Page 1 Service Manual Model 6036 S/N 9B0499 & Before 8990151 Revised February 11, 2005...
Page 3 Effectivity Page January, 1997 - 001 - Original Issue. February 11, 2005 - B - Replaced all branding with JLG. Model 6036 S/N 9B0499 and Before...
Page 4 Effectivity Page Model 6036 S/N 9B0499 and Before...
Page 5 SECTION CONTENTS Section Subject Page Section 1 Safety Practices ................1-1 Section 2 General Instructions ................2-1 Section 3 Boom ....................3-1 Section 4 Operator's Cab .................. 4-1 Section 5 Wheel Assembly, Tires, and Axle ............5-1 Section 6 Drive Shafts and Drop Box ..............6-1 Section 7 Transmission, Clark Series 18000 .............
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Page 7: Table Of Contents
Section 1. Safety Practices SECTION 1 SAFETY PRACTICES CONTENTS Danger ! Par. Title Page 1.1 INTRODUCTION The signal word “DANGER” signifies that an 1.2 SIGNAL WORDS imminently hazardous situation to a person 1.3 PERSONAL CONSIDERATIONS on or near the forklift exists. This danger to persons is such that it will result in a high 1.4 EQUIPMENT CONSIDERATIONS likelihood of death or permanent injury if the...
Page 8: Personal Considerations
Section 1. Safety Practices 1.3 PERSONAL CONSIDERATIONS Item What to do Clothing Do not wear loose clothing or jewelry. Improper clothing can catch on controls or moving parts and cause accidents and/or injury. Eye Protection Always wear appropriate eye protection Permanent eye damage can be caused when chiseling, grinding, discing, welding, if foreign matter enters the eye.
Page 9: General Considerations
Section 1. Safety Practices 1.4 EQUIPMENT CONSIDERATIONS (cont.) Item What to do Hand Tools Always use the proper tool for the job. Many cuts, abrasions, and/or injuries are caused by defective or improper tools. Always keep tools clean and in good Well maintained tools work better and working order.
Page 10: Final Word
Section 1. Safety Practices 1.6 OPERATIONAL CONSIDERATIONS (cont.) Item What to do Ventilation Avoid prolonged running of the engine in Exhaust fumes are highly toxic and a closed area with inadequate ventilation. can kill. Radiator Cap Always turn the radiator cap slowly to the Escaping coolant can burn you seri- first stop to relieve pressure.
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Page 12: Section 2 General Instructions
Section 2 General Instructions SECTION 2 GENERAL INSTRUCTIONS CONTENTS Par. Title Page Par. Title Page AFTER SERVICE STARTUP INTRODUCTION AND CHECKS CLEANING 2.9.1 Starting After Servicing REPLACEMENT HOSES AND TUBES 2.9.2 After Hydraulic Component Servicing 2.4.1 Inspection 2.9.3 After Brake System Servicing 2.4.2 Installation BEARINGS...
Page 13: Hoses And Tubes
Section 2 General Instructions 2.1 INTRODUCTION 2.3 REPLACEMENT Appropriate service methods and proper repair Replace O-rings, seals, and gaskets whenever procedures are essential for safe, reliable opera- they are disturbed. Never mix new and old seals tion of the forklift and safety of the individual doing or O-rings regardless of condition.
Page 14: Bearings
Section 2 General Instructions Be sure that hydraulic oil is at operating tempera- 2.5 BEARINGS ture (80 to 120 °F) before adjusting relief valves, pressure reducing valve or sequence valve. If 2.5.1 Removal necessary, operate the machine to raise the oil temperature.
Page 15: Painting
Section 2 General Instructions 2.7.4 Straight Thread O-ring Fitting 2.8 PAINTING (non-adjustable) Unless otherwise specified, paint all components 1. Make sure both threads and sealing surfaces as follows: are free of burrs, nicks, scratches, or any foreign material. 2.8.1 Orange Paint Use orange paint on all components except as 2.
Page 16: After Service Startup And Checks
Section 2 General Instructions 2.9.5 After Replacing Transmission 2.9 AFTER SERVICE STARTUP 1. Check transmission fluid level and replenish AND CHECKS as required. 2.9.1 Starting After Servicing 2. Replace transmission filter. 3. Check torque on drive shaft yoke hardware. NOTE: Refer to Owners/Operators Manual for engine cold start procedure.
Page 17: Hydraulic Reservoir
Section 2 General Instructions 2. Clean the area around the magnetic drain plug 2.10.5 Splines and remove the plug and check fluid level. Transmission input shaft splines must be coated Use only Special TRAK Wet Disc Brake Oil (P/ with a molybdenum disulfide or Molykote com- N 8522042) as required to bring level up even pound.
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Page 19: Section 3 Boom
Section 3. Boom SECTION 3 BOOM CONTENTS Par. Title Page BOOM ASSEMBLY BOOM ASSEMBLY The boom assembly, Fig. 3.1, consists of inner, 3.1.1 Inner Boom Replacement intermediate, and outer booms. The intermediate 3.1.2 Intermediate Boom Replacement boom slides in the outer boom and the inner boom 3.1.3 Outer Boom Replacement slides in the intermediate boom.
Page 20: Inner Boom Replacement
Section 3. Boom c. Installation INNER 1. Refer to Fig. 3.3 and install the bottom wear BOOM pad on the inner 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 lb-ft (42 N m).
Page 21: Intermediate Boom Replacement
Section 3. Boom CAPSCREW ENDS TO BE FLUSH TO 0.19" (5 mm) RECESSED IN WEAR PAD INSERT PAD, SPACER, INSERT (2), LOCK WASHER (6), FLAT WASHER (6), 3/8-16 X 1-3/4" CAPSCREW (6), GAP MUST BE 0.07 TO 14 GA SHIM 0.13"...
Page 22 Install a new pad if it is excessively worn (refer ® to paragraph 3.1.8). Apply Loctite Removable 1. Inspect the boom and welds and contact JLG if Threadlocker 242 to the capscrews and torque structural damage is detected. them to 31 lb-ft (42 N m).
Page 23: Outer Boom Replacement
Section 3. Boom PAD, INSERT (1), PAD, INSERT (1), LOCK WASHER (3), LOCK WASHER (3), FLAT WASHER (3), FLAT WASHER (3), 3/8-16 X 7/8" 3/8-16 X 7/8" CAPSCREW (3) CAPSCREW (3) GAP MUST BE 0.07 TO O.13" (1,8 TO 3,3 mm) GAP MUST BE 0.07 TO GAP MUST BE 0.07 TO O.13"...
Page 24 Section 3. Boom OUTER BOOM INTERMEDIATE BOOM INNER BOOM HOSES HOSE GUIDE TUBING CLAMP TO MAIN SUPPORT PLATE CONTROL CONNECTION VALVE GRILLE TILT CYLINDER MA0081 Fig. 3.8 Grille Tilt Cylinder Hoses 14. If the front outer boom wear pads, Fig. 3.9, are 6.
Page 25 Section 3. Boom PAD, INSERT (1), PAD, INSERT (1), LOCK WASHER (2), LOCK WASHER (2), FLAT WASHER (2), FLAT WASHER (2), 3/8-16 X 7/8" 3/8-16 X 7/8" CAPSCREW (2) GAP MUST BE 0.07 TO CAPSCREW (2) 0.13" (1,8 TO 3,3 mm) GAP MUST BE 0.07 TO GAP MUST BE 0.07 TO 0.13"...
Page 26 Section 3. Boom INNER BOOM SHOULDER SCREW AND 1-1/2" LOCKNUT CLEVIS 2-1/2" YOKE (38 mm CHAIN LINK 63 mm) SHOULDER PIN AND SCREW AND RETAINING LOCKNUT RING INTERMEDIATE BOOM EXTEND CHAIN, LOCKNUT AND EXTEND CHAIN FLAT WASHER BLOCK OUTER BOOM INNER BOOM INTERMEDIATE BOOM INNER BOOM...
Page 27: Chain Replacement
Section 3. Boom 3.1.4 Chain Replacement Two chains extend the inner boom and one chain retracts it. 8. Refer to paragraph 3.1.5 and lubricate the Extend Chains chain. IMPORTANT: Replace extend chains in pairs or 9. Refer to paragraphs 3.1.6 and 3.1.7 and check sets ONLY.
Page 28: Chain Lubrication
Section 3. Boom 3.1.5 Chain Lubrication BOOM EXTEND 250 Hour Intervals CHAINS 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.
Page 29: Chain Tension Adjustment
Section 3. Boom Adjustment is accomplished using extend chain (a) Tighten the locknut, Fig. 3.15, on the adjustment locknuts, Fig. 3.14. bottom of the outer boom. This retracts the inner boom and takes up the sag in the a. Chain Locknut Functions extend chains.
Page 30: Hose Tensioning
Section 3. Boom IMPORTANT: Inspect the pads as follows: intermediate boom raises up, thereby providing clearance for removing the bottom pad. • Replace wear pads that are less than 0.5" (13 mm) thick. 3. Inspect the wear pads removed as described in •...
Page 31: Long Term Storage Preparation
Section 3. Boom 4. Loosen capscrews securing the hose clamps RETAINER NUT to the inner boom, Fig. 3.16a or Fig. 3.16b. COUNTERBALANCE VALVE 5. Manually remove all hose slack between the pulley and the inner boom hose clamps and the pulley and the outer boom tubes.
Page 32: Hydraulic Line Failure
Fig. 3- doing. Consult your local JLG Distributor or the 19. Loosen the retainer nut and control the JLG Service Department before proceeding.
Page 33: Quick Attach Assembly
Section 3. Boom adjusting screw on each cartridge simulta- b. Installation neously into the cartridge very slowly 1. If the latch assembly was removed, install it as clockwise. Hydraulic oil from inside the follows: hoist cylinders will escape through the fault (a) Assemble flat washer (2, Fig.
Page 34: Troubleshooting
Section 3. Boom TROUBLESHOOTING Trouble Probable Cause Remedy Reference Broken hydraulic line and/or Locate break and/or stop Fails to Extend or Retract connection leaks. leaks. Faulty Extend/Retract Repair Cylinder. Section 9 Cylinder. Section 9 Faulty components in Extend/ Troubleshoot components Retract hydraulic circuitry.
Page 35: Specifications
Section 3. Boom 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.
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Page 37: Section 4 Operator's Cab
Section 4. Operator's Cab SECTION 4 OPERATOR'S CAB CONTENTS Par. Title Page SEAT SEAT CUSHION MECHANICAL HAND CONTROLS 4.2.1 Steering Wheel and Steering Unit 4.2.2 Travel Select and Range Select Lever 4.2.3 Boom Control and Grille and Frame Tilt Joystick MECHANICAL SLIDES FOOT CONTROLS...
Page 38: Steering Wheel And Steering Unit
Section 4. Operator's Cab TRAVEL SELECT RANGE SELECT LEVER FOR LEVER FOR LOW-1, FORWARD-F, MEDIUM-2, AND NEUTRAL-N, AND HIGH-3 REVERSE-R GATE PLATE BELL CRANKS SHIFTER ASSEMBLY CLEVIS PIN, WASHER, AND COTTER PIN SWIVEL COTTER PIN AND WASHER LOCKNUT CABLE MOUNTING STRAP REVERSE SWITCH CONTROL CABLE ANGLE BRACKET...
Page 39 Section 4. Operator's Cab b. Transmission Cable Removal Maintenance 1. Remove lower panel below control console. 1. Prepare to clean and lubricate the spring, disk and ball in each travel and range select lever 2. Remove the clamp that secures control cable mechanism by removing the cotter pins, to angle bracket, Fig.
Page 40: Boom Control And Grille And Frame Tilt Joystick
Section 4. Operator's Cab 4.2.3 Boom Control and Grille and Frame 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.
Page 41: Mechanical Foot Controls
Section 4. Operator's Cab BRAKE VALVE BRAKE VALVE PUSH ROD 4. Install the covers on the joystick assembly. JAM NUT 5. Install the lower panel. b. Joystick Control Cables SPRING YOKE Removal SHAFT 1. Remove the lower panel which is below the COTTER PIN side console.
Page 42: Throttle Pedal And Cable
Section 4. Operator's Cab PEDAL LIMIT STOP SCREW CAB FLOOR LOCKNUT WASHER CLAMP LEVER ASSEMBLY CABLE SUPPORT CLEVIS PIN AND LOCK CLIP MA0191 THROTTLE CABLE SPRING JAM NUT CLEVIS Fig. 4.8 Throttle Pedal 2. Install the spring on the pedal and hook the a.
Page 43 Section 4. Operator's Cab 2. Adjust the limit stop screw until it touches the 7. Remove the long clevis and jam nut from the pedal. cable end. 3. Tighten the locknut to 120 to 125 lb-inch (13,6 8. Remove the throttle cable from the forklift. to 14,1 N m).
Page 44 Section 4. Operator's Cab 3. Tighten “preset” pivot bolt to a 3/16" (5 mm) REAR VIEW MIRRORS gap as shown in Fig. 4.11. The forklift has two rear view mirrors. PIVOT BOLT LOOP • A 6-1/2 by 10" flat glass mirror on the cab RETAINING CAP frame to the left of the operator.
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Page 46 Section 5. Wheel Assembly, Tires, and Axle SECTION 5 WHEEL ASSEMBLY, TIRES, AND AXLE CONTENTS Par. Title Page Par. Title Page WHEEL ASSEMBLY AND TIRE 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...
Page 47: Wheel Assembly And Tire
Section 5. Wheel Assembly, Tires, and Axle The forklift may have standard or optional wheels WHEEL ASSEMBLY and tires. AND TIRE • Standard 13.00 - 24, 10 ply tires and three piece 8.00 - 24 TGF wheels Warning ! • Optional 15.00 x 19.5, 12 ply tires and single piece 12.5 x 19.5 wheels.
Page 48 Section 5. Wheel Assembly, Tires, and Axle SOME TIRES HAVE THIS INSTRUCTION EMBOSSED IN SIDE WALL: DRIVING TIRES MUST ROTATE AS THE ARROW POINTS (OTHER TIRES MUST ROTATE IN THE OPPOSITE DIRECTION) VALVE POSITION FOR FILLING TIRE WITH HYDROFILL AND AIR ARROW POINTS TO RIGHT MA0212 ON BOOM SIDE OF FORKLIFT...
Page 49: Removing Hydrofill From Tire Or Tube
Section 5. Wheel Assembly, Tires, and Axle LOOSE SIDE FLANGE FIXED SIDE FLANGE AND TIRE SEAT AND TIRE SEAT RIM BASE LOCK RING EMBOSSED VALVE HOLE TR618A AIR-WATER TYPE VALVE O-RING SEALING RING MA0221 Fig. 5.2 Standard Wheel Assembly with T-Type Rim and Fixed Back Flange 5.1.1 Removing Hydrofill from Tire or Tire and wheel maintenance is covered in the Tube within Tire...
Page 50: Demounting Tire
Section 5. Wheel Assembly, Tires, and Axle START BEAD ON THIS SIDE OF RIM DEEP WELL MA0231 Fig. 5.3 Optional Wheel Assembly with Single Piece Rim 5.1.2 Demounting Tire IMPORTANT: Always completely deflate tire as 5. Use a suitable hoist or jack to raise the axle described in paragraph 5.1.1 before you attempt to until the tire clears the ground.
Page 51: Demounting Optional Tire
Section 5. Wheel Assembly, Tires, and Axle 5.1.5 Demounting Optional Tire CLIP-ON CHUCK from Single Piece Wheel IMPORTANT: Always completely deflate tire as described in paragraph 5.1.1, before you attempt CORE EJECTOR BODY to demount a tire. CORE REMOVER 1. Be sure you’ve read and understood the warning notices and general instructions in EJECTOR CHUCK paragraph 5.1.
Page 52: Wheel Cleaning
Section 5. Wheel Assembly, Tires, and Axle 9. Remove the valve stem from the rim base. 5.1.9 Mixing Hydrofill Solution 10. Refer to paragraph 5.1.12 for tire mounting Prepare the hydrofill mixture by pouring calcium instructions. chloride into water; never add water to calcium chloride as considerable heat is generated in this 5.1.6 Wheel Cleaning mixing process.
Page 53: Mounting Tire
Section 5. Wheel Assembly, Tires, and Axle 5. Inspect both sides of the tire to be sure beads 18. Insert the valve core in the stem and pressur- are evenly seated. If not, completely deflate ize the tire as follows: tire, unseat beads and repeat entire mounting AIR PRESSURES: procedure.
Page 54: Mounting Optional Tire
Section 5. Wheel Assembly, Tires, and Axle tube and attaching the tool may be facilitated 6. Lubricate a new rubber O-ring. Place O-ring by placing a block under the tire). in groove on one side and stretch O-ring snapping it into place rather than rolling it into 7.
Page 55: Installing A Wheel On The Forklift
Section 5. Wheel Assembly, Tires, and Axle 5.1.15 Installing a Wheel experience shows was started by the overheated condition that developed when the unit was towed on the Forklift at high speed. 1. Be sure you’ve read and understood the If tires are to operate for any length of time on warning notices and general instructions in roads or other hard surfaces, it is advisable to...
Page 56: Axle Assembly
Section 5. Wheel Assembly, Tires, and Axle AXLE ASSEMBLY The axle assembly rotates and turns the wheels. front axle wheel ends contain service brakes. If Both front and rear axles consist of a differential the forklift has a turbocharged engine both the carrier assembly, a left and right axle steering front and rear axle wheel ends contain service joint, and a left and right wheel end, Fig.
Page 57: Axle
Section 5. Wheel Assembly, Tires, and Axle IMPORTANT: larly over the breather, drain the hypoid gear lubricant and inspect internal parts for water • When replacing a fastener, replace it with one damage and contamination. Before you assemble of equal or higher grade and quality. Torque and refill the unit with the specified lubricants, fasteners are recommended for the applica- clean, examine, and replace damaged parts.
Page 58 Section 5. Wheel Assembly, Tires, and Axle Warning ! from the mounting blocks. Wait for the hydraulic fluid to cool before 10. Using the hoist, remove the axle from the servicing any hydraulic component. Hot hy- frame and place it on a support at three points draulic fluid can cause severe burns.
Page 59 Section 5. Wheel Assembly, Tires, and Axle PA0332 17. Plate, lining stop 32. Cone, bearing (outer) Screw, self-locking 33. Hub Assembly 18 Disc Assembly Planetary Gear Assembly 34. Hub, planetary 19. Piston Flange, planetary drive 35. Cup, bearing (outer) 20. O-ring, piston OD Plug, drain/fill 21.
Page 60: Wheel End With Service Brakes
3. After the drive flange is installed, rotate the hub end and lower axle onto support stands. so drain/fill plug (5, Fig. 5.8) is up and fill hub with JLG Special Wet Disc Brake Fluid (8522042). Warning ! Wheel End Service Brakes a.
Page 61 Section 5. Wheel Assembly, Tires, and Axle PA0322 Wheel End Assembly Screw, self-locking 10. Washer, keyed 18 Locknut 26. Slinger, hub oil Planetary Gear Assembly 11. Bearing, single roller 19. Pin, roll 27. Nut, wheel 12. Washer, planet gear 20. Cone, bearing (outer) Flange, planetary drive 28.
Page 62: Wheel End Without Service Brakes
Section 5. Wheel Assembly, Tires, and Axle After drying, components should be lightly 2. Support the hub assembly with a lifting device. coated with oil or rust preventive to protect 3. Refer to page 15 of Spicer ® Dana Maintenance them from corrosion.
Page 63 Section 5. Wheel Assembly, Tires, and Axle PA0312 14. Locknut Shaft, inner yoke, right Shaft and Joint Assembly 20. Shim, formed 15. Washer, flat Shaft, outer Deflector, seal 21. Shim, formed 16. Fitting, grease Cross Assembly 10. Seal, oil 22. Seal, oil 17.
Page 64 Section 5. Wheel Assembly, Tires, and Axle a. Disassembly 5. Tap the spindle with a soft-faced hammer to loosen the knuckle assembly (12, Fig. 5.10). 1. Refer to page 13 through 16 of Spicer ® Dana Remove the spindle assembly. Maintenance Manual for Axle Models PS/PR- 7036 for removing and disassembling the drive 6.
Page 65 Section 5. Wheel Assembly, Tires, and Axle 4. Replace roller bearing cups (24) or cones (23) NOTE: If the cotter pin cannot be installed after if any are worn, pitted, or damaged. minimum torque is attained, the nut must be 5.
Page 66: Steering Cylinder And Tie Rod
Section 5. Wheel Assembly, Tires, and Axle turn and align any hole in the nut with a b. Cleaning and Drying major spline on the spindle. Mark the end 1. Clean all parts with approved petroleum based of the aligned spline on the edge of the cleaner.
Page 67 Section 5. Wheel Assembly, Tires, and Axle PA0281 Screw, socket head cap (4) 19. Piston Screw, socket head cap (4) 13. Ring, retainer Plate, cover 20. Ring, backup Disc, rotor (7) 14. Bearing Spline, outer Plate, lining (7) 15. Ring, retainer 21.
Page 68: Carrier Assembly
Section 5. Wheel Assembly, Tires, and Axle LINING PLATE THRUST PLATE CAPSCREW SHOULDER BOLT MA0291 Fig. 5.14 Plate and Disc Alignment c. Cleaning and Drying e. Assembly 1. Clean all parts with approved petroleum based Refer to page 55 of Spicer ®...
Page 69 Section 5. Wheel Assembly, Tires, and Axle PA1360 Differential Carrier Assembly (includes 23. Screw, differential bearing cap (4) items 2 thru 40) 24. Washer, differential bearing cap (4) Ring, adjusting (2) 25. Bolt, hex (2) Cup, roller bearing (2) 26. Washer, flat (2) Cone, roller bearing (2) 27.
Page 70 Section 5. Wheel Assembly, Tires, and Axle PA1530 Differential Carrier Assembly (includes 23. Screw, differential bearing cap (4) 24. Washer, differential bearing cap (4) items 2 thru 39) 25. Bolt, hex (2) Ring, adjusting (2) 26. Washer, flat (2) Cup, roller bearing (2) Cone, roller bearing (2) 27 Clip, adjusting ring (2) 28.
Page 71: Axle Lubrication
Section 5. Wheel Assembly, Tires, and Axle PIVOT PIN KNUCKLE STEER CYLINDER BALL JOINT TIE ROD BALL JOINT KNUCKLE OA0192 Fig. 5.17 Axle Grease Points AXLE LUBRICATION Warning ! 5.3.1 Grease Lubricate the following axle points (Fig. 5.17) after overhaul or at 50 hour intervals using multi-purpose •...
Page 72: Wheel End Brake Oil
6. Install the fill and level plug. end housing is pointing up. 5.3.3 Wheel End Brake Oil 6. Fill the wheel end using only Special JLG Wet Disc Brake Oil P/N 8522042 as required to Magnetic Plug Check (First 50 hours) bring the level up to the drain plug hole.
Page 73: Troubleshooting
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:...
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Page 75: Section 6 Drive Shafts And Drop Box
Section 6. Drive Shafts and Drop Box SECTION 6 DRIVE SHAFTS AND DROP BOX CONTENTS 3. Remove the U-bolt assemblies securing the Title Page drive shaft cross assembly to the axle input DRIVE SHAFT ASSEMBLIES shaft yoke. 6.1.1 Drive Shaft Servicing NOTE: Wrap tape around bearings and cross so DROP GEAR BOX bearings do not drop off cross.
Page 76 Section 6. Drive Shafts and Drop Box SLEEVE ASSEMBLY DUST CAP SHAFT ASSEMBLY SPLIT FELT RETAINING SEAL RING DRIVE SHAFT SLEEVE ASSEMBLY DUST DROP BOX INPUT SHAFT SPLIT YOKE RETAINING CROSS RING FELT ASSEMBLY SEAL GREASE FITTING BEARING ASSEMBLY RETAINING RING U-BOLT OR BEARING...
Page 77 Section 6. Drive Shafts and Drop Box c. Cleaning and Drying Drive Shaft–Transmission to Drop Gear Box 1. Disassemble and clean all parts using an 1. Position the drive shaft assembly on the forklift approved cleaning fluid. so slip joint mounts to the drop box, Fig. 6.1. 2.
Page 78 Torque U-bolt assembly to 20 to 24 warranty, JLG recommends that the box be re- turned to the factory for rebuild or replaced with a lb-ft (27 to 37 N m).
Page 79 Section 6. Drive Shafts and Drop Box VENT/FILL PLUG OIL SEAL END YOKE SCREW & WASHER SCREW & WASHER END YOKE OIL SEAL FRAME DROP BOX INSPECTION COVER CAPSCREW LEVEL PLUG LOCK WASHER (on late models) LEVEL PLUG (on early models) OIL SEAL END YOKE...
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Page 81: Preventive Maintenance
Section 7. Transmission SECTION 7 TRANSMISSION, CLARK SERIES 18000 7.1.1 Daily or 10 Hour Intervals CONTENTS Par. Title Page Level Check TRANSMISSION PREVENTIVE 1. Check the oil level with the engine running MAINTENANCE at idle, and oil at normal operating tempera- 7.1.1 Daily or 10 Hour Intervals ture.
Page 82: 1000 Hour Intervals
Section 7. Transmission 3. Remove sump plug and screen with gasket TRANSMISSION FILTER 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.
Page 83: How To Back Flush Oil Cooler
Section 7. Transmission HOW TO BACK FLUSH TRANSMISSION OIL COOLER REPLACEMENT The transmission oil cooler, Fig. 7.4, is mounted If the transmission is to be replaced as a complete behind the radiator. Periodically disconnect and assembly, detach and transfer the following: back flush the oil cooler with oil and compressed •...
Page 84: Troubleshooting
Section 7. Transmission TROUBLESHOOTING Trouble Probable Cause Remedy Low Clutch Pressure Low oil level Fill to proper level Clutch pressure regulat- Clean valve spool and housing ing valve stuck open Faulty charge pump Replace pump Replace sealing rings Broken or worn clutch shaft or piston sealing rings Clean bleed valve thoroughly...
Page 85: Specifications
Section 7. Transmission 7.10 SPECIFICATIONS System Capacity (inc. filter and oil cooler) 4.3 gallons (16,3 liter) Filter Capacity 1 quart (0,95 liter) John Deere J20 A Tractor Fluid Detroit Diesel C-3, C-2 Ford Tractor M2C134B White Farm UTHF Q1766, Q1722 Converter: 180 to 200 °F (82 to 93 °C) Transmission in Neutral.
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Page 87 Section 8. Engine SECTION 8 ENGINE, PERKINS SERIES 4.236 AND T4.236 CONTENTS Throughout this section, the left or right side of the engine is the side of the engine when viewed from Par. Title Page the flywheel end. ENGINE PREVENTIVE MAINTENANCE Warning ! 8.1.1...
Page 88: Maintenance
Section 8. Engine IMPORTANT: These instructions cover only the ENGINE PREVENTIVE routine maintenance of the engine. Refer to your MAINTENANCE Perkins Engine Distributor for engine diagnosis, repair and component replacement. 8.1.1 Daily Before Operation A gradual running in of a new engine is not 1.
Page 89 Section 8. Engine 4. Remove the air cleaner cover wing nut, cover, RESTRICTION INDICATOR and primary element, Fig. 8.5. INDICATOR Warning ! WINDOW Wear safety glasses when using compressed air to clean element. 5. Clean the primary element with compressed OA0202 air or by washing.
Page 90 Section 8. Engine Engine Coolant 2. Level forklift, lower the carriage to ground, shut off engine, and engage park lock. 1. Level the forklift, lower carriage to ground, shut off engine and engage park lock. 3. Place a receptacle under the engine oil pan drain plug.
Page 91 Section 8. Engine 3. Loosen drain cock on bottom of fuel pre-filter 5. Position a new filter element between the base and allow water to completely drain from it. and head and install and tighten screw on top of filter assembly until snug. 4.
Page 92: Hour Intervals
Section 8. Engine INJECTOR HIGH PRESSURE LINE FITTINGS GOVERNOR VENT SCREW INJECTION PUMP VENT OA0342 SCREW Fig. 8.13 Injector High Pressure Line Fittings OA0322 5. Loosen any two high pressure fittings, Fig. 8.13, that come from the fuel injection pump. Fig.
Page 93: Hour Intervals
Section 8. Engine 8.1.7 2,500 Hour Intervals 1. Inspect and service proprietary equipment such as starter motor, alternator, turbocharger CYLINDER (if applicable) etc. BLOCK DRAIN PLUG 2. Service atomizers (fuel injectors), para. 8.4.9. 3. Check and adjust valve tip clearances, para. 8.10.
Page 94: Lubricating Oils
Section 8. Engine Do not use a lubricating oil to the MIL-L-2104C specification in naturally aspirated engines for the 8.1.10 Lubricating Oils 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.
Page 95: Engine Cooling System
Section 8. Engine An approved antifreeze as described in 8.2 ENGINE COOLING SYSTEM paragraph 2 protects against corrosion and also raises the boiling point of the coolant. A The engine cooling system consists of coolant 50 percent concentration of antifreeze is passages in the engine, a thermostat, pump, preferred, but if there is a less likely chance hoses, a radiator and a radiator overflow tank.
Page 96: Integral Cooler In Oil Filter
Section 8. Engine 8.2.3 Integral Oil Cooler in Oil Filter diesel fuel. The initial savings is a false economy when you consider the damage poor fuel can do to The oil filter for a turbocharged engine, Fig. 8.17, your forklift engine. has an integral oil cooler.
Page 97 Section 8. Engine LIFT PUMP FROM THERMO LIFT START PUMP TO FUEL INJECTION PUMP FROM FUEL INJECTION PUMP PA0424b Fuel Tank 17. Fuel Pump Tube Tie Wrap Fuel Level Sender 18. Fuel Filter Tube 10. Hose Support Filler Cap with Tether 19.
Page 98: Fuel Level Sender And Gauge
Section 8. Engine 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. b. Disassembly Replace tank for long term repair. 1. Remove five capscrews, fuel level sender (2, e.
Page 99: Fuel Lift Pump
Section 8. Engine a. Removal 5. Remove air from the fuel system. (See para- 1. Remove fuel pre-filter inlet and outlet tubes graph 8.4.8, How to Bleed to Fuel System). (11, Fig. 8.18). 6. Close and lock access door. 2. Support filter with one hand and remove lock nuts (15) and capscrews (14) and remove fuel a.
Page 100: Fuel Filter
Section 8. Engine e. Fuel Lift Pump Installation 8.4.6 Fuel Filter Position the fuel lift pump on the engine and install Change element (5, Fig. 8.21) every 500 hours of the four capscrews and lock washers that secure operation. the fuel lift pump to the engine. 1.
Page 101 Section 8. Engine 8.22 AI 20 18 MA0361 Fuel Injection Pump 23. Union Nut 12. Injection Pipe for No. 3 Cylinder 24. Ball Sleeve 13. Injection Pipe for No. 4 Cylinder Seal 14. Bridle (4) 25. Bolt (4) Wire 26. Washer (8) 15.
Page 102: Fuel Injection Pump
JLG. Failure to do so may void engine and forklift a. Fuel Injection Pump Removal warranties. IMPORTANT: Instructions and specifications in When installing a replacement fuel injection pump the Perkins Workshop Manual for the Perkins 4.236...
Page 103: Engine Exhaust System
Section 8. Engine rigid spacer. Tighten securing nuts evenly to 12 lb-ft (16 N m). b. Atomizer Identification a. How to Locate Faulty Atomizer(s) Currently, the atomizer code is stamped on the A faulty atomizer can cause: atomizer body. • Misfiring c.
Page 104 Section 8. Engine Whenever you replace a muffler you should also When installing an exhaust system be careful to replace the tail pipe. provide for expansion when the system is hot. Use Exhaust System Sealer at all slip joint con- Check complete exhaust system for broken, dam- nections before assembly.
Page 105: Engine Removal
Section 8. Engine Removal from Naturally Aspirated Engine (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.
Page 106 Section 8. Engine 13. Disconnect the engine wire harness at the 15. Detach throttle cable from engine as follows: following components, Fig. 8.26: (a) Remove cable clamp securing throttle • Starter cable to throttle cable bracket. • Starter Ground Cable (b) Disconnect the throttle cable from the fuel •...
Page 107: Engine Overhaul
Section 8. Engine ENGINE OVERHAUL Refer to the Perkins Engine Workshop Manual for (b) Remove the U-bolt assembly or bearing the 4.236 Series engines. straps, Fig. 6.1, attaching the drive shaft cross assembly to the drop box input shaft ENGINE INSTALLATION yoke.
Page 108 Section 8. Engine 10. After all eight capscrews have been installed, 13. Secure transmission drive shaft to transmis- rotate the engine flywheel again and individually sion with U-bolt or bearing strap. Torque U-bolt torque all eight to 25 to 30 lb-ft (34 to 40,8 N m). to 20 to 24 lb-ft (27 to 37 N m) or bearing strap to 55 to 60 lb-ft (75 to 82 N m).
Page 109 Section 8. Engine 15. Attach the throttle control cable to the engine 26. Install the transmission oil cooler on the rear fuel injection pump as follows: support and connect it to the transmission. (a) Fasten the throttle cable to the throttle 27.
Page 110: Head Torque Check
Section 8. Engine HEAD TORQUE CHECK 1. Run engine until coolant outlet temperature is higher than 170 °F (77 °C). 2. Stop the engine and remove the cylinder head cover. 3. Check the torque of the cylinder head nuts and capscrews in the correct sequence as shown in Fig.
Page 111: Engine Storage
Perkins Engines Ltd. lubricating oil used when the engine is returned and JLG are not responsible for any damage that to service. occurs in relation to a service storage period.
Page 112: Troubleshooting
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...
Page 113 This Page Left Blank Intentionally...
Page 114: Section 9 Hydraulic System
Section 9. Hydraulic System SECTION 9 HYDRAULIC SYSTEM CONTENTS Warning ! Par. Title Page CIRCUITS • If anyone is injured by or if any hydraulic fluid 9.1.1 Boom Raise/Lower is injected into the skin, obtain medical 9.1.2 Boom Extend/Retract attention immediately or gangrene may result. 9.1.3 Grille Tilt and Slave Circuit 9.1.4...
Page 115 Section 9. Hydraulic System MAIN CONTROL VALVE TO FRAME TILT CYLINDER TO GRILLE TILT AND SLAVE CYLINDERS DIRECTIONAL CONTROL VALVE POSITIONS RAISE LOWER TO BOOM EXTEND/ RETRACT CYLINDER A B C A B C A B C RIGHT BOOM HOIST CYLINDER LOWER D E F D E F...
Page 116 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.
Page 117 Section 9. Hydraulic System 4. Install a tee and pressure gauge capable of GRILLE TILT FRAME TILT BOOM "UP" PORT "RIGHT" PORT EXTEND measuring 0 - 4000 psi (275,6 bar) in the RELIEF VALVE RELIEF PORT MAIN tandem pump outlet of the 30 gpm section, VALVE RELIEF RELIEF...
Page 118: Boom Extend/Retract
Section 9. Hydraulic System 5. Starting at the fully raised position, lower the suction stainer in the reservoir, Fig. 9.3. Supply boom at full engine speed. The time required pressure is directed to either side of the extend/ to lower the boom to its lowest position should retract cylinder piston by the shifting of a spool in a be 8 to 10 seconds (no load).
Page 119 Section 9. Hydraulic System Extend Position • Should any of the hydraulic lines going to the extend cylinder fail, there will be a loss When the joystick is placed in the extend position, of hydraulic system pressure to the the directional control valve spool is shifted so that cylinder.
Page 120 Section 9. Hydraulic System 3. Remove the transmission cover from the Warning ! frame. 4. Install a tee and pressure gauge capable of Before starting the engine be sure all hydraulic measuring 0 - 4000 psi (275,6 bar) in the connections are tight and all tools are removed tandem pump outlet of the 30 gpm section, from the forklift.
Page 121: Grille Tilt And Slave Circuit
Section 9. Hydraulic System 6. Repeat steps 4 and 5 to recheck performance. Center Position 7. If the boom extend/retract circuit test does not When the grille and frame tilt control lever is meet performance requirements, locate the placed in the center or neutral position, the cause of the problem and correct before directional control valve spool is positioned so that putting the vehicle into service.
Page 122 Section 9. Hydraulic System grille tilt “up” relief valve, Fig. 9.2, will open When the boom is raised, the slave cylinder is allowing hydraulic oil to return to the return filter extended which causes pressure buildup on the and reservoir, Fig. 9.4. rod end of the piston.
Page 123 Section 9. Hydraulic System 5. Start the engine. Operate the grille tilt control Warning ! several times to purge the system of air. 6. Depress the accelerator to full throttle. Place Before starting the engine be sure all hydraulic the grille and frame tilt control lever in the “up” connections are tight and all tools are removed position and hold until the grille tilt cylinder has from the forklift.
Page 124: Frame Tilt Circuit
Section 9. Hydraulic System 5. Starting at the full tilt up position, tilt the grille suction screen in the reservoir, Fig. 9.5. Pressure down fully at full engine speed. The time is directed to either side of the frame tilt cylinder required for full tilt down should be 3 to 5 piston by the shifting of a spool in a directional seconds (no load).
Page 125 Section 9. Hydraulic System Left Position 2. Operate the hydraulic controls after the engine has stopped to relieve any trapped pressure. When the grille and frame tilt control lever is placed in the “left” position”, the directional control Warning ! valve spool is positioned so that pump supply pressure is directed through ports E to A, Fig.
Page 126 Section 9. Hydraulic System turning the adjustment screw clockwise to Warning ! increase pressure or counterclockwise to decrease pressure. Torque nuts on relief valve to 10 ± 1.5 lb-ft (13,5 ± 2 N m) after Relieve hydraulic pressure before servicing any adjustment.
Page 127: Brake Circuits
Section 9. Hydraulic System 9.1.5 Brake Circuits and during initial start-up before the tandem pump is fully operational. This pump is driven by an a. Description electric motor; it also draws fluid through the suction strainer in the reservoir. Hydraulic pressure is normally applied in the service and park lock brake circuits by the 15 gpm The steering and emergency brake pump is section (front half) of the tandem pump, which...
Page 128 Section 9. Hydraulic System positioned so that hydraulic flow is blocked at port 2. Operate the hydraulic controls after the engine C, Fig. 9.6: no pressure is applied to the service has stopped to relieve any trapped pressure. brakes. Return flow from the service brakes passes through ports B to D to the reservoir.
Page 129 Section 9. Hydraulic System 2. Operate the hydraulic controls after the engine c. Testing has stopped to relieve any trapped pressure. The service brakes should be tested whenever repairs or adjustments are made to components of the circuit. Warning ! 1.
Page 130: Power Steering Circuit
Section 9. Hydraulic System 9.1.6 Power Steering Circuit When the pressure rises above 4 psi (0,3 bar), (engine running), the oil pressure switch a. Description opens to stop the steering and emergency brake pump. 1. Hydraulic pressure is applied in the power steering circuit by the 15 gpm section (front No Steering Action half) of the tandem pump, which draws its...
Page 131 Section 9. Hydraulic System LEFT REAR STEERING CYLINDER RIGHT REAR STEERING CYLINDER STEER SELECT VALVE RIGHT FRONT STEERING CYLINDER 4-WHEEL CRAB 2-WHEEL COUNTER- BALANCE VALVE LEFT FRONT STEERING CYLINDER MAIN CONTROL METERING VALVE SECTION CONTROL POWER STEERING UNIT VALVE SECTION RIGHT TURN LEFT TURN A B C D...
Page 132 Section 9. Hydraulic System 3. The steer select valve solenoid is energized 3. Supply oil is routed from port A to the extend and shifts the valve spool. Oil is channeled side of the right front steering cylinder and through ports J to G and to the retract side of the retract side of the left front steering the left rear steering cylinder and the extend cylinder.
Page 133: Optional Auxiliary Circuit
Section 9. Hydraulic System 4. Return oil from each of the front steering 7. Increase engine speed to full throttle and cylinders passes through the solenoid-ener- check the pressure gauge reading. It should gized select steer valve from ports I to G to the read between 575 ±...
Page 134 Section 9. Hydraulic System Center Position Forward Position When the auxiliary control lever is placed in the When the auxiliary control lever is placed in the center or neutral position, the directional control forward position, the directional control valve spool valve spool is positioned so that supply pressure is is positioned so that pump applied pressure is applied through ports F to C, Fig.
Page 135 Section 9. Hydraulic System Backward Position When the auxiliary control lever is placed in the 5. Start the engine and maintain engine speed at backward position, the directional control valve 1000 rpm. spool is positioned so that pump applied pressure 6.
Page 136: Cylinders
Section 9. Hydraulic System 4. Do not overstretch seals, wipers and O-rings. 9.2 CYLINDERS Make sure that seals, wipers and O-rings are not twisted or distorted in their grooves. Rebuild cylinders only in a clean, well lighted area where you can carefully inspect all components. If 5.
Page 137: Extend Cylinder
Section 9. Hydraulic System IMPORTANT: Do not attempt to reset the boom Warning ! hoist cylinder counterbalance valves. If replace- ment is necessary, replace both left and right hoist cylinder cartridges at the same time with new Wait for the hydraulic fluid to cool before servic- ones.
Page 138 Section 9. Hydraulic System 11. Remove the O-ring (12), backup ring (13), c. Cleaning wiper (16) and rod seal (15) from the gland. 1. Discard all seals and backup rings. Replace 12. If the bushing (18) needs replacement, with a complete new seal kit. support the rod (17) in a soft-jawed vise or 2.
Page 139 Section 9. Hydraulic System 2. Inspect the inside of the tube (7) for scoring 9. Lubricate the inside of the tube, outside of the and other damage. If the tube is damaged, piston, seal (10) and O-ring (12) with clean replace with new tube.
Page 140 Section 9. Hydraulic System 4. Have a helper start the forklift engine. 7. Remove the rod end pin and retaining rings attaching the rod end of the extend cylinder to 5. Position the hoist cylinder so that the rod is the intermediate boom.
Page 141 Section 9. Hydraulic System NOTE: It may be necessary to apply heat to 11. If necessary, remove the plugs (16) from break the bond of the sealant between piston (5), bottom inside of the tube (13) setscrew (6) and rod (1) before the piston can be c.
Page 142 Section 9. Hydraulic System 2. Inspect inside of the tube (13) for deep scoring a pin spanner wrench, thread the gland into and other damage. If the tube is damaged, tube. Remove the compression tool. replace with new tube. IMPORTANT: When sliding the rod and piston 3.
Page 143: Slave Cylinder
Section 9. Hydraulic System 7. Extend the boom as far as it will go; then the b. Disassembly retract it as far as it will go five times or until 1. Remove all dirt and grease from cylinder. the operation of the boom extend cylinder is normal (no jerks or spongy feel).
Page 144 Section 9. Hydraulic System d. Inspection, Repair and Replacement e. Assembly 1. Check that the rod (12, Fig. 9.13) is straight. If NOTE: Follow general assembly instructions in paragraph 9.2c. the rod is bent, install new rod. 2. Inspect inside of the tube (2) for scoring and 1.
Page 145 Section 9. Hydraulic System 2. Fasten the piston rod eye in a vise and put a 13. Increase the operating pressure to the maxi- padded support below and near other end of mum (4000 psi or 275,6 bar) for the cylinder rod to prevent damage to the rod.
Page 146: Grille Tilt Cylinder
Section 9. Hydraulic System 9.2.4 Grille Tilt Cylinder 5. Remove the rod end pin, Fig. 9.14, and its locking capscrew and locknut securing the a. Removal grille tilt cylinder rod to the quick attach. 1. Remove any attachment from the quick attach 6.
Page 147 Section 9. Hydraulic System MA0562 Gland Rod Seal 10. Wiper Cylinder Tube 11. Rod 12. Bushing Piston Seal 13. Counterbalance Valve 14. Grease Fitting Piston O-ring 15. Grease Fitting (90°) O-ring 16. O-ring (3) Backup Ring 17. Backup Ring (3) Fig.
Page 148 Section 9. Hydraulic System and check for external leakage and free NOTE: Wiper lip should be toward outer end of movement in both directions. gland and seal lips toward the inner end of the gland. Use tools that will not damage the seals. If 15.
Page 149: Frame Tilt Cylinder
Section 9. Hydraulic System 9.2.5 Frame Tilt Cylinder a. Removal TUBE PIVOT 1. Level the frame. Place blocking between frame and axle to maintain machine stability when frame tilt cylinder is removed. FRAME TILT 2. Engage the park lock, place the travel select CYLINDER lever in neutral, and stop the engine.
Page 150 Section 9. Hydraulic System d. Inspection, Repair and Replacement bottom of the piston (5) with a fine file. Clean parts with trichlorethylene after repair. 1. Check that rod (13, Fig. 9.17) is straight. If the rod is bent, install new rod. e.
Page 151 Section 9. Hydraulic System NOTE: The wiper lip should be toward the outer 15. Increase the operating pressure to the maxi- end of the gland and seal lips toward the inner end mum (4000 psi or 275,6 bar) for the cylinder of the gland.
Page 152: Steering Cylinder
Section 9. Hydraulic System 9.2.6 Steering Cylinder 5. The steer cylinder socket is a taper fit in knuckle. Use an impact fork to release the a. Removal socket from the knuckle. 1. Engage the park lock, place the travel select 6.
Page 153 Section 9. Hydraulic System c. Cleaning 5. Pull rod (3) and attached parts straight out of the tube. 1. Discard all seals and lockwire. Replace with a complete new seal kit. NOTE: It may be necessary to apply heat to break the bond of the sealant between locknut (11) and 2.
Page 154 Section 9. Hydraulic System of the socket assemblies by turning them until 3. Remove small scratches on inside of the tube the total length equals the measured length with emery cloth of very fine grit. Use the taken during removal. emery cloth with a rotary motion.
Page 155: Side Tilt Carriage Cylinder (Optional)
Section 9. Hydraulic System 9.2.7 Side Tilt Carriage Cylinder 3. Remove check valves (2) and three O-rings (15) and backup rings (16). (Optional) 4. Using a pin spanner wrench, unscrew gland a. Removal (4, Fig 9.21) from the tube (1). 1.
Page 156 Section 9. Hydraulic System Tube Check Valve (2) Piston Gland Piston Nut Self Aligning Bearing Rod Seal Wiper 10. O-ring 11. Backup Ring 12. O-ring 13. Piston Seal 14. Grease Fitting (2) 15. O-ring (3) 16. Backup Ring (3) MA0620 Fig.
Page 157 Section 9. Hydraulic System e. Assembly valve was removed for replacement. Lubri- cate outside of the valves with clean filtered NOTE: Follow general assembly instructions in hydraulic oil. Install the valves and torque to paragraph 9.2c. 30 to 35 lb-ft (40,8 to 47,6 N m). 1.
Page 158: Valves
Section 9. Hydraulic System a. Main Control Valve Removal VALVES 1. Engage the park lock, place the travel select 9.3.1 Main Control Valve Assembly lever in neutral, and stop the engine. The main control consists of eight relief valves, four directional control valves, and an inlet and Warning ! outlet section, Fig.
Page 159 Section 9. Hydraulic System Cotter Pin Retaining Pin Locknut Washer Capscrew Main Control Valve Linkage FRAME MA0641 Fig. 9.23 Main Control Valve Installation The relief valve setting is determined by the internally. The differential pressure between the compression of the pilot spring as set by the supply pressure and the internal pressure causes adjustment screw.
Page 160 Section 9. Hydraulic System Disassembly 1. Remove the relief valve from the control valve housing. 2. Unscrew plug (1, Fig. 9.25) and remove the relief valve cartridge from housing (8). 3. Remove and discard O-ring (9) from housing. 4. Remove acorn nut (19) and jam nut (17) from adjustment screw (15).
Page 161 Section 9. Hydraulic System 5. Insert pilot poppet (13) and spring (14) into the c. Repair of Main Control Valve plug. Disassembly 6. Install adjustment screw (15) into the plug. To replace seals between the sections of the main 7. Lubricate and install new O-rings (16 and 18) control valve: on nuts (17 and 19).
Page 162 Section 9. Hydraulic System 2. Install new O-ring (3) in inlet section (2). 3. Install tie rods (9 and 10) from the outside of inlet section (2) through the holes in the inlet section. 4. Install boom hoist section (4) over tie rods (9 and 10) 5.
Page 163: Brake Valve
Section 9. Hydraulic System Warning ! Warning ! Before starting the engine be sure all hydraulic Relieve hydraulic pressure before servicing any connections are tight and all tools are removed hydraulic component. Escaping hydraulic fluid from the forklift. under pressure can penetrate the skin causing serious injury.
Page 164 Section 9. Hydraulic System 5. Tag and disconnect three hydraulic hoses (4, 6. Remove cup (11) from plunger (10). Fig. 9.30) from the right side of the service 7. Remove plug (23) from housing (13). brake valve. Cap and plug the open hose connectors.
Page 165 Section 9. Hydraulic System REAR SERVICE PRESSURE BRAKES REDUCING VALVE PARK RESERVOIR LOCK PARK LOCK RELEASE VALVE FRONT SERVICE SERVICE BRAKE BRAKES VALVE MACHINE FRONT S/N 8L0333 AND BEFORE FRONT SERVICE SERVICE BRAKES BRAKE VALVE MACHINE FRONT MA0711 Cap Used on Forklifts with Only Front Service Brakes Bulkhead Tee Connector Hydraulic Hose...
Page 166 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 Bleed the brake lines very carefully as soon as the cloth with a rotary motion. brake valve is installed in the machine.
Page 167: Park Lock Release Valve
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.
Page 168 Section 9. Hydraulic System Steer Select Valve 1A. Electrical Connector 1B. Solenoid (2) 1C. Screw (4) Park Lock Release Valve Sequence Valve Pressure Reducing Valve Relief Valve Connector (4) MA0741 Connector (1) Connector (1) Run Tee (1) 10. Connector HOSE CONNECTIONS 11.
Page 169: Steer Select Valve
Section 9. Hydraulic System 9.3.4 Steer Select Valve c. Cleaning Without submerging the electrical portion of the a. Removal steer select valve, clean valve in an approved 1. Engage the park lock, place the travel selector cleaning solvent and blow dry. lever in neutral, and stop the engine.
Page 170: Sequence Valve
Section 9. Hydraulic System 9.3.5 Sequence Valve e. Installation 1. Install connector (10, Fig. 9.33) and run tees a. Removal (11 and 12) on sequence valve (3). 1. Engage the park lock, place the travel selector lever in neutral, and stop the engine. 2.
Page 171: Pressure Reducing Valve
Section 9. Hydraulic System 3. Tag and disconnect tube assembly (16) from connector (13). CARTRIDGE WITH SEALS 4. Remove two hex nuts (21), lock washers (19), flat washers (20) and socket head capscrews BODY (28) to detach the relief valve. 5.
Page 172: Counterbalance Valve
Section 9. Hydraulic System b. Disassembly MACHINE FRONT 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.
Page 173: Pumps
Section 9. Hydraulic System b. Disassembly PUMPS NOTE: There are no serviceable parts in the 9.4.1 Main Tandem Pump counterbalance valve; do not disassemble. Remove the counterbalance valve cartridge, Fig. a. Removal 9.34. 1. Engage the park lock, place the travel selector c.
Page 174 Section 9. Hydraulic System 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.
Page 175 Section 9. Hydraulic System 3.00 " 1.47 " 1/4" DIAMETER DRILL THROUGH HOLE 0.06 " 0.06 " C RADIUS 30° 30° GRIND RELIEF ALLOWABLE 0.015" X 45° C = 1.054 PLUS 0.000, MINUS 0.002" CHAMFER D = 1.250" DIAMETER MA0811 Fig.
Page 176 Section 9. Hydraulic System d. Disassembly Instructions 5. Carefully remove drive and driven gear set (9). Avoid tapping the gear teeth together or 1. Prepare to disassemble the pump by placing it against other hardened surfaces to avoid in a vise with the drive shaft pointing down. possible chipping.
Page 177 Section 9. Hydraulic System 8. Remove connecting shaft (10). Remove thrust straightedge in the cutout area, replace the plate (8), seal (7) and seal (11). gear housing. Pressure pushes the gears against the housing on the low pressure side. 9. Remove integral gear set (14). Keep these As the hubs and bushings wear, the cutout together as they are a matched set.
Page 178 Section 9. Hydraulic System NOTE: If new plugs are being installed, coat 12. Slide the driven gear and shaft through the threads with Loctite ® Threadlocker 242. housing (15) and into the bushing in the shaft end cover (16). Coat the steel sleeve tool 5.
Page 179 Section 9. Hydraulic System 19. Thread four studs (3), washers (2) nuts (1) into provide a feed flow velocity not in excess of 8 shaft end cover (16) and tighten alternately or feet per second. cross corner. Rotate the drive shaft with a 6 6.
Page 180: Steering And Emergency
Section 9. Hydraulic System 9.4.2 Steering and Emergency Brake 5. Disconnect red electrical cable from power terminal on solenoid. Pump (S/N 7P0013 and Before) a. Removal Warning ! 1. Engage the park lock, place the travel selector lever in neutral, and stop the engine. Wait for the hydraulic fluid to cool before servic- ing any hydraulic component.
Page 181: Steering And Emergency
6. Connect the yellow switch wire to the solenoid warranty, do not disassemble further; refer the unit switch terminal. to your JLG authorized dealer. The pump (2) and g. Testing motor (1) can be separated by removing four screws (11) and washers (12).
Page 182 JLG authorized dealer. Cap the connector. 7. Tag, disconnect, and plug the pump outlet c.
Page 183 Section 9. Hydraulic System e. Assembly 2. Secure the pump and motor assembly to the frame with two 3/8-16 UNC-28 hex head 1. If the pump and motor assembly was disas- capscrews (5, Fig. 9.45) and lock washers (6). sembled, mount the end head assembly (12, Fig.
Page 184: Troubleshooting
Section 9. Hydraulic System 9.5 TROUBLESHOOTING Trouble Probable Cause Remedy Cannot Lower Ruptured hoist or extend Lower load using Emergency Boom Lowering Elevated load hose instructions in Owners/Operators Manual. Loss of engine power or Lower load using Emergency Boom Lowering hydraulic pump failure instructions in Owners/Operators Manual.
Page 185 Section 9. Hydraulic System Trouble Probable Cause Remedy Boom Hoist or Defective counterbalance Repair or replace cylinders seals and/or counter- Extend Function valve or cylinder seals balance valves as required (para 9.2.1 or 9.2.2). Drifts Grille Tilt Slow or Malfunctioning External fluid leakage at Check and tighten connections at valves, pumps tubes, hoses or fittings...
Page 186 Section 9. Hydraulic System Trouble Probable Cause Remedy Service Brakes Fail Brake pedal not adjusted Adjust pedal linkage (para 4.3.1). to Release correctly Faulty brake valve Repair brake valve as required (para 9.3.2). plunger, piston, or spring Service Brake Failure Ruptured hydraulic hose Replace hose.
Page 187 Section 9. Hydraulic System Trouble Probable Cause Remedy Steers too Slowly Steer relief valve not set Check and set relief valve (para 9.1.6). correctly Defective sequence valve Install new cartridge or replace valve (para 9.3.5). Steering cylinder leakage Install cylinder seal kit(s) (para 9.2.6). Front or Rear Wheels Wheel misalignment Check and adjust wheel alignment as needed per...
Page 188 Section 9. Hydraulic System Trouble Probable Cause Remedy Tandem Pump Fails to Fluid viscosity is too heavy Check working temperature and service and Deliver Fluid to pick up prime change fluid in system if necessary Worn, broken or stuck Repair tandem pump (para 9.4.1). parts in pump Cylinder Fails to Move Faulty hose...
Page 189 Section 9. Hydraulic System Trouble Probable Cause Remedy Directional Control Binding valve cable linkage Check cable linkage and lubricate or free up as Valve Difficult to Shift required. Broken internal parts Disassemble control valve and replace broken parts (para 9.3.1). Scored valve body bore Inspect valve body and spool and replace valve causing leakage between...
Page 190 Section 9. Hydraulic System MA0861 Fig. 9.46 Hydraulic Schematic for SKYTRAK 6036 Forklift — S/N 9B0499 and Before 9-77 Model 6036 S/N 9B0499 and Before...
Page 191: Specifications
Section 9. Hydraulic System 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.
Page 192 Section 9. Hydraulic System 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...
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Page 194: Section 10 Electrical System
Section 10. Electrical System SECTION 10 ELECTRICAL SYSTEM CONTENTS Par. Title Page Par. Title Page 10.1 SYSTEM COMPONENTS 10-2 10.8.5 Engine Low Oil Pressure Switch 10-43 10.8.6 Engine Coolant 10.1.1 Service Warnings High Temperature Sender 10-44 and Recommendations 10-2 10.8.7 Alternator Not Charging Light 10-44 10.1.2...
Page 195: System Components
Section 10. Electrical System 10.1.1 Service Warnings and Recommendations 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. MA0871 •...
Page 196: Effective Ground Connections
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 ±...
Page 197: Backup Alarm And Reverse Switch
Section 10. Electrical System 10.2.2 Backup Alarm To replace the bulb within the warning light, remove the lower panel (7, Fig. 10.40) which is and Reverse Switch secured by four capscrews (6). To gain access to A backup alarm sounds when the forward-neutral- the bulb, pull straight downward on the lower part reverse travel select lever is in reverse.
Page 198: Warning Lights
Section 10. Electrical System 10.2.4 Warning Lights e. Installation The harnesses are held securely in place by clips There are four warning lights in a cluster between or other devices to prevent chafing or wearing of the hourmeter and fuel gauge. When you turn the the insulation due to vibration.
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Page 200 Section 10. Electrical System OPTIONAL CIRCUIT BREAKER FOR WINDSHIELD WASHER/WIPER OPTIONAL WINDSHIELD WIPER OPTIONAL CAB HEATER OPTIONAL WINDSHIELD WASHER PA1081 16. Backup Alarm Cab Harness 17. Capscrew, hex hd, 5/16 NC x 3-1/2 (2) Engine Harness 18. Hex Nut, 5/16 (2) Battery, 12 Volt (2) 19.
Page 201 Section 10. Electrical System USED 17 21 14 37 ITEM 30 IS TIE WRAP WHICH IS NOT SHOWN PA0684 31. Emergency Pump Oil Pressure Sender 46. Park Lock Brake Switch 32. Street Tee, 1/8 NPT 47. Test Switch 33. Water Temperature Sender 48.
Page 202 Section 10. Electrical System Electrical System Circuits Use with Fig. 10.5 Electrical System Wire No. Color Gauge From 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...
Page 203: Starting Circuit
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.
Page 204: Testing Starter In Forklift
Section 10. Electrical System FROM TO THERMO ALTERNATOR START PLUG TO FUEL RUN SOLENOID TO BRAKE RELEASE VALVE FROM 6 A CIRCUIT BREAKER MA0901 Battery, 12 V Starter Relay Positive Battery Cable 10. Starter Starter Solenoid 11. Starter Ground Cable Circuit Breaker, 40 A 12.
Page 205 Section 10. Electrical System BATTERY NEGATIVE(–) POSITIVE (+) BATTERY BATTERY TERMINAL TERMINAL SUN ELECTRIC VAT-33 TESTER STARTER IGNITION SWITCH TERMINAL SOLENOID BATTERY TERMINAL LINK BATTERY STRAP TERMINAL STARTER WASHER STARTER MOTOR TERMINAL MA0911 END VIEW OF STARTER SOLENOID Fig. 10.8 Positive and Negative Battery Cables with End View of Starter Solenoid starter now cranks, the problem is in the wiring Starter Circuit Checks–Test 2 circuit.
Page 206: How To Check Voltage Loss
Section 10. Electrical System solenoid terminal and the starter yoke. b. Test 1—Voltage Loss in Complete Starting Operate the starter. Circuit 2. If no volts are indicated, check for: 1. Disconnect the wire from the fuel run solenoid • poor lug connections at battery (2, Fig.
Page 207 Section 10. Electrical System 4. Select the voltmeter range that will measure e. Test 4—Voltage Loss in Starter Solenoid 12 V and release the starter button. 1. Connect the positive lead of the voltmeter to 5. If the voltage indication was: the battery terminal on the starter solenoid, Fig.
Page 208 Section 10. Electrical System MA0971 Bushing kit Armature Retainer 10. Parts kit Forked engagement lever 11. Solenoid Drive end bracket 12. Commutator end bracket Seal kit 13. Brush kit Drive pinion assembly 14. Brush kit Intermediate bracket 15. Thrust washer Field coil 16.
Page 209 Section 10. Electrical System relative to the flywheel. When the teeth become b. Removal aligned, spring pressure slides the pinion into Remove the starter only if it fails the tests listed in mesh with the flywheel. paragraph 10.5.2. To remove the starter: When the pinion is properly engaged with the 1.
Page 210 Section 10. Electrical System 2. If the 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.
Page 211 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.
Page 212 Section 10. Electrical System bars. Use an armature tester to test the connections which must be clean and tight, brush armature. Use instructions included with wear and the commutator. the armature tester. After the starter motor has been in service for (c) Brushes are not making good contact with some time, remove the starter motor from the the commutator bars.
Page 213: Starting Motor Relay
Section 10. Electrical System 4. Connect the positive (+) cable (2) to the b. Disassembly of Starting Motor Relay positive terminals on the batteries. IMPORTANT: Do not disassemble starting motor relay; service only as a complete assembly. 5. Connect the negative (–) cable (1) to the negative terminals on the batteries.
Page 214: Thermo Start Plug For Cold Weather Starting
Section 10. Electrical System MA1071 Thermo Start Plug Intake Manifold Electrical Terminal Fuel Line Fitting Fig. 10.24 Thermo Start Plug for Cold Weather Starting 10.5.5 Thermo Start Plug for Cold The engine is fitted with an efficient cold starting Weather Starting aid and no responsibility can be accepted for any damage caused by unauthorized starting aids.
Page 215: Charging Circuit
Section 10. Electrical System 10.6 CHARGING CIRCUIT The alternator has a solid state regulator that is The charging circuit, Fig. 10.26, is described in mounted inside the alternator slip ring end frame. paragraph 10.6.1.a. The regulator voltage setting never needs adjust- ing, and no provision for adjustment is provided.
Page 216 Section 10. Electrical System IGNITION SWITCH ALTERNATOR NOT CHARGING BAT. WARNING LIGHT DIODE TRIO STARTER SOLENOID TERMINAL REGULATOR BATTERIES FIELD (ROTOR) STATOR RECTIFIER BRIDGE MA1092 Fig. 10.26 Charging Circuit Showing Internal Circuits of a Typical 12-SI Alternator Capacitor C1 smooths out the voltage across R3, As alternator speed increases, current is provided resistor R4 prevents excessive current through for charging the battery and operating electrical...
Page 217 Section 10. Electrical System The other method follows: 3. Switch On, Lamp On, Engine Running. Check for an open circuit breaker between indicator A basic wiring diagram showing lead connections lamp and switch. Other possibilities are is shown in Fig. 10.26. To avoid damage to the covered in “B.
Page 218 Section 10. Electrical System MA1111 16. Bracket 20. Belt Self-locking Nut 12. Sleeve Screw Bolt 17. Stud 21. Pulley Washer 13. Nut Lock Washer Lock Washer 22. Alternator 10. Screw 14. Washer 18. Hex Nut Washer Lever 19. Washer 11. Sleeve 15.
Page 219 Section 10. Electrical System c. Alternator Removal e. Rotor Field Winding Checks 1. Disconnect negative (–) cable (2, Fig. 10.38) 1. To check for opens, connect the test lamp or from batteries. ohmmeter to each slip ring (refer to Fig. 10.29).
Page 220 Section 10. Electrical System 3. Repeat the same test between the single connector and each of the other two connec- tors. Also, connect the ohmmeter to each pair DIODE TRIO of the three connectors (not illustrated). If any reading is zero on this test, replace the diode trio.
Page 221 Section 10. Electrical System 2. A short-circuit in the stator windings is difficult k. Bearing Replacement and Lubrication to locate without laboratory test equipment due The bearing in the drive end frame can be removed to the low resistance of the windings. How- by detaching the retainer plate screws, and then ever, if all other electrical checks are normal pressing the bearing from the end frame, refer to...
Page 222 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- 2.
Page 223 Service Test Specifications When starting the forklift, crank for a maximum of The JLG Alternator, Part Nos. 8270217 and 15 seconds, then rest for two minutes to avoid 8270219, are also identified by Delcotron Alternator burning up the starter. Do not idle excessively.
Page 224 Section 10. Electrical System voltages. Besides reducing gassing, the special c. Built-In Hydrometer chemistry greatly reduces the possibility of over- A special temperature-compensated hydrometer is charge damage. built into the cover of each battery to show at a The vents require keeping the battery in an upright glance the battery’s state-of-charge.
Page 225 Section 10. Electrical System Relation of Battery Temperature to Minimum Voltage Temperature (21 °C ) (10 °C) (–1 °C) (–10 °C)(–18 °C)Below 70 °F & 50 °F 30 °F 15 °F 0 °F 0 °F Above Minimum Voltage • The battery is sufficiently charged when 2.
Page 226: Batteries
Section 10. Electrical System likewise increase. not due to a discharged battery and the crank- ing system should be checked. If charge • Charger Capacity. A charger which can supply only 5 amperes will require a much indicator is dark but the green dot does not appear in the center, proceed as follows: longer period of charging than a charger that can supply 30 amperes or more.
Page 227: Switches And Solenoids
THERMO START Service Test Specifications position before turning it fully to the START posi- The JLG 12 V Battery, Part No. 8270014, is also tion. identified by Delco Freedom Battery Cat. No. 24-60. • In the OFF position, the entire electrical BCI Group Size is 24 A.
Page 228 Section 10. Electrical System • In the RUN position with the Park Lock 2. Disconnect negative (–) cable (2, Fig. 10.38) engaged, park lock warning, oil pressure and from the batteries. alternator lights must be ON. Press Bulb 3. Remove the hex nut which secures the switch Check switch;...
Page 229: Neutral Start Switch
Section 10. Electrical System 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. 2. Position the switch from under the panel. 3. Install hex nut. 4.
Page 230: Park Lock Switch
Section 10. Electrical System PARK STEERING 4. Place the spring and plunger in the solenoid. TRAVEL LOCK SELECT SELECT 5. Energize the solenoid using 12 Vdc to see if LIGHT SWITCH LEVER the plunger retracts. Replace fuel run sole- noid if it doesn’t retract. e.
Page 231: Park Lock Release Valve Solenoid
Section 10. Electrical System c. Cleaning and Drying Jam Nut Name Plate 1. Clean and condition the hex nut cap seal Park Lock Release using an appropriate vinyl cleaner. Valve Solenoid Valve Core 2. Without submerging the switch, clean the Tee-Run switch with an approved solvent and dry with a Connector...
Page 232 Section 10. Electrical System REVERSE SWITCH MA1261 Lock Washer Spacer Cotter Pin Washer Washer Plate Hex Nut Capscrew 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.
Page 233: Reverse Switch
Section 10. Electrical System e. Installation • To test for engagement, engage the park 1. Connect electric wires as tagged during switch lock switch, place the drive in forward or removal. reverse and second or medium gear and 2. Install capscrew (6, Fig. 10.45) through lower apply full throttle.
Page 234: Gauges And Indicator Lights
Section 10. Electrical System In the de-energized condition, the spool (3) is held 2. Replace switch if it fails tests in step 1. by the return springs (4) in the center position. e. Installation The spool is shifted by energizing wet pin sole- noids (2).
Page 235: Hourmeter
Section 10. Electrical System MA1281 MA1282 Nut, hex, 1/4" Screw, hex hd 1/4 by 3/4" 11. Fuel Gauge 16. Bulb Lock Washer, 1/4" Hourmeter 12. Flange Head Bolt 17. Fuel gauge light assembly Gauge Mounting Plate Warning Lights Gauge 13. Bulb socket 18.
Page 236: Warning Lights
Section 10. Electrical System HOURMETER FUEL GAUGE 2. Use an ohmmeter or a continuity tester to test WARNING switch for continuity in the depressed TEST LIGHTS position and for a short in the released OFF position. 3. Replace the switch if it fails the test in step 2. b.
Page 237 Section 10. Electrical System c. Removal of Warning Lights Gauge 3. Tag and disconnect wire from terminal of low oil pressure sender, Fig. 10.42. 1. Refer to paragraph 10.8.1 for removal of gauge cluster. 4. Remove low oil pressure sender. 2.
Page 238: Engine Coolant High Temperature Sender
Section 10. Electrical System 10.8.6 Engine Coolant Wire number 6 from the alternator is energized and lights the alternator not charging bulb if the High Temperature Sender alternator stops supplying current upon demand The engine coolant temperature light warns the by the charging circuit.
Page 239: Fuel Gauge
Section 10. Electrical System TO LIGHTING SYSTEM FOR OPTIONAL FUEL GAUGE LIGHT FUEL LEVEL HYDRAULIC SENDER PUMP CASE GROUND BACK SIDE OF FUEL GAUGE MA1312 Fig. 10.51 Fuel Lever Sender and Fuel Gauge Schematic When the tank is low, the resistance of the sender d.
Page 240 Section 10. Electrical System 4. If gauge shows no indication, look for an 5. Loosen the nuts on the clip which secures the empty fuel tank, no current to ignition terminal gauge to the gauge mounting plate. because of broken or disconnected lead, 6.
Page 241 Section 10. Electrical System 8 IS A GROMMET (NOT SHOWN) 24 IDENTIFIES FOUR PLASTIC TIES (NOT SHOWN) 5 11 52 53 8 10 MA1331 Wiring Harness Headlight (3) Turn Signal Light (2) Front Bracket (2) Hose Clamp, 5/16 Locknut, 3/8 NC (2) Capscrew, hex hd, 3/8 NC x 1 (2) Grommet (not shown) Momentary Brake Light Switch...
Page 242 Section 10. Electrical System Lighting System Circuits Use with Fig. 10.53 Lighting System Wire No. Color Gauge From Black Turn Signal Switch (17) Momentary Brake Switch (9) Black Not Used Black Turn Signal Switch (17) Stop and Tail Light (23) Black Turn Signal Switch (17) Stop and Tail Light (23)
Page 243: Optional Lighting System
Section 10. Electrical System GREEN BLACK GRAY GRAY/BLACK BLUE YELLOW MA1341 Fig. 10.54 Schematic of Directional Signal and Emergency Flasher Switch Loose or corroded connections may cause a 5. Install nut and wire on the right (IGN) terminal discharged battery, difficult starting, dim lights, and post.
Page 244 Section 10. Electrical System a. How to Operate the Emergency Flashers The flasher mount (12, Fig. 10.53) is located above and to the right of the brake pedal. When To operate the emergency flashers, pull flasher replacing a flasher, use Flasher No. 180 for this 12 tab out.
Page 245: Momentary Brake Light (Stop Light)
Section 10. Electrical System 6. Insert assembled anchor screws into slots in 10.9.3 Momentary Brake Light Switch switch. Do not tighten. a. Removal 7. Bend strap end through and around clip. 1. Disconnect negative (–) cable (2, Fig. 10.38) Engage clip between anchor and switch from the batteries.
Page 246: Headlight And Rear Work Light Switch
Section 10. Electrical System 3. Tag and disconnect the wires from the switch. 3. Work the opening in the boot into the groove of the plunger so the metal of the plunger 4. Remove the hex nut which secures the switch bears against the actuator plate, not the boot.
Page 247: Windshield Washer Motor And Reservoir (Enclosed Cab Only)
Section 10. Electrical System 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.
Page 248 Section 10. Electrical System MA1391 Flange Head Capscrews (4) Right Console Overlay Right Front Console Panel Spring Jam Nuts (2) Lock Washers (4) 17 18 Capscrews (2) Brake Valve Clevis Pin 10. Cotter Pin 11. Nut 12. Washer 13. Wiper Arm 14.
Page 249: Windshield Wiper Motor (Enclosed Cab Only)
Section 10. Electrical System e. Installation 4. Prepare to position the brake valve (8, Fig. 10.62) to one side by disconnecting spring (4). 1. Prepare to install washer reservoir assembly by taping a tooth-type lock washer (4, Fig. 5. Remove two jam nuts (5), four lock washers 10.61) to back side of the lower right corner of (6) two capscrews (7) and position the brake reservoir.
Page 250 Section 10. Electrical System c. Disassembly 2. Inspect gear and shaft assembly (7) for damaged or worn gear teeth, damaged 1. To facilitate reassembly, place parts on a threads or worn flats on the end of the shaft. clean bench or in a clean pan in the order in Replace gear and shaft assembly if damaged.
Page 251 Section 10. Electrical System g. Reassembly 3. If adjustment is required to obtain the proper parking position, proceed as follows: 1. Solder the coil leads and cable assembly to the parking switch as shown in Fig. 10.65. (a) Loosen the cover fastening screws (1, Fig. 10.63).
Page 252: Fan Switch And Fan Motor (Optional)
Section 10. Electrical System 11. Connect spring (4). e. Installation 12. Position the right front console panel (3) and 1. Position the fan and install four screws, Fig. right console overlay (2) and install four flange 10.66. head capscrews (1). 2.
Page 253 Section 10. Electrical System MA1442 MA1441 Capscrew Heater and Fan Unit 13. Valve 19. Grommet Lock Washer Hex Nut with Cap 14. Clamps 20. Hoses Tooth-Type Grounding Washers Knurled Nut 15. Hose Connector 21. Sheet Metal Screws Capscrew 10. Decal 16.
Page 254: Heater Fan Motor And Coil (Enclosed Cab Only)
Section 10. Electrical System c. Cleaning and Drying nut (9) to provide the desired projection of the switch stem through the suspension support. 1. Clean the interior of the heater core by con- Install decal (10), knurled nut (9), heater necting a hose to the inlet and flushing the switch (11), and hex nut with cap (8).
Page 255: Emergency Braking And Steering System
Section 10. Electrical System 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. 7. Connect wiring to motor. 8.
Page 256: Steering And Emergency Hydraulic Pump (S/N 7P0013 And Before)
Section 10. Electrical System 3. Connect negative (–) cable (2, Fig. 10.38) to 2. Remove solenoid (4) by removing two 1/4-20 the batteries. by 1/4" Torx head screws. 4. Start the engine and inspect for oil leaks. 3. In warranty the pump and motor assembly is replaced as a complete unit.
Page 257: Steering And Emergency Hydraulic Pump (S/N 7P0014 And After)
Section 10. Electrical System 7. Position the red electrical cable on the sole- Installation noid (4) and secure with nut. 1. Lower the pump and motor assembly into 8. Connect negative (–) cable (2, Fig. 10.38) to position and secure to machine frame. batteries.
Page 258: Troubleshooting
Section 10. Electrical System 2. Remove solenoid (4) by removing two 1/4-20 3. Reconnect wiring to solenoid and motor. by 1/4" Torx head screws. 4. Position the appropriate yellow ground wire on 3. In warranty the pump and motor assembly is the end head assembly (2) and secure with replaced as a complete unit.
Page 259 Section 10. Electrical System Trouble Probable Cause Remedy Reference Warning Devices—HORN Horn doesn't 1. No voltage at horn (7, Fig. Replace wiring and circuit See para. 10.2.1 sound when horn 10.5); broken wire or circuit breaker as required. button is pressed. breaker (11) doesn't reset.
Page 260 Section 10. Electrical System Trouble Probable Cause Remedy Reference Warning Devices—PARK LOCK WARNING LIGHT (cont'd) Park lock warning 1. Short circuit in wiring. Determine and repair cause of See para. 10.8.4 bulb lights when short circuit. park lock brake 2. Defective park lock brake Test park lock brake switch See para.
Page 261 Section 10. Electrical System Trouble Probable Cause Remedy Reference Starting System—GENERAL Engine will not 1. Battery is discharged. Check battery and charge or See para. 10.6.2 crank and starting replace battery. motor relay or 2. Ignition switch, relay or Check circuitry and repair or See para.
Page 262 Section 10. Electrical System Trouble Probable Cause Remedy Reference Starting System—STARTER Starter doesn't run 1. Discharged batteries. See corrections for problem of See para. 10.6.2 or doesn't run discharged batteries. 2. Bad connections, wires, correctly. cables or other parts in the See troubleshooting the starting circuit.
Page 263 Section 10. Electrical System Trouble Probable Cause Remedy Reference Starting System—THERMO START PLUG FOR COLD WEATHER STARTING Intake manifold 1. Discharged batteries. Charge batteries only if See para. 10.6.2 remains cold after electrolyte is not frozen; if ignition key switch frozen, remove batteries from is momentarily forklift, completely thaw and...
Page 264 Section 10. Electrical System Trouble Probable Cause Remedy Reference Charging System—BATTERIES Warning ! • Wear safety glasses when working near batteries. • Keep batteries out of the reach of children. • Never wear rings, metal watch bands or other items that may ground a live circuit. •...
Page 265 Section 10. Electrical System Trouble Probable Cause Remedy Reference Charging System—BATTERIES (cont'd) Refer to paragraph 10.6.2.d Discharged 1. Short circuit in battery cell See para. 10.6.2.d batteries. or cells. and perform battery load test. 2. Loose or dirty battery cable Clean the clamp on the See para.
Page 266 Section 10. Electrical System Trouble Probable Cause Remedy Reference Switches and Solenoids—IGNITION (KEY) SWITCH (cont'd) Ignition switch 1. Fuel run solenoid (34, Fig. Refer to fuel run solenoid See para. 10.7.3 causes starter to 10.5) fails to admit fuel to troubleshooting.
Page 267 Section 10. Electrical System Trouble Probable Cause Remedy Reference Switches and Solenoids—PARK LOCK SWITCH & 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...
Page 268 Section 10. Electrical System Trouble Probable Cause Remedy Reference Gauges and Indicator Lights—WARNING LIGHTS Bulbs in warning 1. Bulbs are burned out. Replace bulbs. See para. 10.8.4 lights gauge fail to 2. No voltage at warning Test switches for continuity See para.
Page 269 Section 10. Electrical System Trouble Probable Cause Remedy Reference Gauges and Indicator Lights—ENGINE COOLANT HIGH TEMPERATURE SWITCH Coolant high Coolant high temperature Replace bulb. See para. 10.8.4 temperature indicator bulb is burned out. indicator bulb fails to light when the test switch is pressed or the engine is...
Page 270 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.
Page 271 Section 10. Electrical System Trouble Probable Cause Remedy Reference Optional Light Circuit—MOMENTARY BRAKE LIGHT (STOP LIGHT) AND SWITCH Stop and tail light 1. Stop and tail light bulb(s) Replace stop and tail light See para. 10.9.2 bulbs fail to light (23, Fig.
Page 272 Section 10. Electrical System Trouble Probable Cause Remedy Reference Optional Light Circuit—HEADLIGHT AND REAR WORK LIGHT SWITCH (cont'd) All lights are 1. Tripped circuit breaker. Determine cause of overload See para. 10.4 inoperative or and reset circuit breaker. intermittent. 2. Loose connection. Check and secure connections at light switch.
Page 273 Section 10. Electrical System Trouble Probable Cause Remedy Reference Windshield Washer/Wiper for Enclosed Cab—GENERAL (cont'd) Windshield wiper 1. Remove connector from If the wiper runs in high, See para. 10.10.3 has low speed terminal H of wiper motor proceed to step 2; if the wiper only and is and connect a 12 Vdc is inoperative, proceed to...
Page 274 Section 10. Electrical System Trouble Probable Cause Remedy Reference Windshield Washer/Wiper for Enclosed Cab—GENERAL (cont'd) Wiper shuts off 1. Remove connector from If wiper is inoperative or See para. 10.10.3 but blades do not terminal P of wiper motor doesn’t park proceed to step return to park and connect a jumper from 2;...
Page 275 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;...
Page 276 Section 10. Electrical System Trouble Probable Cause Remedy Reference Cab Heater for Enclosed Cab—CAB HEATER SWITCH Blower fan motor 1. Check circuit breaker. Replace circuit breaker if See para. 10.4 doesn’t run. open. 2. Check continuity through Replace switch if defective. See para.
Page 277 Section 10. Electrical System 10.15 SPECIFICATIONS RATING ....................12 Vdc Negative Ground NUMBER AND TYPE OF BATTERIES ......2 in parallel, Maintenance Free Lead Acid CIRCUIT BREAKER RATINGS Steering Select Valve ......................... 6 A Horn and Backup Alarm (Optional - Heater Fan)..............10 A Instrument Panel, Park Lock Switch ...................
Page 280 England Fax: (49) 421 693 5035 Fax: (61) 2 65 810122 Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI.

JLG Skytrak 6036 Service Manual

Caution !

Section 3 Boom

Section 4 Operator's Cab

4.2 Mechanical Hand Controls 4-1

4.1 Seat

Section 5 Wheel Assembly, Tires, and Axle

Section 5

Section 6

Section 9 Hydraulic System Warning !

9.1 Circuits

Cylinders

Valves

Pumps

Troubleshooting

Specifications

Section 10 Electrical System

Quick Links

Chapters

Troubleshooting

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Questions and answers

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Summary of Contents for JLG Skytrak 6036