Skytrak 6036 Service Manual Manuel d'utilisateur

Service ManualModel6036S/N 9B0500 thru 148338990163Revised February 11, 2005

1-46036/6036T S/N 9B0500 thru 14833Section 1 Safety Practices1.6 OPERATIONAL CONSIDERATIONS (cont.)Item What to do Why1.7 FINAL WORDThe safety precaut

Section 8A Perkins Engine8A-8Model 6036/6036T S/N 9B0500 thru 14833OA0312Fig. 8A.12 Fuel Lift Pump4. Install the cover making sure that it seats onthe

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-9OA0332FUEL LIFT PUMPPRIMING LEVERFig. 8A.14 Priming Lever4. Continue to pump fuel a

Section 8A Perkins Engine8A-10Model 6036/6036T S/N 9B0500 thru 14833PETCOCKMUFFLEROA0252Fig. 8A.17 Radiator Petcock4. Detach the line from the bottom

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-11FAN PULLEYALTERNATORPULLEY1/4" TO 3/8"(6 TO 9 MM) BELTDEFLECTIONCRANKSHA

Section 8A Perkins Engine8A-12Model 6036/6036T S/N 9B0500 thru 148338A.10 ENGINE OILSPECIFICATIONSUse 10W30 or 15W40 motor oil that is equal toAPI, CD

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-138A.11.2 Radiator Pressure CapThe system is designed to use a radiator pressurecap

Section 8A Perkins Engine8A-14Model 6036/6036T S/N 9B0500 thru 148331. Fuel Tank2. Fuel Level Sender3. Filler Cap with Tether4. Elbow, 90°, with stand

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-15Do not mix gasoline or alcohol with diesel fuel.This mixture can cause an explosio

Section 8A Perkins Engine8A-16Model 6036/6036T S/N 9B0500 thru 14833WarningNever drain or store fuel in an open containerdue to the possibility of fir

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-178A.13.4 Fuel Pre-FilterDrain water from fuel pre-filter, Fig. 8A.26 and8A.27, ever

Section 2 General Instructions2-16036/6036T S/N 9B0500 thru 14833TABLE OF CONTENTSPar. Title Page2.1 INTRODUCTION ... 2-

Section 8A Perkins Engine8A-18Model 6036/6036T S/N 9B0500 thru 14833c. Fuel Lift Pump Removal1. Disconnect lines from the water separator andto the fu

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-198A.13.7 Fuel Injection PumpThe fuel injection pump is a distributor type pumpwith

Section 8A Perkins Engine8A-20Model 6036/6036T S/N 9B0500 thru 14833Whenever you replace a muffler you should alsoreplace the tail pipe.Use Exhaust Sy

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-21WarningTo avoid severe burns, DO NOT attempt thisprocedure when the engine, coolin

Section 8A Perkins Engine8A-22Model 6036/6036T S/N 9B0500 thru 148333421620253111714343627S I31563815441929273651844143735 1293719211735203818256161

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-238A.16 HOW TO OVERHAULTHE ENGINERefer to the Perkins Engine Workshop Manual forthe

Section 8A Perkins Engine8A-24Model 6036/6036T S/N 9B0500 thru 14833(d) Secure the engine mount to the frame witha capscrew, vibration mount, reboundw

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-2515. Attach the throttle control cable to the enginefuel injection pump as follows:

Section 8A Perkins Engine8A-26Model 6036/6036T S/N 9B0500 thru 148338A.19 ENGINE STORAGEUse the following procedures immediately whenengine is removed

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-27Possible Causes (see Key)TroubleLow Cranking Power 1, 2, 3, 4Will Not Start 5, 6,

Section 2 General Instructions2-26036/6036T S/N 9B0500 thru 148332.1 INTRODUCTIONAppropriate service methods and proper repairprocedures are essential

Section 8A Perkins Engine8A-28Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-1SECTION 8BENGINE, CUMMINS 4B3.9 AND 4BT3.9Par. Title PageTABLE OF CONTENTSSAFETY CO

Section 8B Cummins Engine8B-2Model 6036/6036T S/N 9B0500 thru 14833Warning• To avoid burns, be alert for componentswhich remain hot after power is tur

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-3IMPORTANT: These instructions cover only theroutine maintenance of the engine. Re

Section 8B Cummins Engine8B-4Model 6036/6036T S/N 9B0500 thru 14833Fig. 8B.4 Air Cleaner Restriction Indicator8B.4.5 Check Air CleanerRestriction Indi

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-55. Rinse the filter from the inside out with agentle stream of water to remove all

Section 8B Cummins Engine8B-6Model 6036/6036T S/N 9B0500 thru 14833Warning• Hot oil can cause personal injury.• Avoid prolonged and repeated skin cont

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-7IMPORTANT: Fill filter with clean lubricating oilbefore installation.13. Check and

Section 8B Cummins Engine8B-8Model 6036/6036T S/N 9B0500 thru 14833Fig. 8B.13 Remove Elements and Sealing Rings andClean Sealing Surfaces of Filter He

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-9• It is necessary to put the engine in the “Run”position. Because the engine may s

Section 2 General Instructions2-36036/6036T S/N 9B0500 thru 14833the oil temperature. The oil temperature can bechecked by placing a hand against the

Section 8B Cummins Engine8B-10Model 6036/6036T S/N 9B0500 thru 14833• The pressure of the fuel in the high pressureline is sufficient to penetrate the

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-112. Inspect the belt for damage.• Transverse (across the belt width) cracksare acce

Section 8B Cummins Engine8B-12Model 6036/6036T S/N 9B0500 thru 14833Fig. 8B.29 Rotate Crankshaft One Full Turn5. Mark the vibration damper and the fro

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-136. Check for damaged hoses and loose ordamaged hose clamps. Replace as required.C

Section 8B Cummins Engine8B-14Model 6036/6036T S/N 9B0500 thru 148338B.8 ENGINE OILSPECIFICATIONSThe use of quality engine lubricating oils combinedwi

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-15• U.S.A.—Engineering StandardGM6038-M.• U.K.—BS 3151: 1959: Ethanediol Anti-freeze

Section 8B Cummins Engine8B-16Model 6036/6036T S/N 9B0500 thru 14833Do not mix gasoline or alcohol with diesel fuel.This mixture can cause an explosio

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-171. Fuel Tank2. Fuel Level Sender3. Filler Cap with Tether4. Elbow, 90° with Standp

Section 8B Cummins Engine8B-18Model 6036/6036T S/N 9B0500 thru 14833WarningNOTE: When using diesel fuel with a sulfurcontent below 1.3 percent, the f

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-19a. Fuel Filter Head Adapter ReplacementPreparatory Steps:• Clean debris• Remove fu

Section 2 General Instructions2-46036/6036T S/N 9B0500 thru 148332.7.4 Straight Thread O-ring Fitting(non-adjustable)1. Make sure both threads and sea

Section 8B Cummins Engine8B-20Model 6036/6036T S/N 9B0500 thru 14833Failure of the needle valve to lift and close at thecorrect time or needle valve s

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-21Warning• Exhaust fumes contain carbon monoxide, acolorless, odorless gas which is

Section 8B Cummins Engine8B-22Model 6036/6036T S/N 9B0500 thru 14833Fig. 8B.44 Exhaust System for a Turbocharged EngineFig. 8B.43 Exhaust System for a

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-23(c) Remove the parts attaching the exhaustpipe to the exhaust manifold or turbo-ch

Section 8B Cummins Engine8B-24Model 6036/6036T S/N 9B0500 thru 1483317. Disconnect transmission drive shaft from thetransmission:(a) Remove the U-bolt

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-2534216202531117143436276,3163815441929273651844143735 12937192117352038182561615

Section 8B Cummins Engine8B-26Model 6036/6036T S/N 9B0500 thru 14833Fig. 8B.47 Guide StudsFig. 8B.48 Locating StudCONVERTERHOUSINGMA0401(d) Secure the

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-2730. Check the fluid levels as follows:(a) Start the engine and allow it to heat to

Section 8B Cummins Engine8B-28Model 6036/6036T S/N 9B0500 thru 148336. Drain the cooling system as described inparagraph 8B.7.5. To give protection a

Section 8B Cummins EngineModel 6036/6036T S/N 9B0500 thru 148338B-29Possible Causes (see Key)TroubleLow Cranking Power 1, 2, 3, 4Will Not Start 5, 6,

Section 2 General Instructions2-56036/6036T S/N 9B0500 thru 148333. If a hydraulic component failed and contami-nated the system, flush the system, cl

Section 8B Cummins Engine8B-30Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-1SECTION 9HYDRAULIC SYSTEMPar. Title PageTable of Contents9.1 SYSTEM OPERATION ...

Section 9 Hydraulic System9-2Model 6036/6036T S/N 9B0500 thru 148339.1 SYSTEM OPERATIONThere are two different types of operator controlsystems availa

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-3Fig. 9.2 Parallel Working Section (Sectional View)MA2080LOAD-DROPCHECK VALVEPARALLE

Section 9 Hydraulic System9-4Model 6036/6036T S/N 9B0500 thru 14833c. Working SectionsThere are two parallel working sections of thecontrol valve, Fig

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-5DEF DEF DEFALOWERRAISECENTERRAISELOWERTO BOOM EXTEND/RETRACT CYLINDERRIGHT BOOM RAI

Section 9 Hydraulic System9-6Model 6036/6036T S/N 9B0500 thru 14833Before starting the engine be sure all hydraulicconnections are tight and all tools

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-7Wait for the hydraulic fluid to cool before serv-icing any hydraulic component. Ho

Section 9 Hydraulic System9-8Model 6036/6036T S/N 9B0500 thru 14833ABC ABC ABCFig. 9.5 Boom Extend/Retract CircuitCENTERRETRACTEXTENDMA3010RESERVOIRRE

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-9Relieve hydraulic pressure before servicing anyhydraulic component. Escaping hydra

Section 2 General Instructions2-66036/6036T S/N 9B0500 thru 148332.9.10 After Axle Servicing1. Check fluid levels.2. Check torque of drive shaft yoke

Section 9 Hydraulic System9-10Model 6036/6036T S/N 9B0500 thru 148333. Remove the transmission cover from theframe.4. Install a tee and pressure gauge

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-11Fig. 9.7 Inlet Section - Sectional Vieweither of the two pulsar solenoids, one for

Section 9 Hydraulic System9-12Model 6036/6036T S/N 9B0500 thru 14833isolate the section from interference as supply orload pressure changes. Under st

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-13PRESSURECOMPENSATORSPRINGPORT C2COMPENSATORSPOOLPORT C1MAINSPOOLINTERNALSENSINGPAS

Section 9 Hydraulic System9-14Model 6036/6036T S/N 9B0500 thru 14833Fig. 9.10 Electronic Control Boom Raise/Lower CircuitRIGHT BOOM HOISTCYLINDERLEFT

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-15Fig. 9.11 Electronic Control Boom Extend/Retract Circuitb. Pressure Checks and Adj

Section 9 Hydraulic System9-16Model 6036/6036T S/N 9B0500 thru 14833balance valve will have no effect and thecylinder rod will bend and other damagema

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-17The secondary control valve is the same type ofvalve as the cable controlled main

Section 9 Hydraulic System9-18Model 6036/6036T S/N 9B0500 thru 14833Fig. 9.12 Grille Tilt and Slave CircuitMA3030GRILLE TILT PORT RELIEFVALVES 3250 +

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-19b. Grille Tilt Cylinder, Slave Cylinder andRaise Cylinder InteractionThe slave cyl

Section 2 General Instructions2-76036/6036T S/N 9B0500 thru 148332.10.2 Hydraulic ReservoirWith the oil cold and the forklift on a level surfaceand al

Section 9 Hydraulic System9-20Model 6036/6036T S/N 9B0500 thru 148331. Engage the park lock, place the travel selectlever in neutral, and stop the eng

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-21WarningRelieve hydraulic pressure before servicing anyhydraulic component. Escapi

Section 9 Hydraulic System9-22Model 6036/6036T S/N 9B0500 thru 14833LEFTRIGHTCENTER GRILLE TILTAND SLAVECYLINDERSFRAME TILTCYLINDERFRAME TILTPORT RELI

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-23Wait for the hydraulic fluid to cool before serv-icing any hydraulic component. H

Section 9 Hydraulic System9-24Model 6036/6036T S/N 9B0500 thru 14833c. TestingThe frame tilt circuit should be tested wheneverrepairs or adjustments a

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-25Fig. 9.14 Brake Circuit – Without De-Clutch4. Park the forklift on level ground an

Section 9 Hydraulic System9-26Model 6036/6036T S/N 9B0500 thru 148339.4.5 Brake Circuits(S/N OE1180 and After –With Trans. De-Clutch)a. DescriptionHyd

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-27Park Lock Release Valve andTransmission De-Clutch ValveWhen the park lock switch o

Section 9 Hydraulic System9-28Model 6036/6036T S/N 9B0500 thru 148332. Operate the hydraulic controls after the enginehas stopped to relieve any trapp

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-299.4.6 Power Steering Circuita. Description1. Hydraulic pressure is applied in the

Section 2 General Instructions2-86036/6036T S/N 9B0500 thru 14833Notes

Section 9 Hydraulic System9-30Model 6036/6036T S/N 9B0500 thru 148334-WHEELCRABG HG H2-WHEEL G H EFE EFFNO STEERSTEER SELECT VALVER

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-313. The steer select valve solenoid is energizedand shifts the valve spool. Oil fr

Section 9 Hydraulic System9-32Model 6036/6036T S/N 9B0500 thru 14833WarningWarningWait for the hydraulic fluid to cool before servic-ing any hydraulic

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-333. Remove the transmission cover from theframe.4. Install a tee and pressure gauge

Section 9 Hydraulic System9-34Model 6036/6036T S/N 9B0500 thru 14833Fig. 9.17 Optional Auxiliary CircuitMA3080BACKWARDTO GRILLE TILTANDSLAVE CYLINDERS

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-354. Do not over stretch seals, wipers and O-rings.Make sure that seals, wipers and

Section 9 Hydraulic System9-36Model 6036/6036T S/N 9B0500 thru 14833WarningIMPORTANT: Do not attempt to reset the boomhoist cylinder counterbalance v

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-371. Counterbalance Valve2. Backup Ring (3)3. O-ring (3)4. Plug5. Grease Fitting (2)

Section 9 Hydraulic System9-38Model 6036/6036T S/N 9B0500 thru 148332. Inspect the inside of the tube for scoring andother damage. If the tube is dam

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-395. Position the hoist cylinder so that the rod isaligned with the rod end mounting

Section 3 Boom3-16036/6036T S/N 9B0500 thru 14833CONTENTSPar. Title Page3.1 BOOM ASSEMBLY ... 3-13.1.1 Inner Boom Replaceme

Section 9 Hydraulic System9-40Model 6036/6036T S/N 9B0500 thru 14833bushing into position in the eye of rod so thatthe bushing is located an equal dis

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-41BHEBHE17. O-Ring18. O-Ring19. Wiper20. Rod Seal21. O-Ring22. Head23. Backup Ring24

Section 9 Hydraulic System9-42Model 6036/6036T S/N 9B0500 thru 14833WarningFig. 9.21 Boom Extend Cylinder Removal3. Remove the counterbalance valve (1

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-43MA0531c. Cleaning1. Discard all seals and backup rings. Replacewith a complete ne

Section 9 Hydraulic System9-44Model 6036/6036T S/N 9B0500 thru 14833Before starting the engine be sure all hydraulicconnections are tight and all tool

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-45BHEFig. 9.23 Exploded View of “BHE” Boom Extend Cylinder1. Rod2. Wiper3. Rod Seal4

Section 9 Hydraulic System9-46Model 6036/6036T S/N 9B0500 thru 1483311. If necessary remove the plugs (18) and O-rings (17) from the tube (16).9. If r

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-47Relieve hydraulic pressure before servicing anyhydraulic component. Escaping hydr

Section 9 Hydraulic System9-48Model 6036/6036T S/N 9B0500 thru 1483310. Remove the O-ring (7) from inside of thepiston.11. Remove the O-ring (6), back

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-49Before starting the engine be sure all hydraulicconnections are tight and all tool

Section 3 Boom3-26036/6036T S/N 9B0500 thru 14833BASE ENDPINGRILLE TILTCYLINDERQUICK ATTACHPIVOT PINWITH GREASEFITTINGLOCKPINROD END PINQUICK ATTACHAS

Section 9 Hydraulic System9-50Model 6036/6036T S/N 9B0500 thru 148335. Remove the rod end pin, Fig. 9.25, and itslocking capscrew and locknut securing

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-5112. If the bushing (12) needs replacement,support the rod (11) in a soft-jawed vis

Section 9 Hydraulic System9-52Model 6036/6036T S/N 9B0500 thru 1483314. Increase the operating pressure to the maxi-mum (4000 psi or 275 bar) for the

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-53Warning9.5.9 Frame Tilt Cylindera. Removal1. Level the frame. Place blocking betw

Section 9 Hydraulic System9-54Model 6036/6036T S/N 9B0500 thru 148331. Check Valve (2)2. Plug (2)3. Cylinder Tube4. Nut5. Piston6. O-ring7. Piston Sea

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-55NOTE: The wiper lip should be toward the outerend of the gland and seal lips towa

Section 9 Hydraulic System9-56Model 6036/6036T S/N 9B0500 thru 14833WarningFig. 9.29 Steering Cylinder InstallationRelieve hydraulic pressure before s

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-57MA0602Fig. 9.30 Steering Cylinder Exploded View (Old Style)13110351074674658912112

Section 9 Hydraulic System9-58Model 6036/6036T S/N 9B0500 thru 14833f. Installation1. Screw the socket assemblies (3, Fig. 9.29) ontothe retracted cyl

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-59WarningRelieve hydraulic pressure before servicing anyhydraulic component. Escapi

Section 3 Boom3-36036/6036T S/N 9B0500 thru 14833CAPSCREW ENDS TO BE FLUSHTO 0.19" (5 mm) RECESSED INWEAR PAD INSERTINTERMEDIATEBOOMCAPSCREW ENDS

Section 9 Hydraulic System9-60Model 6036/6036T S/N 9B0500 thru 14833Fig. 9.32 Steering Cylinder Exploded View (New Style)MA610013110379589121121514746

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-61f. Installation1. Screw the socket assemblies (3, Fig. 9.31) ontothe retracted cyl

Section 9 Hydraulic System9-62Model 6036/6036T S/N 9B0500 thru 14833WarningWarning9.5.12 Side Tilt Carriage Cylinder(Optional)a. Removal1. Place the b

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-637. Remove piston seal (13) from piston (3).NOTE: It may be necessary to apply hea

Section 9 Hydraulic System9-64Model 6036/6036T S/N 9B0500 thru 14833e. AssemblyNOTE: Follow general assembly instructions inparagraph 9.5.c.1. If bea

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-65WarningWarning9.5.13 Swing Carriage Cylinder(Optional)a. Removal1. Place the boom

Section 9 Hydraulic System9-66Model 6036/6036T S/N 9B0500 thru 148337. Remove piston seal (3) and wear ring (2) fromthe piston (4).NOTE: It may be ne

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-67Fig. 9.36 Swing Carriage Cylinder Exploded ViewMA6120567843211314151612111091. Cyl

Section 9 Hydraulic System9-68Model 6036/6036T S/N 9B0500 thru 148332. Operate all of the hydraulic functions (boomraise/lower and extend/retract) aft

Section 9 Hydraulic System Model 6036/6036T S/N 9B0500 thru 148339-691. Main Control Valve2. Cotter Pin3. Retaining Pin4. Linkage5. Capscrew6. Washer7

Section 3 Boom3-46036/6036T S/N 9B0500 thru 14833Boom4. Use a sling and a suitable hoist to slide theintermediate boom out the front of the outerboom.

Section 9 Hydraulic System9-70Model 6036/6036T S/N 9B0500 thru 148336. Unscrew adjustment screw (15) from plug(12).7. Invert the plug. Pilot spring (

Section 9 Hydraulic System Model 6036/6036T S/N 9B0500 thru 148339-71Fig. 9.40 Main Control Valve Exploded View321192223211755671089151112111820222675

Section 9 Hydraulic System9-72Model 6036/6036T S/N 9B0500 thru 14833Assembly1. Insert spool in the linkage end of the section.IMPORTANT. Take care du

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-73INLETSECTIONOUTLETSECTIONEXTEND/RETRACTSECTIONRAISE/LOWERSECTION4. Remove the caps

Section 9 Hydraulic System9-74Model 6036/6036T S/N 9B0500 thru 14833SUPPLY PORTRETURN PORTEXT. RAISEEXT.RETR.RAISELOWERRETR.LOWERCleaning and DryingCl

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-756MK02308123711103219491. Jam Nut (Small)2. Hex Nut (Large)3. Tie Rod4. Outlet Sect

Section 9 Hydraulic System9-76Model 6036/6036T S/N 9B0500 thru 148331234567891213, 14161718192021222324252715. Inlet Valve Section16. Spring17. Washer

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-775. To remove the compensator spool (22),unscrew plug (23) and remove and discard O

Section 9 Hydraulic System9-78Model 6036/6036T S/N 9B0500 thru 1483341011201617222624252115121819195879LOAD SENSINGBALLOPTIONAL61314231231232714. Nut1

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-79f. Assembly of Control Valve SectionsNOTE: Whenever a control valve has beendisas

Section 3 Boom3-56036/6036T S/N 9B0500 thru 14833GAP MUST BE 0.07 TO0.13" (1,8 TO 3,3 mm)GAP MUST BE 0.07 TO0.13" (1,8 TO 3,3 mm)GAP MUST BE

Section 9 Hydraulic System9-80Model 6036/6036T S/N 9B0500 thru 14833g. Installation of Control Valve in the VehicleNOTE: Be sure that the boom is ret

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-81Fig. 9.48 Control Valve Inlet Section (Sectional View)MK0370Bypass and Relief Adju

Section 9 Hydraulic System9-82Model 6036/6036T S/N 9B0500 thru 148331. Hex Head Capscrew and Lock Washer (4)2. Lower Panel3. Brake Valve4. Connector (

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-832. Remove piston (3), shim or shims (4), andsprings (5 and 6) from housing bore.3.

Section 9 Hydraulic System9-84Model 6036/6036T S/N 9B0500 thru 148331. Place the transmission in neutral, start theengine and engage parking brake.2.

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-85Fig. 9.52 Valve Plate Assembly (w/o De-Clutch) - Exploded Underside View (S/N 9B05

Section 9 Hydraulic System9-86Model 6036/6036T S/N 9B0500 thru 14833Fig. 9.53 Valve Plate Assembly (with De-Clutch) - Exploded Underside View (S/N OE1

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-879.6.4 Valve Plate AssemblyThe secondary control valve (25), brake manifoldvalve as

Section 9 Hydraulic System9-88Model 6036/6036T S/N 9B0500 thru 14833e. Installation1. Lubricate with hydraulic oil and install thecheck valve, park lo

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-899.6.7 Steer Select Valvea. Removal1. Engage the park lock, place the travel select

Section 3 Boom3-66036/6036T S/N 9B0500 thru 148336. Disconnect and cap or plug the grille tiltcylinder tubing, extend cylinder tubes andbulkhead fitti

Section 9 Hydraulic System9-90Model 6036/6036T S/N 9B0500 thru 148338. Remove steer select valve (32) from thesubplate by removing four capscrews (33)

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-91b. Tools Required for Pump RepairThe following tools are required for tandem pumpd

Section 9 Hydraulic System9-92Model 6036/6036T S/N 9B0500 thru 14833Fig. 9.58 Main Tandem Pump InstallationMA07818109141146573211512131. Hose Clamp2.

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-93CD3.00 "1.47 "0.06 " 0.06 "GRIND RELIEF ALLOWABLE30°30°32C = 1

Section 9 Hydraulic System9-94Model 6036/6036T S/N 9B0500 thru 14833d. Disassembly Instructions1. Prepare to disassemble the pump by placing itin a vi

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-958. Remove connecting shaft (10). Remove thrustplate (8), seal (7) and seal (11).9

Section 9 Hydraulic System9-96Model 6036/6036T S/N 9B0500 thru 14833NOTE: If new plugs are being installed, coatthreads with Loctite® Threadlocker 24

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-9719. Thread four studs (3), washers (2) nuts (1)into shaft end cover (16) and tight

Section 9 Hydraulic System9-98Model 6036/6036T S/N 9B0500 thru 148339.8 TROUBLESHOOTINGTroubleProbable Cause RemedyCannot LowerElevated loadCavitation

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-99TroubleProbable Cause RemedyBoom Hoist or ExtendFunction DriftsGrille Tilt Slow or

Section 3 Boom3-76036/6036T S/N 9B0500 thru 14833PAD, #10 GA SHIM,INSERT (4),LOCK WASHER (8),FLAT WASHER (8),3/8-16 X 3/4"CAPSCREW (8)Fig. 3.10 B

Section 9 Hydraulic System9-100Model 6036/6036T S/N 9B0500 thru 14833TroubleProbable Cause RemedyService Brakes Fail toReleaseService Brake FailurePar

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-101TroubleProbable Cause RemedyCheck and set relief valve (para 9.4.6).Install new c

Section 9 Hydraulic System9-102Model 6036/6036T S/N 9B0500 thru 14833TroubleProbable Cause RemedyDirectional ControlValve Does Not ReturnFluid viscosi

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-103Trouble Probable Cause RemedyDirectional ControlValve Difficult to ShiftDirection

Section 9 Hydraulic System9-104Model 6036/6036T S/N 9B0500 thru 14833MAINFILTER10MICRONHYDRAULICRESERVOIR200MESHEXTEND CYLINDERRIGHT HOIST CYLINDERLEF

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-105MA5070MAINFILTER10MICRONHYDRAULICRESERVOIR200MESHEXTEND CYLINDERRIGHT HOIST CYLIN

Section 9 Hydraulic System9-106Model 6036/6036T S/N 9B0500 thru 14833MA5080MAINFILTER10MICRONHYDRAULICRESERVOIR200MESHEXTEND CYLINDERRIGHT HOIST CYLIN

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-107MA5090MAINFILTER10MICRONHYDRAULICRESERVOIR200MESHEXTEND CYLINDERRIGHT HOIST CYLIN

6036/6036T S/N 9B0500 thru 14833Section 9 Hydraulic System9-108MAINFILTER10MICRONHYDRAULICRESERVOIR200MESHEXTEND CYLINDERRIGHT HOIST CYLINDERLEFTHOIST

6036/6036T S/N 9B0500 thru 14833Section 9 Hydraulic SystemHydraulic Pump Flow TestHYDRAULIC TESTINGEngine InformationIdle ...

Section 3 Boom3-86036/6036T S/N 9B0500 thru 1483316. Refer to Fig. 3.9 and check the wear pad gapbetween the front outer boom side and top wearpads an

Section 9 Hydraulic System9-110Model 6036/6036T S/N 9B0500 thru 148339.9 SPECIFICATIONSHYDRAULIC SYSTEMSystem Capacity 38 gallons (143,8 liters)Reser

Section 9 Hydraulic SystemModel 6036/6036T S/N 9B0500 thru 148339-1119.9 SPECIFICATIONS (cont.)HYDRAULIC SYSTEM (CONT)Performance:Boom Extend, Horizo

Section 9 Hydraulic System9-112Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 10. Electrical SystemModel 6036/6036T S/N 9B0500 thru 1483310-1Par. Title PagePar. Title PageTable Of ContentsSECTION 10ELECTRICAL SYSTEM10.8.

Section 10. Electrical System10-2Model 6036/6036T S/N 9B0500 thru 1483310.1.1 Service Warningsand Recommendations• DO NOT disconnect the battery while

Section 10. Electrical SystemModel 6036/6036T S/N 9B0500 thru 1483310-3A. Partial sectional view of component to begroundedB. Stud, bolt or capscrew1.

Section 10. Electrical System10-4Model 6036/6036T S/N 9B0500 thru 14833EMERGENCYEMERGENCYBRAKEBRAKEPP10.2.2 Backup Alarmand Reverse SwitchA backup ala

Section 10. Electrical SystemModel 6036/6036T S/N 9B0500 thru 1483310-510.3 WIRING HARNESSESThe forklift has harnesses (Fig 10.5) for cab andengine wi

Section 10. Electrical System10-6Model 6036/6036T S/N 9B0500 thru 148333461521. Circuit breaker, 6 A, protects steering selectvalve circuit2. Circuit

Section 10. Electrical SystemModel 6036/6036T S/N 9B0500 thru 1483310-710.4.2 Fuses and Circuit BreakerS/N 1883 and AfterThe fuses and circuit breaker

Section 3 Boom3-96036/6036T S/N 9B0500 thru 148333.1.4 Chain ReplacementTwo chains extend the inner boom and one chainretracts it.Extend ChainsIMPORTA

Section 10. Electrical System10-8Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.7 Drawing 1 Cab Harness and Components of Electrical System - Perkins E

Section 10. Electrical SystemModel 6036/6036T S/N 9B0500 thru 1483310-9Fig. 10.7 Drawing 2 Engine Harness and Components of Electrical System - Perkin

Section 10. Electrical System10-10Model 6036/6036T S/N 9B0500 thru 1483313 2NOTUSED4WASHER BOTTLES-OPT.5STEER SELECTVALVESGINOTUSEDREDBLACK32337354320

Section 10. Electrical SystemModel 6036/6036T S/N 9B0500 thru 1483310-11342163111714343627S I3163815441930A27361844143735 12937192117352038182561615

Section 10. Electrical System10-12Model 6036/6036T S/N 9B0500 thru 14833Electrical System Circuits - Perkins EnginesUse with Fig. 10.7 (Drawing 1 &

Section 10. Electrical SystemModel 6036/6036T S/N 9B0500 thru 1483310-13Electrical System Circuits - Cummins EnginesUse with Fig. 10.7 (Drawing 3 &

Section 10. Electrical System10-14Model 6036/6036T S/N 9B0500 thru 1483310. When the ignition key is released after start-ing, it returns to a neutral

Section 10. Electrical System10-15Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.8 Starting Circuit1MA6160RED/WHITESTARTERRELAYREDFUEL RUNSOLENOIDRED/B

Section 10. Electrical System10-16Model 6036/6036T S/N 9B0500 thru 1483310.5.2 StarterThe starter is located behind the left access door atthe back of

Section 10. Electrical System10-17Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.10 Starting Motor Relay1MA6180c. Periodic MaintenanceThe starter motor

Section 3 Boom3-10Model 6036/6036T S/N 9B0500 thru 148333.1.5 Chain Lubrication250 Hour Intervals1. Remove the rear boom cover from the outerboom.2. E

Section 10. Electrical System10-18Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.11 Ignition Key SwitchRUN POSITIONMA1061a. Removal of Starting Motor R

Section 10. Electrical System10-19Model 6036/6036T S/N 9B0500 thru 148334321MA107110.5.4 Thermo Start Plug for ColdWeather Starting - PerkinsWhen the

Section 10. Electrical System10-20Model 6036/6036T S/N 9B0500 thru 1483320. Belt21. Pulley22. Alternator1. Screw2. Lock Washer3. Washer16. Bracket17.

Section 10. Electrical System10-21Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.14 Alternator Removal - Cummins Engines1. Alternator Assembly2. Tensio

Section 10. Electrical System10-22Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.15 Typical Hydrometer OperationGREEN DOTDARKCLEAR65% OR ABOVESTATE OFC

Section 10. Electrical System10-23Model 6036/6036T S/N 9B0500 thru 14833Relation of Battery Temperature to Minimum VoltageTemperature (21 °C ) (10 °C)

Section 10. Electrical System10-24Model 6036/6036T S/N 9B0500 thru 14833f. TroubleshootingIf a battery has tested good and then has notperformed satis

Section 10. Electrical System10-25Model 6036/6036T S/N 9B0500 thru 148333. Attach one end of one jumper cable to thepositive terminal of the booster b

Section 10. Electrical System10-26Model 6036/6036T S/N 9B0500 thru 148331. Steering Wheel2. Horn3. Accelerator Pedal4. Service Brake Pedal5. Ignition

Section 10. Electrical System10-27Model 6036/6036T S/N 9B0500 thru 148331. Seal Cap2. Horn Button3. Washer/Wiper SwitchFig. 10.18 Removal of Switches

Section 3 BoomModel 6036/6036T S/N 9B0500 thru 148333-11Adjustment is accomplished using extend chainadjustment locknuts, Fig. 3.14.a. Chain Locknut F

Section 10. Electrical System10-28Model 6036/6036T S/N 9B0500 thru 148331. Neutral Start Switch2. Switch Actuating Pin3. Control Valve Housing Assembl

Section 10. Electrical System10-29Model 6036/6036T S/N 9B0500 thru 14833EMERGENCYBRAKEPPTRAVELSELECTLEVERSTEERINGSELECTSWITCHPARKLOCKSWITCHRANGESELECT

Section 10. Electrical System10-30Model 6036/6036T S/N 9B0500 thru 14833d. Inspection and Replacement1. Inspect the switch terminals for continuity an

Section 10. Electrical System10-31Model 6036/6036T S/N 9B0500 thru 14833e. Installation1. Connect electric wires as tagged during switchremoval.2. Ins

Section 10. Electrical System10-32Model 6036/6036T S/N 9B0500 thru 148332. Replace switch if it fails tests in step 1.e. Installation1. Connect the wi

Section 10. Electrical System10-33Model 6036/6036T S/N 9B0500 thru 148334. Position the plate and cover under the rightconsole panel (5) and secure wi

Section 10. Electrical System10-34Model 6036/6036T S/N 9B0500 thru 14833EMERGENCYBRAKEPP2. Use an ohmmeter or a continuity tester to testswitch for co

Section 10. Electrical System10-35Model 6036/6036T S/N 9B0500 thru 14833c. Removal of Warning Lights Gauge1. Refer to paragraph 10.8.1 for removal ofg

Section 10. Electrical System10-36Model 6036/6036T S/N 9B0500 thru 1483310.8.6 Engine CoolantHigh Temperature SenderThe engine coolant temperature lig

Section 10. Electrical System10-37Model 6036/6036T S/N 9B0500 thru 14833d. Inspection and ReplacementTest the sender by suspending its probe in hy-dra

Effectivity PageAugust, 1997 - 001 - Original IssueFebruary 11, 2005 - B - Replaced all branding with JLG.Model 6036 S/N 9B0500 thru 14833A

Section 3 Boom3-12Model 6036/6036T S/N 9B0500 thru 148334. The front bottom pad may be removed by firstremoving the top pads. Lower the gooseneckend

Section 10. Electrical System10-38Model 6036/6036T S/N 9B0500 thru 148334. If gauge shows no indication, look for anempty fuel tank, no current to ign

Section 10. Electrical System10-39Model 6036/6036T S/N 9B0500 thru 1483312. Flasher Mount13. Flasher14. Machine Screw, rd hd, #10-24 x 3/4 (2)15. Lock

Section 10. Electrical System10-40Model 6036/6036T S/N 9B0500 thru 14833Lighting System Circuits - Early VersionUse with Fig. 10.30 Lighting SystemWir

Section 10. Electrical System10-41Model 6036/6036T S/N 9B0500 thru 14833RIGHT FRONTLEFT FRONTTO FUEL GAUGERIGHT REARLEFT REARIGN. SW.548123469T

Section 10. Electrical System10-42Model 6036/6036T S/N 9B0500 thru 148331 Harness, Wiring2 Light, Head and Work Lamp3 Light, Turn Signal4 Bracket, Mou

Section 10. Electrical System10-43Model 6036/6036T S/N 9B0500 thru 14833GREENREDBLACKGRAYGRAY/BLACKBLUEYELLOW694315253Fig. 10.32 Directional Signal Sw

Section 10. Electrical System10-44Model 6036/6036T S/N 9B0500 thru 14833a. How to Operate the Emergency FlashersTo operate the emergency flashers, pul

Section 10. Electrical System10-45Model 6036/6036T S/N 9B0500 thru 148331. Jam Nut2. Actuator Plate3. Jam Nut4. Capscrew5. Momentary Brake Light Switc

Section 10. Electrical System10-46Model 6036/6036T S/N 9B0500 thru 14833LIGHTS3. Work the opening in the boot into the grooveof the plunger so the met

Section 10. Electrical System10-47Model 6036/6036T S/N 9B0500 thru 14833The 6 A rated switch has a built-in circuit breaker.a. Removal1. Disconnect ne

Section 3 BoomModel 6036/6036T S/N 9B0500 thru 148333-13ABAADOA0182C A A B (FIG. 3.13)3.1.10 Long Term Storage PreparationRemove rust and corrosion fr

Section 10. Electrical System10-48Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.39 Windshield Wiper Motor Removal and Disassembly1. Flange Head Capscr

Section 10. Electrical System10-49Model 6036/6036T S/N 9B0500 thru 1483310.10.3 Windshield Wiper Motor (Enclosed Cab Only)The windshield wiper mo

Section 10. Electrical System10-50Model 6036/6036T S/N 9B0500 thru 14833Fig. 10.40 Roof Wiper Motor Removal and DisassemblyMA62301. Hose, Washer2. Nut

Section 10. Electrical System10-51Model 6036/6036T S/N 9B0500 thru 1483310.10.5 Roof Washer Motor andReservoir - Later ModelsThe roof washer motor and

Section 10. Electrical System10-52Model 6036/6036T S/N 9B0500 thru 14833e. Installation1. Prepare to install the roof washer reservoirassembly (16, Fi

Section 10. Electrical System10-53Model 6036/6036T S/N 9B0500 thru 14833WIRESCREWS (4)MA1431Fig. 10.41 Air Circulation Fan Removal10.11 FAN SWITCH

Section 10. Electrical System10-54Model 6036/6036T S/N 9B0500 thru 14833123456789101112131416151718192021232414Fig. 10.42 Removal of Optional Cab Heat

Section 10. Electrical System10-55Model 6036/6036T S/N 9B0500 thru 14833c. Cleaning and Drying1. Clean the interior of the heater core by con-necting

Section 10. Electrical System10-56Model 6036/6036T S/N 9B0500 thru 148335. Replace coolant in engine and heater lines,connect the ground cable (2, Fig

Section 10. Electrical System10-57Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceWarning Devices—HORNHorn doesn'tso

Section 3 Boom3-14Model 6036/6036T S/N 9B0500 thru 14833Loosen the retainer nut on each cartridge and turnthe adjusting screws in (clockwise) until th

Section 10. Electrical System10-58Model 6036/6036T S/N 9B0500 thru 14833No voltage at theseoperations caused by abroken wire or switch, or acircuit br

Section 10. Electrical System10-59Model 6036/6036T S/N 9B0500 thru 148331. Battery is discharged.2. Defective starting motorconnections or loosebatter

Section 10. Electrical System10-60Model 6036/6036T S/N 9B0500 thru 148331. Discharged batteries.2. Bad connections, wires,cables or other parts in the

Section 10. Electrical System10-61Model 6036/6036T S/N 9B0500 thru 14833Charging System—GENERALTrouble Probable Cause Remedy ReferenceStarting System—

Section 10. Electrical System10-62Model 6036/6036T S/N 9B0500 thru 14833Warning• Wear safety glasses when working near batteries.• Keep batteries out

Section 10. Electrical System10-63Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceCharging System—BATTERIES (cont'd)

Section 10. Electrical System10-64Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceSwitches and Solenoids—IGNITION (KEY) S

Section 10. Electrical System10-65Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceSwitches and Solenoids—REVERSE SWITCH A

Section 10. Electrical System10-66Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceGauges and Indicator Lights—WARNING LIG

Section 10. Electrical System10-67Model 6036/6036T S/N 9B0500 thru 14833Coolanttemperaturewarning bulblights when theengine is runningbut notoverheate

Section 3 BoomModel 6036/6036T S/N 9B0500 thru 148333-15Warning1. Block the boom so it cannot be lowered.2. If the line failure is isolated to the hoi

Section 10. Electrical System10-68Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceGauges and Indicator Lights—FUEL LEVEL

Section 10. Electrical System10-69Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceOptional Light Circuit—MOMENTARY BRAKE

Section 10. Electrical System10-70Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceOptional Light Circuit—HEADLIGHT AND RE

Section 10. Electrical System10-71Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceWindshield Washer/Wiper for Enclosed Ca

Section 10. Electrical System10-72Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceWindshield Washer/Wiper for Enclosed Ca

Section 10. Electrical System10-73Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceWindshield Washer/Wiper for Enclosed Ca

Section 10. Electrical System10-74Model 6036/6036T S/N 9B0500 thru 14833Trouble Probable Cause Remedy ReferenceCab Heater for Enclosed Cab—CAB HEATER

Section 10. Electrical System10-75Model 6036/6036T S/N 9B0500 thru 1483310.15 SPECIFICATIONSRATING ...

Section 10. Electrical System10-76Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 10. Electrical System10-77Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 3 Boom3-16Model 6036/6036T S/N 9B0500 thru 14833Fig. 3.21 Quick Attach Assembly2. Install quick attach assembly (10) on goose-neck (7) with qu

Section 10. Electrical System10-78Model 6036/6036T S/N 9B0500 thru 14833Notes

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

Section 3 BoomModel 6036/6036T S/N 9B0500 thru 148333-173.4 TROUBLESHOOTINGReferenceRemedyProbable CauseTroubleBroken hydraulic line and/orconnection

Section 3 Boom3-18Model 6036/6036T S/N 9B0500 thru 14833For 13.00-24 10 ply Tires For 15,00-19.5 12 ply TiresReach at maximum lift angle – boom –26.0

Section 4 Operator's CabModel 6036/6036T S/N 9B0500 thru 148334-1 CONTENTSPar. Title Page4.1 SEAT ...

Section 4 Operator's Cab4-2Model 6036/6036T S/N 9B0500 thru 14833terminates at a linkage which moves a spool in thetransmission control valve.a.

Section 4 Operator's CabModel 6036/6036T S/N 9B0500 thru 148334-3b. Transmission CableRemoval1. Remove lower panel below control console.2. Remov

Effectivity PageModel 6036 S/N 9B0500 thru 14833B

Section 4 Operator's Cab4-4Model 6036/6036T S/N 9B0500 thru 14833Fig. 4.5 Joystick Assembly With Covers Removed5. Assemble the other end of each

Section 4 Operator's CabModel 6036/6036T S/N 9B0500 thru 148334-54. Install the covers on the joystick assembly.5. Install the lower panel.b. Joy

Section 4 Operator's Cab4-6Model 6036/6036T S/N 9B0500 thru 148334.3.3 Electronic Joystick Calibration(without TLC)Locate the forklift in an area

Section 4 Operator's CabModel 6036/6036T S/N 9B0500 thru 148334-7To calibrate the Extend/Retract functions, proceedas follows:1. Through the bott

Section 4 Operator's Cab4-8Model 6036/6036T S/N 9B0500 thru 148334.3.4 Joystick Resistance Check(without TLC)6. Connect the ohmmeter between the

Section 4 Operator's CabModel 6036/6036T S/N 9B0500 thru 148334-9++3124312MAX.OUTPUTMAX.OUTPUTDEADBANDDEADBAND452245452COMNONCCOMNONCCOMNO NCCOMN

Section 4 Operator's Cab4-10Model 6036/6036T S/N 9B0500 thru 14833Fig. 4.12 Service Brake Pedal4.4 MECHANICAL FOOTCONTROLS4.4.1 Service Brake Ped

Section 4 Operator's CabModel 6036/6036T S/N 9B0500 thru 148334-11Fig. 4.13 Throttle PedalLIMIT STOP SCREWLOCKNUTWASHERCLAMPCABLE SUPPORTTHROTTLE

Section 4 Operator's Cab4-12Model 6036/6036T S/N 9B0500 thru 148332. Adjust the limit stop screw until it touches thepedal.3. Tighten the locknut

Section 4 Operator's CabModel 6036/6036T S/N 9B0500 thru 148334-134.5 REAR VIEW MIRRORSThe forklift has two rear view mirrors.• A 6-1/2 by 10&quo

Model 6036/6036T S/N 9B0500 thru 14833SECTION CONTENTSSection Subject PageSection 1 Safety Practices ...

Section 4 Operator's Cab4-14Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-1SECTION 5WHEEL ASSEMBLY, TIRES, AND AXLECONTENTSPar. Title Page5.1 W

Section 5 Wheel Assembly, Tires, and Axle5-2Model 6036/6036T S/N 9B0500 thru 14833WarningWhenever you remove tire(s) and wheel(s)from forklift:• Posit

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-3solution from the tire.These instructions cover tire removal and ins

Section 5 Wheel Assembly, Tires, and Axle5-4Model 6036/6036T S/N 9B0500 thru 14833FIXED SIDE FLANGEAND TIRE SEATEMBOSSED VALVE HOLERIM BASELOOSE SIDE

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-55.1.2 Demounting TireIMPORTANT: Always completely deflate tire asde

Section 5 Wheel Assembly, Tires, and Axle5-6Model 6036/6036T S/N 9B0500 thru 14833VALVE CORECORE EJECTOR BODYCORE REMOVERHANDLECLIP-ON CHUCKFigure 5.4

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-79. Remove the valve stem from the rim base.10. Refer to paragraph 5.

Section 5 Wheel Assembly, Tires, and Axle5-8Model 6036/6036T S/N 9B0500 thru 148335. Inspect both sides of the tire to be sure beadsare evenly seated.

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-96. Lubricate a new rubber O-ring. Place O-ringin groove on one side

This Page Left Blank Intentionally

Section 5 Wheel Assembly, Tires, and Axle5-10Model 6036/6036T S/N 9B0500 thru 148335.1.15 Installing a Wheelon the Forklift1. Be sure you’ve read and

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-11CautionThe use of non-original equipment replacementparts is not re

Section 5. Wheel Assembly, Tires, and Axle5-12Model 6036/6036T S/N 9B0500 thru 14833particularly over the breather, drain the hypoidgear lubricant an

Section 5. Wheel Assembly, Tires, and Axle5-13Model 6036/6036T S/N 9B0500 thru 14833WarningFig. 5.7 Axle Connections9. At the front axle, remove two

Section 5. Wheel Assembly, Tires, and Axle5-14Model 6036/6036T S/N 9B0500 thru 14833Fig. 5.8 Wheel End and Drive Flange—Front Axle and Service Brakes

Section 5. Wheel Assembly, Tires, and Axle5-15Model 6036/6036T S/N 9B0500 thru 14833Warning5. Connect hydraulic hoses as required tosteering cylinder

Section 5. Wheel Assembly, Tires, and Axle5-16Model 6036/6036T S/N 9B0500 thru 14833Fig. 5.9 Rear Axle Drive Flange and Wheel End Without Service Bra

Section 5. Wheel Assembly, Tires, and Axle5-17Model 6036/6036T S/N 9B0500 thru 14833WarningWear safety glasses at all times when assem-bling and disa

Section 5 Wheel Assembly, Tires, and Axle5-18Model 6036/6036T S/N 9B0500 thru 14833Fig. 5.10 Axle Steering Joints14. Locknut15. Washer, flat16. Fittin

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-19Fig. 5.11 Retaining Ring Inspection5. Tap the spindle with a soft-f

Section 1 Safety Practices6036/6036T S/N 9B0500 thru 148331-1CONTENTSPar Title Page1.1 INTRODUCTION ... 1-11.2 SIGNAL WO

Section 5 Wheel Assembly, Tires, and Axle5-20Model 6036/6036T S/N 9B0500 thru 148334. Replace roller bearing cups (24) or cones (23)if any are worn, p

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-21turn and align any hole in the nut with amajor spline on the spindl

Section 5 Wheel Assembly, Tires, and Axle5-22Model 6036/6036T S/N 9B0500 thru 14833Fig. 5.13 Exploded View of Park Lock1. Screw, socket head cap (4)2.

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-23c. Cleaning and Drying1. Clean all parts with approved petroleum ba

Section 5 Wheel Assembly, Tires, and Axle5-24Model 6036/6036T S/N 9B0500 thru 14833Fig. 5.15 Front Axle Differential Carrier Assembly23. Screw, differ

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-251. Differential Carrier Assembly (includesitems 2 thru 39)2. Ring,

Section 5 Wheel Assembly, Tires, and Axle5-26Model 6036/6036T S/N 9B0500 thru 14833• Do not attempt carrier and differentialremoval and installation a

Section 5 Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0500 thru 148335-27Level Check (250 hour intervals)1. Level the forklift, ground the c

Section 5 Wheel Assembly, Tires, and Axle5-28Model 6036/6036T S/N 9B0500 thru 148335.4 SPECIFICATIONSOil Capacity of Differential Housing18 qts (17 li

Section 6 Drive Shafts and Drop BoxModel 6036/6036T S/N 9B0500 thru 148336-16.1 DRIVE SHAFTS6.1.1 Drive Shaft Servicinga. RemovalDrive Shaft–Transmiss

1-26036/6036T S/N 9B0500 thru 14833Section 1 Safety Practices1.3 PERSONAL CONSIDERATIONSItem What to do WhyClothing Do not wear loose clothing or jewe

Section 6 Drive Shafts and Drop Box6-2Model 6036/6036T S/N 9B0500 thru 14833SLEEVEASSEMBLYDUST CAPSHAFTASSEMBLYSPLITRETAININGRINGFELTSEALSLEEVEASSEMBL

Section 6 Drive Shafts and Drop BoxModel 6036/6036T S/N 9B0500 thru 148336-39. Unscrew the dust cap and slide the sleeveassembly off the spline of the

Section 6 Drive Shafts and Drop Box6-4Model 6036/6036T S/N 9B0500 thru 14833END YOKEOIL SEALEND YOKEDROP BOXINSPECTIONCOVERSCREW &WASHERSCREW &

Section 6 Drive Shafts and Drop BoxModel 6036/6036T S/N 9B0500 thru 148336-56.3 DROP GEAR BOX FORS/N 9N0942 AND AFTER6.3.1 End Yokesa. InspectionRepla

Section 6 Drive Shafts and Drop Box6-6Model 6036/6036T S/N 9B0500 thru 14833Fig. 6.3 Exploded View of Drop Gear Box for S/N 9N0942 and After1. Housing

Section 6 Drive Shafts and Drop BoxModel 6036/6036T S/N 9B0500 thru 148336-76.3.8 Installation of Drop Gear Box1. From above and below the frame, secu

Section 6 Drive Shafts and Drop Box6-8Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 7 TransmissionModel 6036/6036T S/N 9B0500 thru 148337-17.1 TRANSMISSION PREVENTIVEMAINTENANCE ... 7-17.1.1 Dail

Section 7 Transmission7-2Model 6036/6036T S/N 9B0500 thru 14833TRANSMISSION FILTERTRANSMISSIONDIPSTICKFig. 7.2 Transmission Filter and Dipstick6. Turn

Section 7 TransmissionModel 6036/6036T S/N 9B0500 thru 148337-31253644. Flat Washer5. Oil Cooler Support6. Rear SupportFig. 7.4 Transmission Oil Coole

Section 1 Safety Practices6036/6036T S/N 9B0500 thru 148331-31.4 EQUIPMENT CONSIDERATIONS (CONT.)Item What to do WhyHand Tools Always use the proper t

Section 7 Transmission7-4Model 6036/6036T S/N 9B0500 thru 148337.9 TROUBLESHOOTINGTroubleProbable Cause RemedyLow Clutch Pressure Low oil levelFill to

Section 7 TransmissionModel 6036/6036T S/N 9B0500 thru 148337-57.10 SPECIFICATIONSFilter CapacityConverter:Outlet oil temperature1 quart (0,95 liter)1

Section 7 Transmission7-6Model 6036/6036T S/N 9B0500 thru 14833Notes

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-18A.9 ENGINE MAINTENANCEEvery 2,500 Hours or 2 Years ... 8A-118A.10 ENGINE OILSPECI

Section 8A Perkins Engine8A-2Model 6036/6036T S/N 9B0500 thru 14833Warning• DO NOT work on engine or equipment thatis supported ONLY by lift jacks or

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-38A.4 ENGINE MAINTENANCE8A.4.1 Left and Right Sides of EngineThroughout this section

Section 8A Perkins Engine8A-4Model 6036/6036T S/N 9B0500 thru 148338A.5.2 Check Engine Coolant Level1. Check coolant level in overflow bottle, Fig.8A.

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-5Fig. 8A.6 Air Cleaner Primary ElementAIR CLEANEROA0212VACUATORVALVEAUTOMATIC DUSTEJ

Section 8A Perkins Engine8A-6Model 6036/6036T S/N 9B0500 thru 14833IMPORTANT: Make sure the primary elementcannister is thoroughly cleaned before you

Section 8A Perkins EngineModel 6036/6036T S/N 9B0500 thru 148338A-7OILCOOLERRETAINERADAPTERSCREW10. Check and clean the oil drain plug threads andseal