it is out of the way 14 Detach and plug fuel lines as required at fuel pre filter and fuel filter TO BATTERIES 15 16 17 Detach throttle cable from engine as follows a Remove cable clamp securing throttle cable to throttle cable bracket b Disconnect the throttle cable from the fuel injection pump Remove the transmission control cables from the connector kit on the transmission as follows a Remove the cable clamps securing the control cable to the connector kit Fig 4 4 b Disconnect the control cables from the swivel linkage Disconnect transmission drive shaft from the transmission a Remove transmission cover from forklift 29 1 i gt NEUTRAL START SWIT
396. rter solenoid Fig 10 12 Connect the negative lead of the voltmeter to the motor terminal on the starter solenoid Select voltage range that will measure 12 Vdc Push in and hold the starter button and select the lowest voltage range for the voltmeter read the voltmeter Select the voltage range that will measure 12 Vdc and release the starter button If the voltage indication was more than 0 1 V replace the starter solenoid STARTER MA0961 Fig 10 13 Measuring Voltage Loss in Negative Battery Cable Test 5 Voltage Loss in Negative Battery Cable Connect the negative lead of the voltmeter to the negative battery cable at the batteries Fig 10 13 Connect the positive lead of the voltmeter to the negative battery cable at the starter mounting nut Select lowest voltage range for the voltmeter Push in and hold the starter button and read the voltmeter If the voltmeter indication was a More than 0 4 V replace the negative battery cable b 0 4 V or less the negative battery cable is good 10 13 Section 10 Electrical System MAO971 1 Bushing kit 9 Armature 2 Retainer 10 Parts kit 3 Forked engagement lever 11 Solenoid 4 Drive end bracket 12 Commutator end bracket 5 Seal kit 13 Brush kit 6 Drive pinion assembly 14 Brush kit 7 Intermediate bracket 15 Thrust washer 8 Field coil 16 Brake kit Fig 10 14 Starter 10 5 3 Starter a Operation The starter is located
397. ructions in paragraph 5 1 Refer to paragraph 5 1 12 or 5 1 13 when mounting tire on wheel which is not attached to forklift 5 1 12 Mounting Standard Tire on Three Piece Wheel Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 Install the valve stem Fig 5 2 into the hole in the rim and tighten to 45 to 55 Ib inch 5 to 6 2 N m Make sure parts are clean repainted if necessary and have been inspected for damage and cracks before proceeding with mounting Make sure correct parts are being assembled Lay rim base on block with the flange side down Place tire over rim base NOTE A mechanical bead unseating and seating tool may be purchased from the lowa Mold Tooling Company to facilitate step 4 4 Place side flange over rim base and push straight down with hands as far as possible Make sure flange does not bind on rim base Stand on side flange to position it below both grooves in rim base and snap lock ring into lock ring Upper groove Be certain the embossed safety bulge on the lock ring is up toward the operator 5 8 6 Lubricate a new rubber O ring Place O ring in groove on one side and stretch O ring snapping it into place rather than rolling it into place The lubricate the entire O ring groove areas with an approved vegetable based lubricant NOTE It may be necessary to hold the side flange down with the flat end of the tire iron to expose
398. ry cloth with a rotary motion 4 Remove staking burrs from the nut 3 and the bottom of piston 9 with fine file Clean parts with trichlorethylene after repair Bushing 2 Cylinder Tube Locknut Gland Backup Ring O ring O ring Piston Seal Piston 10 Rod Seal 11 Wiper 12 Rod DCONOARWN 13 Grease Fitting ee 14 Grease Fitting 90 Section 9 Hydraulic System e Assembly NOTE Follow general assembly instructions in paragraph 9 2c 1 Install new O ring 6 Fig 9 13 backup ring 5 wiper 11 and rod seal 10 on the gland 4 as shown in Fig 9 13 NOTE Wiper lip should be toward outer end of gland and piston seal lips toward the inner end of the gland Use tools that will not damage the seal If the backup ring is not flat on both sides the side with the arc must be toward the O ring wer A Y ENX 13 ee 12 N b 11 z MA0542 Fig 9 13 Slave Cylinder Exploded View 9 31 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 2 Fasten the piston rod eye in a vise and puta padded support below and near other end of rod to prevent damage to the rod Push the assembled gland onto the rod 12 If necessary use a soft hammer to drive the gland on the rod Install new O ring 7 inside of piston 9 Carefully install piston on rod to avoid damage to the O ring Apply Loctite Prime
399. s 4 and 6 and grease fittings 5 13 Following reassembly test the cylinder at low operating pressure 100 psi or 6 9 bar to be sure the piston and rod are moving freely in both directions 14 Increase the operating pressure to the maximum 4000 psi or 275 6 bar for the cylinder and check for external leakage and free movement in both directions 15 Prepare the cylinder for installation by retracting the piston and capping and plug ging the ports f Installation 1 Lubricate the hoist cylinder pivot pins with multi purpose lithium based grease 2 Using suitable lifting device install the boom hoist cylinder Fig 9 9 on the forklift securing the base end to the frame with pivot pin and snap rings 3 Remove all plugs or caps from hydraulic lines and securely tighten lines to the cylinder A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 9 26 4 Have a helper start the forklift engine Position the hoist cylinder so that the rod is aligned with the rod end mounting holes as much as possible 6 Instruct the operator to raise or lower the hoist cylinder slowly until the rod end eye is aligned with the outer boom mounting holes Secure the rod end to the boom with pivot pin and its locking capscrew and locknut 7 Raise the boom as far as it will go then lower it as far as it will go five times or until the operation of
400. s to connectors 6 Install electrical connectors f Bleeding Steering System A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 1 Start the forklift engine and run at idle 2 Turn the steering wheel fully left to right and back lock to lock several times in all three steering modes until they operate smoothly This should purge the steering system of air 3 Shut down the engine Check the hydraulic oil level and fill as described in the Owners Operators Manual 9 56 Section 9 Hydraulic System 9 3 5 Sequence Valve e Installation a Removal 1 Install connector 10 Fig 9 33 and run tees 1 Engage the park lock place the travel selector rand 12 enisequence valveta lever in neutral and stop the engine 2 Position the sequence valve on valve mount ing plate 30 and secure with two capscrews 18 flat washers 20 lock washers 19 and Warning how nuts 2 m 3 Connect hydraulic tube assemblies 15 16 Relieve hydraulic pressure before servicing any and 17 to connector 10 and run tees 11 hydraulic component Escaping hydraulic fluid and 12 under pressure can penetrate the skin causing serious injury 4 Connect hydraulic hose to run tee 11 Check the hydraulic oil level and fill as de 2 Slowly loosen the fittings at the sequence scribed in the Owners Operators Manual valve 3 Fig 9 33 as
401. se 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 e a lighting system with headlights tail lights directional signals emergency flashers and rear work light e an enclosed cab with air circulating and heater fans and a windshield washer and wiper NOTE Forklifts built thru Serial Number 9B0499 have an electrically powered hydraulic pump This pump maintains hydraulic pressure for power steering and service and park lock brakes if engine oil pressure falls below a predetermined level The pump is actuated by an oil pressure switch which actuates a solenoid which in turn starts the pump if engine oil pressure falls below 4 psi 0 3 bar Model 6036 S N 9B0499 and Before 10 1 1 Service Warnings and Recommendations A Warning 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
402. seals and other damage Replace cartridge if damaged 2 Discard entire sequence valve if damaged Fig 9 34 Valve Cartridge for Sequence Pressure Reducing and Counterbalance Valves MAO751 9 57 Model 6036 S N 9B0499 and Before Section 9 Hydraulic System 3 Tag and disconnect tube assembly 16 from connector 13 4 Remove two hex nuts 21 lock washers 19 flat washers 20 and socket head capscrews 28 to detach the relief valve 5 Remove hydraulic fittings from valve as required b Disassembly NOTE There are no serviceable parts in the relief valve do not disassemble Remove steering relief valve cartridge Fig 9 35 c Cleaning Clean metal parts of valve in an approved cleaning solvent and blow dry d Inspection and Replacement 1 Inspect valve cartridge Fig 9 35 for wear scoring damaged seals and other damage Replace cartridge if damaged 2 Discard entire steer relief valve if damaged e Installation 1 Install connector 13 Fig 9 33 and branch tee 14 on relief valve 5 2 Position the relief valve on valve mounting plate 30 and secure with two capscrews 28 flat washers 20 lock washers 19 and hex nuts 21 Connect tube assembly 16 to connector 13 Connect hydraulic hoses to branch tee 14 and connector 13 f Bleeding Steering System Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed
403. secures the ground wire and sender to the fuel tank and remove the ground wire Remove the other four screws which secure the sender to the fuel tank Carefully remove the sender from the fuel tank by lifting and tilting the assembly so the float and lever clears the opening in the fuel tank Remove and discard the gasket PANEL CLIP INNER NUT Torque lt to 4 Ib inch 0 11 N m IGN _ GAUGE MOUNTING H NUT Torque to 14 HRS Ib inch 1 58N m SEND i ee i OUTER NUT Torque to 14 Ib inch 1 58 N m NYLON SPACER MA1321 Fig 10 52 Top View of Fuel Level Gauge Installation of Fuel Gauge and Sender Installation of Fuel Gauge Position fuel gauge in gauge mounting plate 3 Fig 10 47 Install clip and nuts which secure gauge to gauge mounting plate Install the nut and ground wires on the center GND terminal post of the gauge IMPORTANT Torque inner nuts to 4 Ib inch 0 45 N m and outer nuts to 14 Ib inch 1 6 N m on the terminal posts of the fuel gauge Install the nut and wire on the left SEND terminal post of the gauge Model 6036 S N 9B0499 and Before
404. sembly Wire Assembly Wire Assembly Fuel Gauge Light Assembly Wire Assembly Circuit Breaker 15 A Wire Assembly Wire Assembly Jam Nut 3 8 NC Rear Work Light 10 47 Section 10 Electrical System 10 48 Lighting System Circuits Use with Fig 10 53 Lighting System From Turn Signal Switch 17 Not Used Turn Signal Switch 17 Turn Signal Switch 17 Headlight Switch 19 Turn Signal Switch 17 Headlight Switch 19 Headlight Switch 19 Turn Signal Switch 17 Headlight Switch 19 Stop and Tail Light 23 15 A Circuit Breaker 31 15 A Circuit Breaker 31 Headlight Switch 19 15 A Circuit Breaker Turn Signal Switch 17 Turn Signal Switch 17 15 A Circuit Breaker 31 To Momentary Brake Switch 9 Stop and Tail Light 23 Stop and Tail Light 23 Stop and Tail Light 23 Turn Signal Light 3 Headlight 2 Headlight 2 Turn Signal Light 3 Headlight 2 Stop and Tail Light 23 Headlight Switch 19 Momentary Brake Light Switch 9 Fuel Gauge Light Assembly 29 6 A Circuit Breaker Flasher 13 Flasher 13 Flasher 13 Model 6036 S N 9B0499 and Before Section 10 Electrical System GREEN D RED BLACK j gt j GRAY __ GRAY BLACK BLUE YELLOW oo MA1341 Fig 10 54 Schematic of Directional Signal and Emergency Flasher Switch 5 Install nut and wire on the right IGN terminal post
405. sembly Tires and Axle PA1530 1 Differential Carrier Assembly includes 23 Screw differential bearing cap 4 items 2 thru 39 24 Washer differential bearing cap 4 2 Ring adjusting 2 25 Bolt hex 2 3 Cup roller bearing 2 26 Washer flat 2 4 Cone roller bearing 2 27 Clip adjusting ring 2 5 Screw differential 12 28 Screw hex hd cap 14 6 Differential Case Assembly includes 29 Washer flat 14 items 7 thru 13 30 Spacer flat 7 Washer thrust 2 31 Shim adjusting AR 8 Gear differential side 2 32 Cup roller bearing 9 Washer pinion thrust 4 33 Cone roller bearing 10 Gear pinion 4 34 Washer bearing thrust 11 Spider differential 35 Bolt hex 8 12 Case differential 36 Slinger dust 13 Pin pinion bearing cage 37 End yoke assembly 14 Gear and Pinion Assembly 38 Washer pinion nut 15 Cone roller bearing 39 Nut pinion 16 Cup roller bearing 40 Housing axle 17 Shim bevel pinion bearing 0 003 AR 41 Fitting grease 2 18 Shim bevel pinion bearing 0 005 AR 42 Bushing axle pivot 2 19 Shim bevel pinion bearing 0 010 AR 43 Pin dowel 2 20 Carrier Assembly includes items 21 thru 24 44 Plug pipe 2 21 Carrier 45 Vent 22 Cap differential carrier 2 Fig 5 16 Rear Axle Differential Carrier Assembly 5 25 Model 6036 S N 9B0499 and Before Section 5 Wheel Assembly Tires and Axle PIVOT PIN KNUCKLE STEER CYLINDER A BALL JOINT
406. sing a clean dry cloth Remove all traces of lubricant from the contact spring and grease or oil from the insulation plate 37 64 TO 19 32 1 7 TO 15 1 mm Spring Dimensions e Inspection and Replacement 1 Inspect parking switch assembly 5 Fig 10 63 for security of soldered connections cracked or damaged plate loose terminals damaged or frayed cables loose parking stud and misaligned contact points Spring height must be as indicated in Fig 10 64 10 56 MA1411 Fig 10 64 Minimum and Maximum Parking Switch f Inspect gear and shaft assembly 7 for damaged or worn gear teeth damaged threads or worn flats on the end of the shaft Replace gear and shaft assembly if damaged Replace motor if motor housing is damaged Inspect drive arm assembly 28 Fig 10 62 for wear loose pin and cracks Replace drive arm assembly if damaged Inspect connecting link 26 for worn bearings Replace connecting link if damaged Inspect shaft and pivot assembly 24 for damaged threads and loose drive arm Replace damaged parts Inspect spring clips screws nuts and washers for serviceability Replace as required Lubrication As the parts are being assembled i Lubricate the gear housing by filling the space between the bearings in the drive shaft bore with Electro Systems LU3001 grease e Place a sufficient amount of grease in the worm gear cavity to immerse the lower 1 8 of the driv
407. solenoid 34 Fig Refer to fuel run solenoid See para 10 7 3 causes starter to 10 5 fails to admit fuel to troubleshooting crank engine but fuel injection pump doesn t maintain engine operation in RUN position 2 Fuel tank is empty Fill fuel tank See para 8 4 2 Switches and Solenoids NEUTRAL START SWITCH Starter fails to 1 Check for problems in the Refer to shift lever linkage See para 4 2 2 crank engine with shift lever linkage adjustment instructions in travel select lever paragraph 4 2 2 in NEUTRAL the park lock switch DISENGAGED and ignition key switch in START 2 Be sure the neutral start The switch closes when a See para 10 7 2 switch is closing switch actuating pin presses against a spring loaded ball in the neutral start switch Remove switch from the control valve assembly and check actuator pin for free movement in the control valve assembly Also check for continuity with the pin pressing against the ball If open install new switch Switches and Solenoids FUEL RUN SOLENOID Ignition switch Fuel run solenoid 34 Fig Tighten connections and See para 10 7 3 cranks engine in 10 5 fails to admit fuel to install new wiring as required START but engine fuel injection pump due to doesn t operate in loose connections or RUN broken wiring 2 Fuel tank is empty Fill fuel tank See para 8 4 2 Fuel run solenoid is stuck Install new fuel run solenoid See para 10 7 3 in
408. spect that air has entered the braking system 1 Install new O ring 14 Fig 9 29 in the seat on valve and ball assembly 15 and insert into housing bore so that the seat end is located on the plug end of the brake valve 1 Place the transmission in neutral start the i d king brake 2 Install guide 16 spring 17 sleeve 18 and E E ee washer 19 in the housing bore 2 Install one end of an 18 to 24 inch 457 to 610 mm length of transparent 1 4 inch 6 mm inside diameter tubing over the brake bleeder Fig 9 31 Place the other end of this tubing in a suitable transparent container which is partially filled with hydraulic oil The end of the 3 Insert new backup ring 21 and new cup 20 tubing must be below the oil level in the inside end of plug 23 Note the order of container backup ring and cup 4 Install new O ring 22 on the plug and install 7 l in housing 13 A Warn l ng m 5 Install new cup 11 and spring 12 on plunger NOTE Itis desirable to install a new sleeve 18 in all units The sleeve is part of the valve repair kit Position the sleeve over the spring 17 and up against the seat flange 10 Note that the cup lip should be facing The pressure at the brakes is 525 25 psi toward the plug pressure end of the brake 36 2 1 7 bar Do not open the bleeder valve without holding tubing on the bleeder to prevent releasing a jet of oil that could cause 6 Insert assembled plunger into the h
409. ss door 10 13 2 Steering and Emergency Hydraulic Pump S N 7P0013 and Before The emergency hydraulic pump Fig 10 68 performs three functions e When starting the engine the emergency steer pump supplies oil pressure as the engine is being started e When oil pressure at the engine rises above 4 psi 0 3 bar the emergency steer pump ceases operation because the engine is turning fast enough for the tandem pump to supply sufficient hydraulic oil pressure for forklift operation e f engine oil pressure again falls below 4 psi 0 3 bar the switch will close and the emergency steer pump will resume operation for as long as the battery retains a sufficient charge a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries Remove hydraulic tank cover 3 Disconnect red electrical cable from solenoid 4 Fig 10 68 by removing nut 4 Tag and disconnect yellow ground wire from solenoid 4 by removing nut 5 Tag and disconnect yellow ground wire from housing of motor 1 by removing screw 6 Tag disconnect and plug the hydraulic supply hose at the pump Cap or plug the hose end and pump ports 7 Tag disconnect and plug the hydraulic pressure hose at the pump Cap or plug the hose end and pump ports 8 Prepare to remove pump and motor assembly by supporting assembly while an assistant removes two 3 8 16 UNC hex head capscrews Lift assembly from the forklift b Disassembly
410. stall spacer 7 lever 6 lock washer 5 and screw 4 5 Install washer 3 lock washer 2 and screw 1 6 Connect negative cable 2 Fig 10 38 to batteries Model 6036 S N 9B0499 and Before CARBON PILE BATTERY TESTER ALTERNATOR TEST AMMETER MA1191 Fig 10 36 Connections for Bench Check of Alterna tor o Service Test Specifications The JLG Alternator Part Nos 8270217 and 8270219 are also identified by Delcotron Alternator Model 1101228 Series 12SI Type 100 Specifica tion No 7236 It has the following service test specifications Negative ground When connected to a battery the ground polarity of the alternator must be the same as the ground polarity of the battery Clockwise rotation viewing from drive end 2 4 to 2 8 field ohms at 80 F 27 C A high ohmmeter reading indicates excessive resistance and a low reading indicates shorted field windings which can cause regulator failure 4 2 to 5 0 A field current at 80 F 27 C and 12 V A low ammeter reading indicates excessive resistance and a high reading indicates shorted field windings Cold output of 23 A at approximately 1600 rpm 66 A at 6500 rpm These outputs are with the alternator at 80 F 27 C NOTE A voltmeter is not needed for output check Load battery with carbon pile battery tester to obtain maximum output Refer to paragraphs b and n for test procedures Model 6036 S N 9B0499 and
411. stator windings is difficult to locate without laboratory test equipment due to the low resistance of the windings How ever if all other electrical checks are normal and the alternator fails to supply rated output shorted stator windings or an open delta winding are indicated Also a shorted stator can cause the indicator lamp to be on with the engine at low speed Check the regulator in the next paragraph before replacing stator i Brush Holder and Regulator Replacement IMPORTANT To determine if the regulator is defective use an approved regulator tester After removing the three attaching nuts and diode trio screw Fig 10 30 the brush holder and regula tor may be replaced by removing the two remaining screws Note the two insulators located over the top of the brush clips in Fig 10 30 and that these two screws have special insulating sleeves over the screw body above the threads The third mounting screw may or may not have an insulating sleeve If not this screw must not be interchanged with either one of the other two screws as a ground may result causing no output or uncontrolled alternator output j Slip Ring Servicing If the slip rings are dirty they may be cleaned and finished with 400 grain or finer polishing cloth Spin the rotor and hold the polishing cloth against the slip rings until they are clean IMPORTANT The rotor must be rotated in order to clean the slip rings evenly Cleaning the slip rings b
412. supply and a test lamp to the sender and suspending its probe in engine coolant which is several degrees below 210 F 99 C The sender should remain open It should close when coolant exceeds this temperature e Installation 1 Install high temperature sender 2 Connect wire to terminal of engine coolant high temperature sender Add engine coolant to normal operating level Connect negative cable 2 Fig 10 38 to the batteries 4 Operate engine and check for coolant leaks 5 Close and lock right engine access door 10 8 7 Alternator Not Charging Light The alternator not charging light warns the opera tor to discontinue forklift operation immediately due to a malfunction in the battery charging circuit 10 44 Wire number 6 from the alternator is energized and lights the alternator not charging bulb if the alternator stops supplying current upon demand by the charging circuit Refer to paragraph 10 8 4 for procedure for replacing indicator lamp TRANSMISSION HIGH TEMPERATURE SENDER MA1301 Fig 10 50 Transmission High Temperature Sender 10 8 8 Transmission High Temperature Sender The transmission high temperature light warns the operator to discontinue forklift operation immedi ately because the fluid in the transmission is too hot When the ignition key is in RUN current through the bulb can be grounded through the transmis sion high temperature sender The sender closes when t
413. systems Defects in the electrical system such as shorted wires Extended slow speed driving with many accessories turned on Loose or poor battery cable to post connec tions previous improper charging of a rundown battery or loose hold downs High resistance connections or defects in the starting system Long periods of vehicle storage without discon necting the batteries Small current drains of vehicle accessories which are connected all the time can discharge the batteries in a six to eight week period Batteries left in a dis charged condition for a prolonged period of time are subject to freezing and can become difficult to recharge Jump Starting with Auxiliary Booster Battery Both booster and discharged battery should be treated carefully when using jumper cables Follow exactly the following procedure for this negative ground system being careful not to cause sparks 1 Engage park lock and place transmission in neutral Turn off lights optional heater and other electrical loads Observe charge indicator If indicator is light replace battery If charge indicator is dark and has a green dot in the center failure to start is 10 32 not due to a discharged battery and the crank ing system should be checked If charge indicator is dark but the green dot does not appear in the center proceed as follows Attach one end of one jumper cable to the positive terminal of the booster battery and the o
414. t b Disassembly 1 Remove all dirt and grease from the cylinder 2 Fasten the cylinder in a soft jawed vise or other acceptable holding equipment Do not damage the tube 3 Remove the counterbalance valve 14 Fig 9 12 pilot check valve 15 and related O rings 18 and backup rings 19 from the tube 13 IMPORTANT Do not attempt to reset the extend cylinder counterbalance valve cartridge If re placement is necessary replace the cartridge with a new one 4 Using a pin spanner wrench unscrew the gland 12 Fig 9 13 from the tube 13 IMPORTANT Protect the finish on the rod at all times Damage to the surface of the rod can cause premature seal failure 5 Pull the rod and piston assembly straight out of the tube IMPORTANT When sliding the rod and piston assembly out of the tube be careful so that gland threads in the tube do not damage the piston 5 Keep the rod in line with the tube barrel to prevent binding 6 Remove piston seal 4 from the piston ANTI BUCKLE BAR ROD EXTEND BASE END END PIN CYLINDER PIN MA0521 Fig 9 11 Boom Extend Cylinder Removal Model 6036 S N 9B0499 and Before Section 9 Hydraulic System NOTE It may be necessary to apply heat to break the bond of the sealant between piston 5 setscrew 6 and rod 1 before the piston can be removed Refer to paragraph 9 2a 7 Remove setscrew 6 and nylon setscrew 7 securing piston 5 in place on rod 1
415. t console on the outside cab wall below the fork and frame tilt control lever A breaker will trip if there is a shorted or grounded wire in the applicable circuit It will automatically reset once it cools A circuit breaker has a bimetallic arm and a pair of contact points When the current exceeds preset limits the arm gets hot bends and opens the contact points This shuts off the current through the circuit and protects against damage or fire If a breaker continually trips check the system for shorts grounds or defective components Under normal operating conditions a circuit breaker should never require replacement However if a breaker doesn t automatically reset the breaker is defective and must be replaced The ignition switch feed for the entire electrical system is protected by a 40 A circuit breaker 4 Fig 10 6 the horn backup alarm and optional cab heater fan by a 10 A circuit breaker 2 and the control circuits by two 6 A circuit breakers 1 and 3 A forklift with an enclosed cab has an additional 6 A circuit breaker 5 that protects the windshield washer wiper switch and the circulation fan An optional light package includes head lights and a rear work light and stop directional hazard emergency flasher and tail lights in a circuit which is protected by a 15 A circuit breaker 6 a Removal of Individual Circuit Breaker and Circuit Breaker Bracket 1 Disconnect negative cable 2 Fig 1
416. tall a new transmission warning bulb temperature switch 27 high temperature sender lights with the Fig 10 5 engine running but not overheated If the indicator remains on If there is a short to ground See Fig 10 5 check wire 18 and the remedy the cause of the ignition switch for a short to short ground Model 6036 S N 9B0499 and Before 10 75 Section 10 Electrical System Trouble Probable Cause Remedy Reference Gauges and Indicator Lights FUEL LEVEL GAUGE No indication 1 Empty fuel tank Fill fuel tank See para 8 4 2 2 No current to ignition Connect lead See para 10 8 9 terminal because of broken or disconnected lead 3 Grounded wire between Insulate wire See para 10 8 9 sender and fuel level gauge 4 Fuel level gauge isn t Ground receiver See para 10 8 9 grounded 5 Sender defective Replace sender See para 10 8 9 Excessive pointer 1 Loose wire connections Tighten connectors See para 10 8 9 fluctuation 2 Defective sender Replace sender See para 10 8 9 FULL reading at all 1 Wire to sender is broken Replace wire See para 10 8 9 umes 2 Sender is not properly Ground sender See para 10 8 9 grounded 3 Defective sender Replace sender See para 10 8 9 Gauge indicates 1 Incorrect sender Replace sender See para 10 8 9 inatgurately 2 Defective sender Replace sender See para 10 8 9 3 Low voltage at receiver Determine and correct cause See para
417. tator bars Check for high insulation between the commutator bars broken brush springs or worn brushes 19 Low armature shaft speed and low current draw are indications of a Dirt or corrosion on connections b Damaged wiring c Dirty commutator bars d All of the causes in step 18 20 High armature shaft speed and high current draw are indications of a short circuit in the field coil It is difficult to find a short circuit in a field coil Install a new field coil Do the No Load Test again to check for improvement in the operation of the starter g Starter Field Coil Tests Hold the leads of an ohmmeter against one of the brushes and the frame of the field coil The needle of the ohmmeter must not move If the needle moved install a new field frame assembly 2 Hold the leads of an ohmmeter against one of the brushes and the end of the negative ground cable The needle of the ohmmeter must move If the needle did not move install a new field coil frame assembly h Periodic Maintenance The starter motor requires no routine maintenance beyond the occasional inspection of the electrical Hex Nut Lock Washer Battery Positive Lead Cable Hex Nut Lock Washer Starting Motor Feed Cable Hex Nut Lock Washer Terminal S from Neutral Start Switch 10 Self locking Hex Hut 11 Tooth Type Lock Washer 12 Flat Washer 13 Capscrew hex hd OCOMDNOARWNM gt connections which must be cle
418. tch 48 6 A Circuit Breaker 12 6 A Circuit Breaker 12 6 A Circuit Breaker 12 2 2 2 6 A Circuit Breaker 12 1 1 1 1 Steer Select Solenoid 55 Steer Select Solenoid 55 Low Oil Pressure Switch 31 Steer Select Switch 48 Hourmeter 50 Fuel Level Gauge 52 Warning Lights Test Switch 47 Neutral Start Switch 35 Water Temperature Light 51 Yellow Warning Lights Gauge 51 Black Park Lock Brake Switch 46 Yellow Water Temperature Switch 33 Yellow Engine Oil Pressure Switch 29 Engine Oil Pressure Light 51 Yellow Fuel Level Sender 42 Fuel Gauge 52 Yellow Transmission Temperature Switch 27 Transmission Warning Light 51 Black Starter Relay 36 Starter Solenoid 38 Yellow Circuit Breaker Bracket 13 Frame Ground at Battery 10 8 Yellow Red Not Used Red Red Yellow Red Red Yellow Black Red Yellow Red Yellow Yellow Yellow Black Black Yellow Yellow White Not Used Yellow Yellow Fuel Level Sender 42 6 A Circuit Breaker 12 10 A Circuit Breaker 11 10 A Circuit Breaker 11 Horn Button Switch 49 40 A Circuit Breaker 10 40 A Circuit Breaker 10 Fuel Run Solenoid 34 Starter Relay 36 6 A Circuit Breaker 12 Reverse Switch 53 6 A Circuit Breaker Windshield Washer 23 Ignition Key Switch 24 Not Used Ignition Key Switch 24 Starter Relay 36 Not Used 6 A Circuit Breaker 12 Park Lock Brake Light 45 Park Lock Release Valve Solenoid 56
419. tem 2 Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure A Warning Wait for the hydraulic fluid to cool before servic ing any hydraulic component Hot hydraulic fluid can cause severe burns 3 Remove the transmission cover from the frame 4 Install a tee and pressure gauge capable of measuring 0 1000 psi 68 9 bar on a service brake Fig 9 6 A Warning Before starting the engine be sure all hydraulic connections are tight and all tools are removed from the forklift 5 Install a pressure gauge capable of measuring 1000 psi 68 9 bar on the park lock bleeder fitting Fig 9 6 Start the engine and allow it to idle Depress the brake pedal and continue to hold until a pressure gauge reading is taken at a service brake 8 Place the park lock switch in the disengaged down position and check the pressure gauge reading at the park lock bleeder fitting 9 Pressure gauge readings should read 525 25 psi 36 2 1 7 bar If not adjust the pressure reducing valve turning the adjust ment screw clockwise to increase or counter clockwise to decrease pressure 10 Stop the engine Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure 11 Remove the pressure gauges and tees from the service brake and park lock and reconnect the hydraulic lines 12 Install the transmission cover after adjustment Model 6036 S N 9B0499 a
420. ter mixture 6 When empty refill to overflowing with water Completely flush and empty tank d Inspection and Replacement 1 Plug all outlets before removing a fuel tank for a suspected fuel leak make sure that one of the fuel hoses isn t leaking onto the tank 2 To test a fuel tank which is out of the forklift plug all openings except a supply or return elbow Apply a small amount of air pressure to tank through this elbow approximately 1 to 1 1 2 psi 0 07 to 0 10 bar Test tank for leaks by applying soap solution to exterior of tank or by submerging tank in water and looking for bubbles 8 12 3 For a short term repair you may be able to repair a small leak by installing a sheet metal screw with a neoprene gasket in the opening Replace tank for long term repair e Assembly 1 Install rubber bushings 19 Fig 8 18 and fuel supply and return elbows 4 and 20 in tank 2 Position fuel level sender gasket and fuel level sender 2 in tank 3 Loosely install the screw which secures the ground wire to the sender and fuel tank 4 Install the other four screws and alternately torque the five screws which secure the sender to the fuel tank from 10 to 14 Ib inch 1 13 to 1 58N m Use No 10 24 screws 5 Install the wire and nut on the center terminal of the sender 8 4 3 Fuel Level Sender and Gauge The fuel level sender and gauge assembly is described in Section 10 Electrical System MA0341 1
421. ternator speed and observe the voltage 3 If voltage is uncontrolled with speed and increases above 15 5 volts on a 12 volt system test regulator with an approved regulator tester and check field winding NOTE The battery must be fully charged when making this check 4 If voltage is below 15 5 volts on a 12 volt system connect the carbon pile as shown 5 Operate the alternator at moderate speed as required and adjust the carbon pile as required to obtain maximum current output 6 If output is within 10 amperes of rated output as stamped on the alternator frame alternator is good 7 If output is not within 10 amperes of rated output keep battery loaded with carbon pile and ground alternator field Fig 10 27 8 Operate alternator at moderate speed and adjust carbon pile as required to obtain maxi mum output 9 If output is within 10 amperes of rated output test regulator with an approved regulator tester and check field winding 10 If output is not within 10 amperes of rated output check the field winding diode trio rectifier bridge and stator as previously covered n Alternator Installation 1 If necessary install pulley 21 Fig 10 28 belt 20 washer 19 and hex nut 18 2 If necessary install stud 17 bracket 16 washers 15 and washers 14 3 Position alternator 22 on the engine and install sleeve 12 sleeve 11 screw 10 washer 9 self locking nut 8 4 In
422. the positive terminals on the batteries 5 Connect the negative cable 1 to the negative terminals on the batteries 6 Connect the ground cable 1 to the starter 10 5 4 Starting Motor Relay The starting motor relay Fig 10 22 consists of a movable contact with a fixed coil in a weatherproof casing The relay is internally grounded and is equipped with two large and two small terminals The small terminal S is for connection to the ignition system resistance wire The two large terminals are for connection between the batteries and the starting motor Turning the ignition switch with the transmission in neutral allows current to flow through the relay coil via terminal S to the ground point on the casing The flow of current energizes the coil forming a magnetic field which attracts a movable contact When the contacts fully close current from the batteries is allowed to flow to the starting motor through the relay Once the key switch is released the flow of current to the coil is stopped thereby breaking the magnetic field and allowing the return spring to open the contacts This action stops the current flow from the batteries to the starting motor a Removal of Starting Motor Relay and Relay Mounting Plate 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Disconnect positive battery cable 3 Fig 10 22 by removing hex nut 4 and lock washer 5 3 Disconnect
423. the O ring groove 7 Check the components to make certain they are correctly assembled The lock ring must be fully seated in its gutter 8 Partially inflate tube and insert in tire casing with valve located near valve hole in rim Attach valve retrieval tool to valve and thread tool through valve hole inserting the tube and attaching the tool may be facilitated by placing a block under the tire 9 Inflate tire using hydrofill as described in paragraph 5 1 10 5 1 13 Mounting Optional Tire on Single Piece Wheel 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 Install the valve stem Fig 5 3 into the hole in the rim and tighten to 45 to 55 Ib inch 5 to 6 2 N m Make sure parts are clean repainted if necessary and have been inspected for damage and cracks before proceeding with mounting Place rim on floor with narrow ledge on top Lubricate bottom tire bead and top rim flange with a thin solution of vegetable oil soap in water or equivalent rubber lubricant recom mended for this requirement never use petroleum base or silicone lubricants NOTE A mechanical bead unseating and seating tool may be purchased from the lowa Mold Tooling Company to facilitate step 5 5 Push bottom bead over rim as far as possible Use 36 tire irons to work the first bead completely over rim flange taking small bites and being careful not to damage bead NOTE On deep w
424. the emergency flashers pull flasher tab out All signal lamps and red pilot light will flash To cancel the emergency flashers move the directional signal lever momentarily in either direction MA1351 Screw 2 Top cover Directional signal switch Spring clip and socket Pilot bulb Wiring harness Oy Or GS Fig 10 56 Pilot Bulb Replacement b Flasher and Pilot Bulb Replacement To replace the pilot bulb remove two screws 1 Fig 10 56 and lift top cover 2 of directional signal switch 3 When cover is removed pull spring clip 4 away from handle Remove old pilot bulb 5 and install a new No 53 bulb for 12 volt service Engage the spring clip into the handle Do not try to test pilot bulb until switch is reas sembled and grounded GREEN PILOT LIGHTDLEFT TURN EMERGENCY FLASHER TAB DIRECTIONAL SIGNAL SWITCH HANDLE The flasher mount 12 Fig 10 53 is located above and to the right of the brake pedal When replacing a flasher use Flasher No 180 for this 12 V system c Switch Removal 1 Remove console cover below steering wheel 2 Disconnect negative cable 2 Fig 10 38 from the batteries Disconnect wiring Remove screws anchors clips strap and switch d Switch Disassembly There are no serviceable parts in the switch except the bulbs e Switch Inspection and Replacement 1 If the switch has been in service for a long period of time prepare to remove the top cover
425. the starter for more than 15 seconds at one time After the starter has run for 15 seconds let the starter cool for two minutes before operating the starter again e These tests will require a voltmeter a Voltage Specifications Minimum voltage while starter is running 9 6 V Maximum voltage loss e Positive battery cable and starter solenoid 0 5 V e Each cable 0 4V e Starter solenoid 0 1 V e Each connection 0 0 V 10 12 b Test 1 Voltage Loss in Complete Starting Circuit 1 Disconnect the wire from the fuel run solenoid 2 Fig 10 42 at fuel injection pump Fig 10 9 Turn ignition key to the ON position Connect a remote starter button to the battery and ignition switch terminals on the starter solenoid 4 Select voltage range that will measure 12 Vdc Move the voltage lead switch on the voltmeter to the EXT position 6 Connect the positive lead of the voltmeter to the positive battery cable at the battery 7 Connect the negative lead of the voltmeter to the negative battery cable at the battery 8 Push in and hold the starter button and read the voltmeter a If the voltmeter indicated 9 6 V or more the starting circuit is in good condition and no other testing is required b If the voltmeter indication was less than 9 6 V complete Test 2 Fig 10 10 Measuring Voltage Loss in the Positive Battery Cable and Starter Solenoid c Test 2 Voltage Loss in the Positive Battery Cable
426. the upper hoses and clamps 8 Replace the rear boom cover 3 1 10 Long Term Storage Preparation Remove rust and corrosion from sliding surfaces and coat with grease B CAA B FIG 3 13 OA0182 Fig 3 17 Forklift Lubrication Points 3 1 11 Boom Lubrication Points Lubricate the following grease fittings using Multi Purpose Grease MPG every 50 hour interval Refer to Fig 3 17 A Hydraulic cylinder pins 8 points B Boom chain sheaves 2 points C Boom pivot pins 2 points D Carriage pivot pin 2 points Lubricate the boom extend and retract chains using Multi Purpose Grease MPG every 250 hour interval 1 Prepare to grease the chains by removing the rear cover from the outer boom 2 Apply MPG to retract chain using a brush or grease gun 3 Extend and retract the boom several times to permit grease to penetrate the entire chain Model 6036 S N 9B0499 and Before Section 3 Boom RETAINER NUT COUNTERBALANCE VALVE ADJUSTING SCREW EXTEND RETRACT CYLINDER OA0542 Fig 3 18 Counterbalance Valve on Boom Extend Retract Cylinder 4 With the boom extended fully apply MPG to the extend chain using a brush or grease gun 5 Replace the rear outer boom cover 3 2 EMERGENCY BOOM LOWERING 3 2 1 Loss of Engine Power or Hydraulic Pump Failure If you lose engine power or hydraulics with an elevated boom lower the boom to the ground by using the following procedure
427. ther end of the same cable to positive terminal of discharged battery DO NOT PERMIT vehicles to touch each other as this could establish a ground connection and counteract the benefits of this procedure Attach one end of the remaining negative cable to the negative terminal of the booster battery and the other end to a ground at least 12 inches from the battery of the vehicle being started DO NOT CONNECT DIRECTLY TO THE NEGATIVE POST OF THE DEAD BATTERY A Warning Personal injury caused by electrolyte squirting out the battery vent Personal injury or property damage due to battery explosion Damage to the charging system of the booster vehicle or of the immobilized vehicle Positive cable Negative cable NONA Two self locking nuts 2 3 Wea 7 matant Spacers 2 Fig 10 38 Battery Hold Down Strap Removal Bolts 2 Batteries Model 6036 S N 9B0499 and Before h Battery Removal 1 Prepare to remove the battery s by unlocking and opening door to battery compartment 2 Disconnect the negative cable 2 10 38 from the batteries Disconnect positive cable 1 from batteries Remove the two self locking nuts 3 from below the cab floor and lift the spacers 4 hold down strap 5 and bolts 6 from the battery compartment 5 Carefully lift the battery s from the battery compartment i Battery Inspection Cleaning and Drying 1 Periodically look for any accumula
428. tings on main control valve 6 Fig 9 23 and nearby components 5 Tag and disconnect the hydraulic lines from the main control valve and cap or plug the connectors 6 Tag and disconnect control linkage 7 from main control valve by removing cotter pins 1 and retaining pins 2 7 Remove the capscrews 5 locknuts 3 and washer 4 securing the control valve to the frame 8 Remove the main control valve from the forklift 9 Remove any remaining dirt and grease from the valve assembly b Relief Valve Repair Operation Fluid at supply pressure is admitted to the relief area Fig 9 24 of the valve through a hole in the piston Initially the pilot poppet relief valve poppet and check valve poppet are seated Model 6036 S N 9B0499 and Before Section 9 Hydraulic System Cotter Pin Retaining Pin Locknut Washer Capscrew Main Control Valve Linkage NO oP ON MA0641 Fig 9 23 Main Control Valve Installation The relief valve setting is determined by the compression of the pilot spring as set by the adjustment screw When the pressure exceeds the relief setting the pilot poppet acts against the poppet spring to unseat The fluid then flows around the pilot poppet through cross drilled holes in the plug to the reservoir some pressure is relieved Due to the reduced pressure the piston seats against the pilot poppet This shuts off fluid flow through the valve and causes a low pressure area
429. tion of dirt or corrosion on top of the battery corroded terminals and cables broken or loose terminal posts and container or cover that is broken or cracked 2 Scrub the exterior of the battery and cable terminals by using a nonmetallic brush which has been dipped in a mixture of baking soda and water Dry the battery with a clean cloth Check the voltage regulator setting at every periodic maintenance inspection Overcharging is acommon cause of battery failure The voltage setting should be 13 6 to 13 8 and never more than 14 0 V j Battery Installation 1 Place batteries in battery compartment 2 Install bolts 6 Fig 10 38 spacers 4 hold down strap 5 and two self locking nuts 3 DO NOT OVERTIGHTEN Be sure hold down strap is properly attached to keep batteries from bouncing Vibration is very harmful to a battery Connect positive cable 1 to the batteries Connect negative cable 2 to batteries Close and lock door to battery compartment rn PF amp Battery Identification and Service Test Specifications The JLG 12 V Battery Part No 8270014 is also identified by Delco Freedom Battery Cat No 24 60 BCI Group Size is 24 A e Load Test Amperage is 260 e SAE BCI reserve capacity in minutes is 95 minutes Model 6036 S N 9B0499 and Before Section 10 Electrical System e Cold cranking current SAE SPEC J537h is 525 A at 0 F 18 C e For battery warranty contact your
430. tion weight added to the assembly is equal to that shown in the table 12 Replace core housing in valve stem by pushing handle 4 in until contact is made turn handle clockwise until core housing is screwed tight in valve stem 13 Withdraw handle set pump to EVACUATE and pump all liquid from hose 14 Shut off pump 15 Unscrew ejector body 2 from valve 16 To assure fully seated beads inflate tire to 35 psi 2 4 bar using a standard air line and then with valve stem at top bleed pressure and excess water or solution down to 1 to 2 psi 0 07 to 0 14 bar above recommended inflation 17 Set final working pressure after tire has been mounted on forklift and with weight of forklift on tire Position the wheel so valve stem is at the bottom position Use an air water gauge to check inflation pressure of each tire at least once a week Model 6036 6036T S N 9B0499 and Before 18 Insert the valve core in the stem and pressur ize the tire as follows AIR PRESSURES 13 00 x 24 Size 10 ply Standard 55 psi 3 79 bar 15 00 x 19 5 Size 12 ply Optional 60 psi 4 14 bar HYDROFILL MIXTURE 13 00 x 24 10 ply Standard 164 Ib 74 kg Calcium Chloride to 33 gal 125 liter of water each tire 15 00 x 19 5 12 ply Optional 120 Ib 54 kg Calcium Chloride to 24 gal 91 liter of water each tire 5 1 11 Mounting Tire 1 Be sure you ve read and understood the warning notices and general inst
431. to the extend side of the right front steering cylinder and the retract side of the left front steering cylinder Since both steer select valve solenoids are de energized return hydraulic oil from the front cylinders circulates through select steer valve ports to J and power steering control valve section ports D to E to the return filter and reservoir Right Turn 4 Wheel Steer When a right turn is being made with the steering select switch in 4 wheel steer up position 1 The power steering control valve spool is shifted so that supply pressure is applied through ports F to C Fig 9 7 to the intake side of the power steering metering section A measured amount of hydraulic oil is ex hausted from the metering section and routed back to the control valve section where it is channeled through ports B to A Supply oil is routed from port A to the extend side of the right front steering cylinder and the retract side of the left front steering cylinder Return oil from each of the front steering cylinders passes through the solenoid ener gized select steer valve from ports to H to the retract side of the right rear steering cylinder and the extend side of the left rear steering cylinder Return oil from each of the rear steering cylinders flows through steer select valve ports G to J and power steering control valve section ports D to E to the return filter and reservoir Right Turn Crab Steer When a
432. to the fuel injection pump throttle and stop lever with cotter and clevis pins Adjust the clevis so that the lever touches the stop screw Connect the fuel lines to the fuel pre filter and fuel filter assemblies Connect engine wire harness to the engine and transmission components Fig 8 26 e Starter e Starter Ground Cable e Starter Relay e Neutral Start Switch on transmission e Transmission Temperature Switch e Low Oil Pressure Sender e Emergency Pump Oil Pressure Switch e Water Temperature Sender e Fuel Run Solenoid e Alternator e Thermo Start Plug Secure the rear support between the side frame members with ten capscrews lock washers and hex nuts Torque to 225 to 275 lb ft 306 to374N m Connect the wiring to the backup alarm Attach the exhaust system to the engine Install the air cleaner system on the rear support and connect the hoses Install the radiator overflow bottle Install the radiator hoses and shroud Connect the radiator hoses to the engine Fill the radiator as follows a Be sure the radiator petcock is closed and the engine cylinder block drain plug is installed b Fill the radiator completely with 50 50 mixture of ethylene glycol and water Capacity is 5 4 gallons 20 4 liter c Replace radiator cap d Add coolant to the overflow bottle until it is about 1 4 to 1 2 full approximately 1 quart 0 9 liter e Clean dirt and debris from radiator fins and core
433. tooth type lock washer 6 at the lower right corner of the reservoir between the reservoir and the cab wall 5 Lift the washer reservoir assembly 8 from the forklift b Disassembly Do not disassemble the reservoir and motor are not available separately c Cleaning and Drying Without submerging the motor or pump rinse out the reservoir and allow it to air dry d Inspection and Replacement 1 Prepare to test the motor by filling the reser voir with water 2 Test the motor by connecting a 12 Vdc source to the motor terminals If motor doesn t run replace reservoir and motor assembly 3 Inspect the condition of the reservoir if cracked brittle or leaking at the joint between the reservoir and pump replace the reservoir and motor assembly 4 Check hose from pump to washer nozzle for proper connection and deterioration 5 Be sure passage through nozzle is open and is not clogged 10 53 Section 10 Electrical System COON O a PO Neo Nut Washer Wiper Arm Washer Panto Adapter Gasket Shaft and Pivot Assembly Nut Drive Arm Screw Lock Washer Motor Mount Wiper Motor Capscrew Lower Panel Washer Nozzle MA1391 Flange Head Capscrews 4 Right Console Overlay Right Front Console Panel Spring Jam Nuts 2 Lock Washers 4 Capscrews 2 Brake Valve Clevis Pin Cotter Pin Knurled Driver Rubber Cap Nut MA1392 Fiber
434. torquing them to 31 lb ft 42 N m Attach the retract chain at the chain support plate Fig 3 11 and route it along the bottom of the outer boom to the rear boom cover opening Remove hoist and sling from outer boom Remove cribbing from front of boom Refer to paragraphs 3 1 2 b and 3 1 1 b and install Mie imenmediate and inner booms 18 Lubricate the outer boom pivot pins Fig 3 7 Refer to Fig 3 9 and check the wear pad gap with multi purpose lithium based grease between the front outer boom side and top wear Model 6036 S N 9B0499 and Before 3 1 4 Chain Replacement Two chains extend the inner boom and one chain retracts it Extend Chains IMPORTANT Replace extend chains in pairs or sets ONLY a 1 Removal Fully retract the boom Remove the rear boom cover Refer to Fig 3 11 and remove the extend chain locknut and flat washer securing each chain clevis to a block at the upper rear of the inner boom Remove the locknut and shoulder screw that attaches each extend chain to the yoke at the front of the boom Pull the chains out the front of the boom Remove a chain clevis at both ends of each chain Installation Be sure the boom is fully retracted Install a chain clevis on both ends of each chain Working from the rear boom cover opening remove both top intermediate boom wear pads to gain access to rear boom chain connection Using a long rod or other suitable tool route the chains betwe
435. trol lever and its associated control cable Control lever positions for tilting the grille are as follows TO FRAME TILT CYLINDER Center Position When the grille and frame tilt control lever is placed in the center or neutral position the directional control valve spool is positioned so that pump supply pressure is directed through ports F to C Fig 9 4 to the return filter and reservoir If the return filter becomes clogged hydraulic oil will bypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar Up Position When the grille and frame tilt control lever is placed in the up position the directional control valve spool is positioned so that pump supply pressure is directed through ports E to A Fig 9 4 to the base extend end of the grille tilt and slave cylinders The extension of the slave cylinder is fixed by the position of the boom so that only the grille tilt cylinder is extended to tilt the grille up If supply pressure reaches 2650 psi 182 6 bar the MAIN CONTROL gt a VALVE I i gpi L p E l iio yas o TRB i M y eet ee tose 4 l m DIRECTIONAL CONTROL VALVE i 3 POSITIONS i UP l l COUNTER DOWN 1 5 TH UP DOWN BALANCE SLAVE I 1 ABC ABC ABC VALVE CYLINDER l l ia TA i w DEF DEF DEF CENTER
436. tted or damaged 4 Replace outer spline 3 if it is worn pitted scored or chipped 5 Replace all weak broken or damaged springs 4 6 If any one of lining plates 9 or rotor discs 8 show wear or scoring replace the complete stack NOTE If anew stack wasn t installed keep the stack of plates and discs in exactly the same order in which they were removed 5 23 e Assembly Refer to page 55 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for assembly instructions f Installation 1 Install dust slinger 37 Fig 5 16 on end yoke assembly 38 2 Refer to page 54 of Spicer Dana Maintenance Manual for Axle Models PS PR 7036 for installation instructions g Bleeding 1 Be sure all pressure lines are secure and don t leak 2 Bleed the pressure release section of the park lock by pressurizing the side inlet port and allowing air to escape from the top port 3 Pressure should not exceed 100 psi 690 kPa during bleeding 4 Apply sufficient pressure to release the park lock and allow for the checking of system operation 5 2 7 Carrier Assembly Refer to paragraph 5 2 1 for axle assembly removal and installation instructions Refer to pages 38 through 53 of Spicer Dana Models PS PR 7036 Maintenance Manual for removal and installation of carrier from axle housing removal and installation of differential from carrier and differential and pinion disassembly and asse
437. tteries 3 Ifthe motor fails to operate remove and replace the motor as follows b Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Prepare to remove the windshield wiper motor by removing four flange head capscrews 1 Fig 10 62 and lifting and positioning the right console overlay 2 and right front console panel 3 to one side to provide access to the windshield wiper motor 3 Tag and disconnect wiring from wiper motor Model 6036 S N 9B0499 and Before A 1 2 3 4 5 6 7 8 9 1 0 Section 10 Electrical System Prepare to position the brake valve 8 Fig 10 62 to one side by disconnecting spring 4 Remove two jam nuts 5 four lock washers 6 two capscrews 7 and position the brake valve 8 out of the way to provide access to the windshield wiper motor Remove nuts 11 and washer 12 If necessary use a gear puller to separate wiper arm 13 from knurled driver 14 Then remove knurled driver Remove rubber cap 15 nut 16 washer 17 and fiber washer 18 While an assistant supports the windshield wiper motor from within the cab remove the screw 19 flat washer 20 panto adapter 21 and gasket 22 your assistant can now lift the motor and attached parts from the cab Place motor and attached parts on a bench and remove nut 27 drive arm 28 and washer 29 from wiper motor assembly 33
438. ty rim components is dangerous Dirt and rust prevent components from seating properly which could result in an explosive separation Such explosions could result in severe injury or death to the operator and to those in the area 5 1 7 Wheel and Tire Inspection and Replacement 1 Inspect the air liquid valve core and stem Fig 5 2 Replace the entire valve if either compo nent is damaged Replace the core O ring and stem seal regardless of condition 2 Replace any tire that is worn or cut through the cords When replacing tires follow the tire manufacturers recommendations 3 Check all metal surfaces for rust corrosion cracks bent flanges sprung lock ring and deep tool marks on rings or gutter areas Replace all damaged worn out or cracked parts 4 Replace the rim base and or lock ring if there is any wearing away of the metal mating surfaces and or if they are deformed broken or cracked or pitted from corrosion 5 Replace the sealing ring regardless of condi tion 5 1 8 Tire and Wheel Lubrication 1 Apply lubricant to the bead seat area tire bead and rim mating surfaces prior to mount ing the tire 2 Use only those lubricants recommended by rim and tire manufacturers 3 Lubricate the new sealing ring with an ap proved vegetable based lubricant 5 7 Section 5 Wheel Assembly Tires and Axle 5 1 9 Mixing Hydrofill Solution Prepare the hydrofill mixture by pouring calcium chloride
439. ue 2 9 7 After Engine Servicing Consult the qualified service agent for proper procedure before startup 2 9 8 After Boom Servicing 1 Check wear pads 2 Check chain tension adjustment 3 Lubricate all grease points 2 9 9 After Axle Servicing 1 Check fluid levels Check torque of drive shaft yoke hardware Check wheel nut torque Check toe in if required Lubricate all grease points Refer to Dana Service Manual for SECTION 1 General Information Pak ON 2 10 FLUID LEVELS AND LUBRICATION 2 10 1 Wheel Ends Use the following procedure to check fluid level on the wheel ends 1 Level the forklift ground the carriage shut off engine and engage the parking lock Be sure that arrow on wheel end housing is pointing down Model 6036 S N 9B0499 and Before Section 2 General Instructions 2 Clean the area around the magnetic drain plug and remove the plug and check fluid level Use only Special TRAK Wet Disc Brake Oil P N 8522042 as required to bring level up even with the plug hole IMPORTANT Other brake oils should not be used You will lose braking force and brake squealing will occur 3 Clean and install drain plug 2 10 2 Hydraulic Reservoir With the oil cold and the forklift on a level surface and all hydraulic cylinders retracted check the sight gauge plug If oil is visible in the sight gauge plug the level is satisfactory If oil level is not visible in the sight gauge the le
440. unt front bead from rim and pump remaining hydrofill solution from tire 5 4 Section 5 Wheel Assembly Tires and Axle START BEAD ON THIS SIDE OF RIM DEEP WELL 22 MA0231 Fig 5 3 Optional Wheel Assembly with Single Piece Rim 5 1 2 Demounting Tire IMPORTANT Always completely deflate tire as described in paragraph 5 1 1 before you attempt to demournt tire 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 Toremove a wheel from the forklift refer to paragraph 5 1 5 5 1 3 Removing Wheel from Forklift The tires are filled with air and hydrofill which is a calcium chloride and water solution Usually this solution is removed from the tire as described in paragraph 5 1 1 before the wheel is removed from the forklift 1 Be sure you ve read and understood the warning notices and general instructions in paragraph 5 1 2 Use a jack to raise the forklift Rotate wheel to position tire valve at bottom and then lower wheel until tire is slightly deflected 3 Remove hydrofill from tire or tube as described in paragraph 5 1 1 IMPORTANT Always completely deflate tire as described in paragraph 5 1 1 before you attempt to demourt tire 4 Loosen the wheel lug nuts 5 5 5 Use a suitable hoist or jack to raise the axle until the tire clears the ground Use approved jack stands to support the forklift never rely solely on jac
441. up ring is not flat on both sides the side with the arc must be toward the O ring 3 Fasten the eye of the rod eye in a soft jawed vise and put a padded support below the other end of the rod to prevent damage to the rod 4 Push the assembled gland onto the rod 13 If necessary use a soft hammer to drive the gland onto the rod Install new O ring 6 inside of the piston 5 Install the piston on rod 7 Apply Loctite Primer T and Threadlocker 271 to the nut 2 in accordance with the manufac turer s instructions Install the nut on the rod and torque to 400 to 450 lb ft 544 to 612 N m Stake the nut in four places 8 Install a new piston seal 7 on the piston Fasten the cylinder tube 3 in a soft jawed vise or other acceptable holding equipment Be careful not to damage the tube 10 Lubricate the inside of the tube piston and gland O ring 9 with clean hydraulic oil 11 Apply a compression sleeve or other suitable tool to the gland in order to compress the O ring 9 on the gland Insert the assembled piston rod and the gland into the tube 3 Using a pin spanner wrench thread the gland into the tube Remove the compression tool IMPORTANT When sliding the rod and piston assembly into the tube be careful so that gland threads in the tube do not damage the piston seal Keep the rod in line with the tube barrel to prevent binding 12 Install new O rings 15 and backup rings 16 on check valves
442. uracy without the proper equipment A perfect atomizer when tested by pumping fuel through it in the open air gives a short pinging sound as the fuel emerges from the holes After the atomizer has been in service for some time the pinging changes to a crackling sound It is not until the atomizer sounds dead that its condi tion is likely to affect the running of the engine Model 6036 S N 9B0499 and Before Section 8 Engine b Atomizer Identification Currently the atomizer code is stamped on the atomizer body c How to Replace an Atomizer 1 Remove the fuel leak off pipe 2 Remove the high pressure pipe union nuts from the atomizer and fuel injection pump and release the pipe 3 Remove the atomizer flange nuts and remove the atomizer and seat washer 4 Put new atomizer with new seat washer in position Be sure atomizer is not tilted and tighten the flange nuts evenly by small amounts to 12 Ib ft 16N m 5 Connect high pressure fuel pipe and tighten nut to 15 lb ft 20 N m 6 Connect the leak off pipe 7 Run the engine and check for fuel and air leakage 8 Bleed the fuel system by following the proce dures in 8 1 5 Bleeding Fuel System 8 5 ENGINE EXHAUST SYSTEM A Warning e Exhaust fumes contain carbon monoxide a colorless odorless gas which is fatal when inhaled in a confined area Avoid breathing exhaust fumes and be sure engine operation will not cause a concentration of to
443. valves set as given above for No 4 cylinder check and adjust clearances for No 3 cylinder valves With No 1 cylinder valves set check and adjust clearances of No 4 cylinder valves With No 3 cylinder set check and adjust Model 6036 S N 9B0499 and Before clearances of No 2 cylinder valves 8 11 ENGINE STORAGE Use the following procedures immediately when engine is removed from service for an extended period The instructions for the use of Perkins POWERPART products are given on the outside of each container 1 Clean outside of engine 2 Where a preservative fuel is to be used drain the fuel system and fill with the preservative fuel POWERPART Lay Up 1 can be added to the normal fuel to change it to a preservative fuel If preservative fuel is not used the system can be kept charged with normal fuel but this will have to be drained and discarded at the end of the storage periods together with the fuel filter 3 Run the engine until itis warm Correct any fuel lubricating oil or air leakage Stop the engine and drain the lubricating oil sump Replace the lubricating oil filter canister Fill the sump to the FULL mark on the dip stick with clean new lubricating oil or with an ap proved preservative fluid POWERPART Lay Up 2 can be added to the lubricating oil to protect against corrosion If a preservative fluid is used this must be drained and normal lubricating oil used when the engine is returned to s
444. ve over charging broken case or tipping the battery over 45 on its side will result in loss of electrolyte level Batteries test Refer to possible causes in Provide a remedy for the See para 10 6 2 f good but don t paragraph 10 6 2 f cause of the trouble perform satisfactorily in service 10 70 Model 6036 S N 9B0499 and Before Trouble Discharged batteries Key binds in ignition switch lock Key cannot enter ignition switch or cannot be turned inside lock Ignition switch fails to function in one or more positions Ignition switch doesn t crank engine in START position Probable Cause Section 10 Electrical System Remedy Charging System BATTERIES cont d Short circuit in battery cell or cells Loose or dirty battery cable connections Dirty battery top Low output or no output from alternator High resistance in the positive battery cable High resistance in the negative battery cable Refer to paragraph 10 6 2 d and perform battery load test Clean the clamp on the battery cables and the battery posts Refer to paragraph 10 6 2 i and clean the top of the battery Refer to paragraph 10 6 1 and test alternator Refer to paragraph 10 6 2 and check the positive battery cable Test No 3 Refer to paragraph 10 6 2 and check the negative battery cable Test No 5 Switches and Solenoids IGNITION KEY SWITCH Sticky painted o
445. ve the clevis pin and lock clip attaching the clevis to the throttle lever assembly Remove the clamp attaching the throttle cable to the cable support Working from inside the cab remove the three bolts lock washers and nuts attaching the pedal to the cab floor Remove the pedal from the floor Installation Secure the pedal Fig 4 8 to the floor with three bolts lock washers and nuts Attach the cable to the support with a clamp Fasten the clevis to the lever assembly with the clevis pin and lock clip Hook one end of the spring around the pedal clamp and the other end around the neck of the clevis Fig 4 8 Check that all connections are secure If necessary adjust the pedal limit stop as follows Adjustment Lightly depress the throttle pedal to full position Model 6036 S N 9B0499 and Before 2 Adjust the limit stop screw until it touches the pedal 3 Tighten the locknut to 120 to 125 Ib inch 13 6 to14 1N m 4 Check engine rpm at full throttle If not 2600 to 2860 rpm readjust the limit stop screw IMPORTANT During the full throttle check operate no hydraulic function e e do not steer and e be sure the transmission is in neutral b Throttle Cable Removal 1 Working beneath the operators cab remove the spring Fig 4 8 from between the pedal clamp and washer on the clevis 2 Remove lock clip and clevis pin that attaches the clevis to the throttle lever assembly 3
446. vel is unsatisfac tory and hydraulic oil must be added 2 10 3 Engine Oil Oil level should be between the full and add mark on the dipstick 2 10 4 Cooling System Check level of coolant in overflow bottle When coolant is hot bottle should be 3 4 full to full When coolant is cool bottle should be 1 4 to 1 2 full Add coolant as required through the overflow bottle 50 50 mixture of ethylene glycol and water Model 6036 S N 9B0499 and Before 2 10 5 Splines Transmission input shaft splines must be coated with a molybdenum disulfide or Molykote com pound 2 10 6 Drop Box Remove level plug in drop box and check level of oil Add Tractor Hydraulic Fluid THF as required through the level plug hole with a squeeze bottle Bring the oil level up even with the level plug hole and install the level plug 2 10 7 Grease Fittings 1 Coat the following with a multi purpose lithium based grease Hydraulic cylinder pins 10 points Drive shaft slip joints 3 points Boom chain sheaves 2 points Boom pivot pins 2 points Carriage pivot pins 2 points Axle pivot pins 4 points Axle steer knuckles 8 points Axle tie rod ball joints 4 points e Axle steer cylinder ball joints 8 points 2 All excess grease must be removed 2 6 This Page Left Blank Intentionally Par 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 1 5 3 1 6 3 1 7 3 1 8 3 1 9 3 1 10 3 1 11 3 2 3 2 1 3 2 2 3 3 3 4 3 5 C
447. ver and unseat the second bead as described in step 3 5 Thoroughly lubricate rim flange and tire bead with a thin solution of vegetable oil soap in water or equivalent rubber lubricant recom mended for this requirement never use petroleum base lubricants or silicones 6 Force part of bead across rim from valve into well Starting at valve pry bead over rim flange using two 18 500 mm tire irons Continue by taking short bites to avoid dam age to bead until top bead is completely over the rim flange 7 Bring assembly to upright position and pull tube out of tire casing When only tube requires repair or replacement thoroughly inspect inside of tire casing for foreign material or damage and make sure both tube and inside of casing are dry before reinserting tube 8 To completely remove tire from rim turn assembly over and lubricate second tire bead and rim flange Be sure one side of bead still on the rim is in the rim well and insert tire irons under opposite side of bead Work rim slowly out of tire by taking small bites alternatively using both tire irons 5 6 9 Remove the valve stem from the rim base 10 Refer to paragraph 5 1 12 for tire mounting instructions 5 1 6 Wheel Cleaning Remove all rust corrosion dirt and other foreign material from all metal surfaces This is especially important in the rim gutter and bead areas and mating surface of the lock ring A Warning Assembling dirty or rus
448. ver wear rings metal watch bands or other items that may ground a live circuit e All lead acid batteries generate hydrogen gas which is highly explosive and 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 e Never cause sparks to occur or smoke near batteries that are charging or have been recently charged Keep sparks flame and smoking materials away Ventilate when charging or using in enclosed area Always shield eyes when working near a battery e Avoid battery acid Batteries contain sulfuric acid Antidote EXTERNAL In case of contact with acid flush immediately with water INTERNAL drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately DO NOT give fluids that would induce vomiting EYES Flush with water for 15 minutes and get prompt medical attention e Never use booster batteries to start the engine or try to charge the battery if the electrolyte in the battery is frozen e Charge batteries only in a well ventilated area Always be sure battery chargers are OFF when connecting to or disconnecting from batteries e See Delco Remy Service Bulletin 1B115 and 1B 116 for additional safety information and procedures IMPORTANT The diodes in the alternator function as one way valves and the transistors in the voltage regulat
449. xercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent and alkali cleaners Be careful when using steam cleaner to avoid burns IMPORTANT These instructions cover only the routine maintenance of the transmission Refer to your 18000 Powershift Transmission Maintenance and Service Manual for transmission diagnosis repair and component replacement Cleanliness is of extreme importance Before attempting any repairs the exterior of the unit must be cleaned to prevent the possibility of dirt from entering the mechanism Model 6036 S N 9B0499 and Before 7 1 1 Daily or 10 Hour Intervals Level Check 1 Check the oil level with the engine running at idle and oil at normal operating tempera ture 2 Level the forklift engage the parking lock ground the carriage and place the travel se lect lever in neutral COVER MOUNTING NUTS 5 ACCESS HOLE IN TRANSMISSION COVER OA0392 Fig 7 1 Transmission Cover Access Hole 3 Remove the transmission dipstick through the access hole in the transmission cover Fig 7 1 and check the reading 4 Add tractor hydraulic fluid to the transmis sion as required to being it up to the full mark Transmission capacity is 4 3 gallons 16 3 liter 7 1 2 First 50 Hours and 500 Hour Intervals Thereafter Filter Change 1 Level the forklift ground the carriage shut off the engine and engage the parking lock 2 Remove the transmiss
450. xic emis sions Exhaust system components get very hot and can cause serious burns The exhaust system is supported by the engine to minimize the transfer of noise and vibration into the operators cab The tail pipe on current forklifts is directed to the right side of the forklift which is more remote from the operators cab Annoying rattles and noise vibrations in the ex haust system are usually caused by misalignment of parts When aligning the system leave all bolts or nuts loose until all parts are properly aligned then tighten working from front to rear 8 17 Section 8 Engine Whenever you replace a muffler you should also replace the tail pipe Use Exhaust System Sealer at all slip joint con nections before assembly When installing exhaust parts make sure there is sufficient clearance between the hot exhaust parts and pipes and hoses and wiring that would be ad versely affected by excessive heat PA0382 1 Muffler 6 Gasket exhaust manifold 2 Pipe exhaust 7 Flat 3 Pipe tail 8 Capscrew hex head 4 Clamp T Bolt 9 Nut 5 Clamp muffler 10 Pipe tail NOTE Items 7 through 10 are for forklifts with right side exhaust SN 8H0289 and after Fig 8 23 Exhaust System for a Naturally Aspirated Engine 8 18 When installing an exhaust system be careful to provide for expansion when the system is hot Check complete exhaust system for broken dam aged missing or mispositioned parts op
451. xle Wheel End Assembly Screw self locking Planetary Gear Assembly Flange planetary drive Plug drain fill Plug Pin roll Shaft planet gear Washer drive flange O 09D O eG Ne Model 6036 S N 9B0499 and Before 10 11 12 13 14 15 16 17 Washer keyed Bearing single roller Washer planet gear Gear planet Ring retaining Gear sun spur Spacer flat Gear planetary ring 18 19 20 21 22 23 24 25 Locknut Pin roll Cone bearing outer Hub Assembly Cup bearing outer Hub planetary Bolt wheel Cup bearing inner Flange and Wheel End Without Service Brakes PA0322 Slinger hub oil Nut wheel Cone bearing inner Seal oil Spindle Assembly Seal oil Fig 5 9 Rear Axle Drive 3 After drying components should be lightly coated with oil or rust preventive to protect them from corrosion c Inspectionand Replacement 1 Replace all discs and plates as a set if any of the following conditions exist e friction material groove depth on any disc is less than 0 005 0 127 mm e plates are warped as determined bya straight edge or e any plate or disc is heat damaged Replace all O rings regardless of condition 3 Replace all bearings cups and cones if they are worn pitted or damaged 4 Replace all gears that are worn pitted scored orchipped d Assembly Refer to page 28 through 30 of Spicer Dana Maintenance Manual for Axle Mod
452. y 1 Place the rotor in a vise position the drive end frame on the rotor and install shaft nut 18 Fig 10 28 2 Remove protective tapes which were applied during alternator disassembly refer to para graph d To install the slip ring end frame assembly to the rotor and drive end frame assembly remove the tape over the bearing and shaft and make sure the shaft is perfectly clean after removing the tape 3 Insert a pin through the holes to hold up the brushes 4 Carefully install the shaft into the slip ring end frame assembly to avoid damage to the seal 5 Join the halves of the alternator by installing the four thru bolts and nuts 6 After tightening the thru bolts remove the brush retaining pin to allow the brushes to fall down onto the slip rings 7 Remember when assembling the pulley to secure the rotor in a vise only tight enough to permit tightening the shaft nut to 40 60 Ib ft 54 81N_ m If excessive pressure is applied against the rotor the assembly may become distorted m Alternator Bench Check To check the alternator in a test stand proceed as follows 1 Make connections as shown in Fig 10 36 except leave the carbon pile battery tester disconnected IMPORTANT Ground polarity of battery and alternator must be the same Use a fully charged battery and a 10 ohm resistor rated at six watts or more between the alternator No 1 terminal and the battery 10 28 2 Slowly increase the al
453. y e Temperature For example a longer time will be needed to charge any battery at 0 F than at 80 F When a fast charger is connected to a cold battery the current accepted by the battery will be very low at first then in time the battery will accept a higher rate as the battery warms e State of Charge A completely discharged battery requires more than twice as much charge as a one half charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the current accepted is very low at first Later as the charging current causes the electrolyte acid content to increase the charging current will 10 31 Section 10 Electrical System f likewise increase e Charger Capacity A charger which can supply only 5 amperes will require a much longer period of charging than a charger that can supply 30 amperes or more Troubleshooting If a battery has tested good and then has not performed satisfactorily in service for no apparent reason the following are some of the more impor tant factors that may point to the cause of trouble 1 Vehicle accessories inadvertently left on overnight Defects in the charging system such as slipping fan belt high wiring resistance or faulty alternator A vehicle electrical load exceeding the alterna tor capacity with the addition of electrical devices such as radio equipment air condi tioner window defoggers or light
454. y Brake Light Stop Light Two stop tail lights 23 Fig 10 53 at the rear of the forklift have dual filament bulbs The brake filament lights as long as the service brake pedal is pressed it goes out when the pedal is released completely Inspect the operation of the stop tail light daily and replace the bulb whenever either filament fails to light You will find the number of the bulb in the Electrical Specifications Table at the end of this section MA1371 Jam Nut Actuator Plate Jam Nut Capscrew Momentary Brake Light Switch aon gt Fig 10 58 Momentary Brake Light Switch Model 6036 S N 9B0499 and Before Section 10 Electrical System 10 9 3 Momentary Brake Light Switch a Removal 1 Disconnect negative cable 2 Fig 10 38 from the batteries 2 Loosen jam nut 1 Fig 10 58 which secures actuator plate 2 to the brake pedal 3 Loosen jam nut 8 which bears against the plate which is welded to the brake pedal 4 Remove capscrew 4 and actuator plate 2 Prepare to remove the rubber capped mount ing nut hereafter referred to as the boot from the switch 5 by loosening the switch jam nut on the back side of the brake pedal 6 Remove the boot from the switch by manually turning the boot counterclockwise Pull and tilt the boot as required to release the boot from the groove in the plunger and remove the boot from the switch 7 Remove the switch from the brake pedal and
455. y brake pump Fig 9 7 provides limited backup hydraulic supply pressure to the steering and brake circuits in the event of engine stoppage or tandem pump failure and during initial start up before the tandem pump is fully operational This pump is driven by an electric motor it also draws fluid through the suction strainer in the reservoir The steering and emergency brake pump is controlled by a oil pressure switch on the engine which senses the engine oil pressure When the ignition switch is in RUN position and the pressure switch is closed at oil pressure below 4 psi 0 3 bar the steering and emergency brake pump is energized and the pump will run Output of the pump is 3 gpm at approximately 1500 psi 104 bar 9 17 Section 9 Hydraulic System When the pressure rises above 4 psi 0 3 bar engine running the oil pressure switch opens to stop the steering and emergency brake pump No Steering Action When no steering maneuver is being accom plished the power steering control valve spool is in the center or neutral position and fluid from the tandem pump circulates through ports F to E Fig 9 7 of the control valve section directly back to the reservoir No fluid is directed to the steer select valve or the steering cylinders Left Turn 2 Wheel Steer When a left turn is being made with the steering select switch in 2 wheel steer center position 1 The power steering control valve spool is shifted s
456. y hand without spinning the rotor may result in flat spots on the slip rings causing brush noise Slip rings which are rough or out of round should be trued in a lathe to 0 002 0 05 mm maximum indicator reading Remove only enough material to make the rings smooth and round Finish with 400 grain or finer polishing cloth and blow away all dust END FRAME BEARING __ SLINGER i ARMATURE SHAFT ae MA1171 Fig 10 34 Drive End Bearing Assembly Some Models Use a Flat Washer Instead of a Slinger Model 6036 S N 9B0499 and Before Section 10 Electrical System k Bearing Replacementand Lubrication The bearing in the drive end frame can be removed by detaching the retainer plate screws and then pressing the bearing from the end frame refer to Fig 10 34 If the bearing is in satisfactory condi tion it may be reused and it should be filled one quarter full with Delco Remy Lubricant No 1948791 before reassembly FAN END FRAME ij FLAT PULLEY RETAINER WASHER COLLAR 5 NUT IN SHAFT COLLAR COLLAR Fig 10 35 Drive End Bearing Assembly Late Production All Series IMPORTANT Do not overfill as this may cause the bearing to overheat and use only 1948791 Lubricant The bearing in Fig 10 35 is sealed on both sides lubrication is not required MA1181 To install a new bearing press in with a tube or collar that just fits over the outer race wit
457. y turning the Model 6036 S N 9B0499 and Before adjusting screw on each cartridge simulta neously into the cartridge very slowly clockwise Hydraulic oil from inside the hoist cylinders will escape through the fault in the line 3 If the line failure is in the boom lowering line the boom must be lowered by following the next 3 steps a At the base of each hoist cylinder locate the counterbalance valve cartridges Fig 3 19 Loosen the retainer nut on each cartridge and turn the adjusting screws in clockwise until they bottom out Doing this will render each counterbalance valve inoperative b Clear the area around the machine of all personnel and return to the operators cab c Move the boom control lever forward to lower the boom IMPORTANT This procedure is to be used in emergency situations only By turning the counter balance cartridge adjusting screws to lower the boom the pressure settings of the cartridge have been altered DO NOT attempt to reset these cartridges Remove and replace all three cartridges with new parts Failure to replace these cartridges with new parts will result in erratic extreme bounc ing lowering action which may cause damage to other components 3 3 QUICK ATTACH ASSEMBLY The quick attach assembly Fig 3 20 provides a structure on which an attachment may be installed or removed from the forklift a Removal 1 Fully lower boom and ground the attachment 2 Remove the
458. ypass the filter when the pressure reaches 10 to 15 psi 0 7 to 1 03 bar The counterbalance valve in the extend cylinder serves two other main functions One prevents component damage and the other is for safety These functions can be described as follows e If the machine is traveling and the boom runs into an immovable object pressure will build up on the base end of the cylinder If the counterbalance valve was not installed the rod of the cylinder would bend damaging the cylinder With the counterbalance valve installed the pres sure will build up until it reaches 2650 psi 182 6 bar and then the counterbalance valve will be internally piloted open allowing the pressure to return to the reservoir This condition will only exist if the cylinder has been extended If the cylinder is already fully retracted the counterbalance valve will have no effect and the cylinder rod will bend Model 6036 S N 9B0499 and Before e Should any of the hydraulic lines going to the extend cylinder fail there will be a loss of hydraulic system pressure to the cylinder Example lf there was a hydrau lic line failure in the pressurized retract line during retracting the counterbalance valve would lose pilot pressure closing off flow returning to the reservoir The oil in the base end of the cylinder would then be trapped which would immediately stop boom retraction preventing an elevated load from retracting uncontrolled The load can be lowe

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