Skytrak 6036 Service Manual Manuel d'utilisateur Page 1

Service ManualModel6036S/N 9B0499 & Before8990151Revised February 11, 2005

1-4Model 6036 S\N 9B0499 and BeforeSection 1. Safety PracticesWhyVentilationRadiator CapSoft GroundSupports andStrapsOil PressurePressureTestingLeavin

Section 8. Engine8-14Model 6036 S/N 9B0499 and Before8.4.6 Fuel FilterChange element (5, Fig. 8.21) every 500 hours ofoperation.1. Unlock and open the

Section 8. EngineModel 6036 S/N 9B0499 and Before8-15Fig. 8.22 Fuel Injection Pump23. Union Nut24. Ball25. Bolt (4)26. Washer (8)27. Gear28. Dowel29.

Section 8. Engine8-16Model 6036 S/N 9B0499 and Beforee. Fuel Injection Pump InstallationIMPORTANT: Instructions and specifications inthe Perkins Work

Section 8. EngineModel 6036 S/N 9B0499 and Before8-17rigid spacer.Tighten securing nuts evenly to 12 lb-ft (16 N m).a. How to Locate Faulty Atomizer(s

Section 8. Engine8-18Model 6036 S/N 9B0499 and BeforeWhenever you replace a muffler you should alsoreplace the tail pipe.Use Exhaust System Sealer at

Section 8. EngineModel 6036 S/N 9B0499 and Before8-191. Remove the transmission cover and open bothengine access doors.2. Lower the boom to the ground

Section 8. Engine8-20Model 6036 S/N 9B0499 and Before375616FUEL RUNSOLENOIDWATER TEMP.SENDERENGINESTARTERENGINE HARNESSTO BATTERIESNOT USEDTRANSMISSIO

Section 8. EngineModel 6036 S/N 9B0499 and Before8-218.7 ENGINE OVERHAULRefer to the Perkins Engine Workshop Manual forthe 4.236 Series engines.8.8 EN

Section 8. Engine8-22Model 6036 S/N 9B0499 and Before13. Secure transmission drive shaft to transmis-sion with U-bolt or bearing strap. Torque U-bolt

Section 8. EngineModel 6036 S/N 9B0499 and Before8-2315. Attach the throttle control cable to the enginefuel injection pump as follows:(a) Fasten the

This Page Left Blank Intentionally

Section 8. Engine8-24Model 6036 S/N 9B0499 and Before4. After all the nuts and capscrews have beenchecked, check the first 10 positions again toensure

Section 8. EngineModel 6036 S/N 9B0499 and Before8-25tion manifold. Seal the manifold with water-proof tape.12. Remove the exhaust pipe. Spray POWER

Section 8. Engine8-26Model 6036 S/N 9B0499 and Before8.12 TROUBLESHOOTINGPossible Causes (see Key)TroubleLow Cranking Power 1, 2, 3, 4Will Not Start 5

This Page Left Blank Intentionally

Section 9. Hydraulic System9-1Model 6036 S/N 9B0499 and BeforeWarning !CONTENTS• If anyone is injured by or if any hydraulic fluidis injected into the

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-2oil from the base end of the cylinder to returnthrough ports A to D, Fig. 9.1, of the di

Section 9. Hydraulic System9-3Model 6036 S/N 9B0499 and Beforeing, the counterbalance valve would lose pilotpressure closing off flow returning to the

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-44. Install a tee and pressure gauge capable ofmeasuring 0 - 4000 psi (275,6 bar) in thet

Section 9. Hydraulic System9-5Model 6036 S/N 9B0499 and BeforeFig. 9.3 Boom Extend Circuit5. Starting at the fully raised position, lower theboom at f

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-6• Should any of the hydraulic lines going tothe extend cylinder fail, there will be a lo

Section 2 General Instructions2-1Model 6036 S/N 9B0499 and Before2.9 AFTER SERVICE STARTUPAND CHECKS 2-52.9.1 Starting After Servicing 2-52.9.2 After

Section 9. Hydraulic System9-7Model 6036 S/N 9B0499 and Before5. Start the engine. Extend and retract the boomseveral times to purge the system of ai

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-8Fig. 9.4 Grille Tilt and Slave Circuit6. Repeat steps 4 and 5 to recheck performance.7.

Section 9. Hydraulic System9-9Model 6036 S/N 9B0499 and BeforeWhen the boom is raised, the slave cylinder isextended which causes pressure buildup on

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-105. Start the engine. Operate the grille tilt controlseveral times to purge the system

Section 9. Hydraulic System9-11Model 6036 S/N 9B0499 and Before5. Starting at the full tilt up position, tilt the grilledown fully at full engine spee

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-122. Operate the hydraulic controls after the enginehas stopped to relieve any trapped pr

Section 9. Hydraulic System9-13Model 6036 S/N 9B0499 and Before2. Operate the hydraulic controls after the enginehas stopped to relieve any trapped pr

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-14M9.1.5 Brake Circuitsa. DescriptionHydraulic pressure is normally applied in theservice

Section 9. Hydraulic System9-15Model 6036 S/N 9B0499 and Before2. Operate the hydraulic controls after the enginehas stopped to relieve any trapped pr

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-162. Operate the hydraulic controls after the enginehas stopped to relieve any trapped pr

Section 2 General InstructionsModel 6036 S/N 9B0499 and Before2-22.3 REPLACEMENTReplace O-rings, seals, and gaskets wheneverthey are disturbed. Never

Section 9. Hydraulic System9-17Model 6036 S/N 9B0499 and Before9.1.6 Power Steering Circuita. Description1. Hydraulic pressure is applied in the power

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-18MRIGHT REARSTEERINGCYLINDERRIGHT FRONTSTEERINGCYLINDERCOUNTER-BALANCEVALVELEFT REARSTEE

Section 9. Hydraulic System9-19Model 6036 S/N 9B0499 and Before3. The steer select valve solenoid is energizedand shifts the valve spool. Oil is chann

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-204. Return oil from each of the front steeringcylinders passes through the solenoid-ener

Section 9. Hydraulic System9-21Model 6036 S/N 9B0499 and BeforeCenter PositionWhen the auxiliary control lever is placed in thecenter or neutral posit

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-22Backward PositionWhen the auxiliary control lever is placed in thebackward position, th

Section 9. Hydraulic System9-23Model 6036 S/N 9B0499 and Before9.2 CYLINDERSRebuild cylinders only in a clean, well lighted areawhere you can carefull

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-24Warning !IMPORTANT: Do not attempt to reset the boomhoist cylinder counterbalance valv

Section 9. Hydraulic System9-25Model 6036 S/N 9B0499 and Before11. Remove the O-ring (12), backup ring (13),wiper (16) and rod seal (15) from the glan

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-262. Inspect the inside of the tube (7) for scoringand other damage. If the tube is dama

Section 2 General Instructions2-3Model 6036 S/N 9B0499 and BeforeSAESizeBe sure that hydraulic oil is at operating tempera-ture (80 to 120 °F) before

Section 9. Hydraulic System9-27Model 6036 S/N 9B0499 and Before9.2.2 Boom Extend Cylindera. Removal1. Retract the boom and support it in a horizontala

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-281. Rod2. Wiper3. Rod Seal4. Piston Seal5. Piston6. Setscrew7. Setscrew (Nylon)8. O-ring

Section 9. Hydraulic System9-29Model 6036 S/N 9B0499 and Before2. Inspect inside of the tube (13) for deep scoringand other damage. If the tube is dam

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-30Warning !Warning !7. Extend the boom as far as it will go; then theretract it as far as

Section 9. Hydraulic System9-31Model 6036 S/N 9B0499 and BeforeFig. 9.13 Slave Cylinder Exploded Viewd. Inspection, Repair and Replacement1. Check tha

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-322. Fasten the piston rod eye in a vise and put apadded support below and near other end

Section 9. Hydraulic System9-33Model 6036 S/N 9B0499 and Before9.2.4 Grille Tilt Cylindera. Removal1. Remove any attachment from the quick attachassem

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-34Fig. 9.15 Grille Tilt Cylinder Exploded View12. If the bushing (12) needs replacement,s

Section 9. Hydraulic System9-35Model 6036 S/N 9B0499 and BeforeNOTE: Wiper lip should be toward outer end ofgland and seal lips toward the inner end

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-369.2.5 Frame Tilt Cylindera. Removal1. Level the frame. Place blocking betweenframe and

Section 2 General InstructionsModel 6036 S/N 9B0499 and Before2-42.7.4 Straight Thread O-ring Fitting(non-adjustable)1. Make sure both threads and sea

Section 9. Hydraulic System9-37Model 6036 S/N 9B0499 and Befored. Inspection, Repair and Replacement1. Check that rod (13, Fig. 9.17) is straight. If

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-38NOTE: The wiper lip should be toward the outerend of the gland and seal lips toward th

9-39Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System9.2.6 Steering Cylindera. Removal1. Engage the park lock, place the travel selectlever

Model 6036 S/N 9B0499 and Before9-40Section 9. Hydraulic System5. Pull rod (3) and attached parts straight out ofthe tube.NOTE: It may be necessary to

9-41Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System3. Remove small scratches on inside of the tubewith emery cloth of very fine grit. Use

Model 6036 S/N 9B0499 and Before9-42Section 9. Hydraulic System9.2.7 Side Tilt Carriage Cylinder(Optional)a. Removal1. Place the boom in a horizontal

9-43Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System7. Remove piston seal (13) from piston (3).NOTE: It may be necessary to apply heat to b

Model 6036 S/N 9B0499 and Before9-44Section 9. Hydraulic Systeme. AssemblyNOTE: Follow general assembly instructions inparagraph 9.2c.1. If bearing (7

9-45Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic Systema. Main Control Valve Removal1. Engage the park lock, place the travel selectlever in n

Model 6036 S/N 9B0499 and Before9-46Section 9. Hydraulic SystemPISTONPILOTPOPPETPILOTSPRINGADJUSTMENTSCREWPLUGTORESERVOIRRELIEF VALVEPOPPETCHECK VALVE

Section 2 General Instructions2-5Model 6036 S/N 9B0499 and Before2.9.5 After Replacing Transmission1. Check transmission fluid level and replenishas r

9-47Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic SystemDisassembly1. Remove the relief valve from the control valvehousing.2. Unscrew plug (1,

Model 6036 S/N 9B0499 and Before9-48Section 9. Hydraulic System1. Special Nuts (4)2. Inlet Section3. O-rings (5)4. Boom Hoist Section5. Boom Extend Se

9-49Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System2. Install new O-ring (3) in inlet section (2).3. Install tie rods (9 and 10) from the

Model 6036 S/N 9B0499 and Before9-50Section 9. Hydraulic SystemWarning !Warning !4. Start the forklift engine.5. Inspect connections at the control va

9-51Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System5. Tag and disconnect three hydraulic hoses (4,Fig. 9.30) from the right side of the se

Model 6036 S/N 9B0499 and Before9-52Section 9. Hydraulic SystemS/N 8L0333 AND BEFORE1. Cap Used on Forklifts with Only Front Service Brakes2. Bulkhead

9-53Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic Systemg. Bleeding the Brake LinesBleed the brake lines very carefully as soon as thebrake val

Model 6036 S/N 9B0499 and Before9-54Section 9. Hydraulic System9.3.3 Park Lock Release Valvea. Removal1. Engage the park lock, place the travel select

9-55Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic SystemFig. 9.33 Valve Plate Assembly - Underside View, Exploded S/N 8G0236 and AfterBJALHGEF1

Model 6036 S/N 9B0499 and Before9-56Section 9. Hydraulic System9.3.4 Steer Select Valvea. Removal1. Engage the park lock, place the travel selectorlev

Section 2 General InstructionsModel 6036 S/N 9B0499 and Before2-62.10.2 Hydraulic ReservoirWith the oil cold and the forklift on a level surfaceand al

9-57Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System9.3.5 Sequence Valvea. Removal1. Engage the park lock, place the travel selectorlever i

Model 6036 S/N 9B0499 and Before9-58Section 9. Hydraulic System9.3.7 Pressure Reducing Valvea. RemovalNOTE: On forklifts with S/N 8F0235 and before,re

9-59Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic Systemb. DisassemblyNOTE: There are no serviceable parts in thepressure reducing valve; do no

Model 6036 S/N 9B0499 and Before9-60Section 9. Hydraulic System9.4 PUMPS9.4.1 Main Tandem Pumpa. Removal1. Engage the park lock, place the travel sele

9-61Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System1. Hose Clamp2. Inlet Hose3. Elbow4. Clamp Half (2)5. Capscrew (4)6. Lock Washer (4)7.

Model 6036 S/N 9B0499 and Before9-62Section 9. Hydraulic SystemCD3.00 "1.47 "0.06 " 0.06 "GRIND RELIEF ALLOWABLE30°30°32C = 1.054

9-63Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic Systemd. Disassembly Instructions1. Prepare to disassemble the pump by placing itin a vise wi

Model 6036 S/N 9B0499 and Before9-64Section 9. Hydraulic System8. Remove connecting shaft (10). Remove thrustplate (8), seal (7) and seal (11).9. Rem

9-65Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System12. Slide the driven gear and shaft through thehousing (15) and into the bushing in the

Model 6036 S/N 9B0499 and Before9-66Section 9. Hydraulic System19. Thread four studs (3), washers (2) nuts (1) intoshaft end cover (16) and tighten al

This Page Left Blank Intentionally

9-67Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System5. Disconnect red electrical cable from powerterminal on solenoid.6. Tag, disconnect, a

Model 6036 S/N 9B0499 and Before9-68Section 9. Hydraulic Systemb. Disassembly1. Remove connector (2, Fig. 9.44) and elbow (4)from the pump (13) if nec

9-69Model 6036 S/N 9B0499 and BeforeSection 9. Hydraulic System6. Tag, disconnect, and plug the hydraulic supplyhose (1) at the connector (2). Wire o

Model 6036 S/N 9B0499 and Before9-70Section 9. Hydraulic Systeme. Assembly1. If the pump and motor assembly was disas-sembled, mount the end head asse

Section 9. Hydraulic System9-71Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause Remedy9.5 TROUBLESHOOTINGCannot LowerElevated loadCavitation and

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-72Trouble Probable Cause RemedyBoom Hoist orExtend FunctionDrifts Grille Tilt Slowor Malf

Section 9. Hydraulic System9-73Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause RemedyService Brakes Failto ReleaseService Brake FailurePark Loc

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-74Trouble Probable Cause RemedyCheck and set relief valve (para 9.1.6).Install new cartri

Section 9. Hydraulic System9-75Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause RemedyTandem Pump Fails toDeliver FluidCylinder Fails to MoveWhe

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-76Trouble Probable Cause RemedyCheck cable linkage and lubricate or free up asrequired.Di

Model 6036 S/N 9B0499 and Before3-1Section 3. BoomCONTENTSPar. Title Page3.1 BOOM ASSEMBLY 3-13.1.1 Inner Boom Replacement 3-13.1.2 Intermediate Boom

Section 9. Hydraulic System9-77Model 6036 S/N 9B0499 and BeforeMAINFILTER10MICRONHYDRAULICRESERVOIR200MESHEXTEND CYLINDERRIGHT HOIST CYLINDERLEFT HOIS

Section 9. Hydraulic SystemModel 6036 S/N 9B0499 and Before9-78HYDRAULIC SYSTEMSystem Capacity 38 gallons (143,8 liter)Reservoir Capacity 24 gallons (

Section 9. Hydraulic System9-79Model 6036 S/N 9B0499 and BeforePerformance:Boom Extend, Horizontal, No Load 12 to 15 secondsBoom Retract, Horizontal,

This Page Left Blank Intentionally

Section 10. Electrical System10-1Model 6036 S/N 9B0499 and Before10.8.5 Engine Low Oil Pressure Switch 10-4310.8.6 Engine CoolantHigh Temperature Send

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-210.1.1 Service Warningsand Recommendations• DO NOT disconnect the battery while theen

Section 10. Electrical System10-3Model 6036 S/N 9B0499 and BeforeA. Partial sectional view of component to begroundedB. Stud, bolt or capscrew1. Hex n

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-410.2.2 Backup Alarmand Reverse SwitchA backup alarm sounds when the forward-neutral-r

Section 10. Electrical System10-5Model 6036 S/N 9B0499 and Beforee. InstallationThe harnesses are held securely in place by clipsor other devices to p

This Page Left Blank Intentionally

Section 3. Boom3-2Model 6036 S/N 9B0499 and BeforeINNERBOOMBASE ENDPINGRILLE TILTCYLINDERQUICK ATTACHPIVOT PINWITH GREASEFITTINGLOCKPINROD END PINQUIC

Section 10. Electrical System10-6Model 6036 S/N 9B0499 and BeforeGRNBLKREDPWHBL1243532331312217161522136181222243139REDBLK1424114241338911GIS252436342

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-731. Emergency Pump Oil Pressure Sender32. Street Tee, 1/8 NPT33. Water Temperature Se

Section 10. Electrical System10-8Model 6036 S/N 9B0499 and BeforeElectrical System CircuitsUse with Fig. 10.5 Electrical System Wire No. Color Gauge

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-910.5 STARTING CIRCUITWhen you turn the ignition key to start the enginewith the trans

Section 10. Electrical System10-10Model 6036 S/N 9B0499 and Before124351. Battery, 12 V2. Positive Battery Cable3. Starter Solenoid4. Circuit Breaker,

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-11starter now cranks, the problem is in the wiringcircuit. If the solenoid fails to “

Section 10. Electrical System10-12Model 6036 S/N 9B0499 and Beforesolenoid terminal and the starter yoke.Operate the starter.2. If no volts are indica

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-134. Select the voltmeter range that will measure12 V and release the starter button.5

Section 10. Electrical System10-14Model 6036 S/N 9B0499 and Before10.5.3 StarterThe starter is located behind the left access doorat the back of the e

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-15relative to the flywheel. When the teeth becomealigned, spring pressure slides the

Model 6036 S/N 9B0499 and Before3-3Section 3. BoomCAPSCREW ENDS TO BE FLUSH TO0.19" (5 mm) RECESSED IN WEARPAD INSERTINTERMEDIATEBOOMCAPSCREW END

Section 10. Electrical System10-16Model 6036 S/N 9B0499 and Before2. If the starter is to be reinstalled, clean theexterior of the starter with an app

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-17Fig. 10.21 Remote Start Button and Hand HeldTachometer10. Connect the leads from the

Section 10. Electrical System10-18Model 6036 S/N 9B0499 and Beforeconnections which must be clean and tight, brushwear and the commutator.After the st

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-19b. Disassembly of Starting Motor RelayIMPORTANT: Do not disassemble starting motorr

Section 10. Electrical System10-20Model 6036 S/N 9B0499 and Before10.5.5 Thermo Start Plug for ColdWeather StartingWhen the ignition key switch, Fig.

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-21Fig. 10.25 Typical 12-SI Series Alternator10.6 CHARGING CIRCUITThe charging circuit,

Section 10. Electrical System10-22Model 6036 S/N 9B0499 and BeforeCapacitor C1 smooths out the voltage across R3,resistor R4 prevents excessive curren

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-23If indicator lamp operates normally, proceed to "B.ABNORMAL CHARGING SYSTEM OPE

Section 10. Electrical System10-24Model 6036 S/N 9B0499 and Before20. Belt21. Pulley22. Alternator1. Screw2. Lock Washer3. Washer16. Bracket17. Stud18

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-25c. Alternator Removal1. Disconnect negative (–) cable (2, Fig. 10.38)from batteries.

Section 3. Boom3-4Model 6036 S/N 9B0499 and BeforeFig. 3.5 Front Wear Pads Attached to IntermediateBoom4. Use a sling and a suitable hoist to slide th

Section 10. Electrical System10-26Model 6036 S/N 9B0499 and BeforeFig. 10.31 Diode Trio Checkf. Diode Trio Check1. The diode trio is identified in Fig

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-272. A short-circuit in the stator windings is difficultto locate without laboratory t

Section 10. Electrical System10-28Model 6036 S/N 9B0499 and Beforeframe with a hollow cylinder to prevent breakage ofthe end frame. Be extremely care

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-2910.6.2 BatteriesAll lead-acid batteries generate hydrogen gaswhich is highly flammab

Section 10. Electrical System10-30Model 6036 S/N 9B0499 and Beforevoltages. Besides reducing gassing, the specialchemistry greatly reduces the possib

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-31Relation of Battery Temperature to Minimum VoltageTemperature (21 °C ) (10 °C) (–1 °

Section 10. Electrical System10-32Model 6036 S/N 9B0499 and Beforelikewise increase.•Charger Capacity. A charger which cansupply only 5 amperes will

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-33Fig. 10.39 Forklift Operating Components10.7 SWITCHESAND SOLENOIDS10.7.1 Ignition (K

Section 10. Electrical System10-34Model 6036 S/N 9B0499 and Before• In the RUN position with the Park Lockengaged, park lock warning, oil pressure and

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-353. Replace the switch if it fails the tests in step 2.e. Installation1. Connect the

Model 6036 S/N 9B0499 and Before3-5Section 3. BoomGAP MUST BE 0.07 TOO.13" (1,8 TO 3,3 mm)GAP MUST BE 0.07 TOO.13" (1,8 TO 3,3 mm)GAP MUST B

Section 10. Electrical System10-36Model 6036 S/N 9B0499 and BeforeTRAVELSELECTLEVERPARKLOCKLIGHTSTEERINGSELECTSWITCHPARKLOCKSWITCHRANGESELECTLEVERFig.

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-37Warning !1. Jam Nut2. Name Plate3. Park Lock ReleaseValve Solenoid4. Valve Core5. Te

Section 10. Electrical System10-38Model 6036 S/N 9B0499 and Before6. Slide the solenoid from valve cartridge stem.7. If the valve cartridge (4) is lea

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-39• To test for engagement, engage the parklock switch, place the drive in forward orr

Section 10. Electrical System10-40Model 6036 S/N 9B0499 and Before2. Replace switch if it fails tests in step 1.e. Installation1. Connect the wires as

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-41(3) to minimize the entry of dust between theplate and the gauge cover (4). Leave t

Section 10. Electrical System10-42Model 6036 S/N 9B0499 and Before2. Use an ohmmeter or a continuity tester to testswitch for continuity in the depres

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-43c. Removal of Warning Lights Gauge1. Refer to paragraph 10.8.1 for removal ofgauge c

Section 10. Electrical System10-44Model 6036 S/N 9B0499 and Before10.8.6 Engine CoolantHigh Temperature SenderThe engine coolant temperature light war

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-45d. Inspection and ReplacementTest the sender by suspending its probe in hy-draulic f

Section 3. Boom3-6Model 6036 S/N 9B0499 and Before6. Disconnect and cap or plug the grille tiltcylinder tubing, extend cylinder tubes andbulkhead fitt

Section 10. Electrical System10-46Model 6036 S/N 9B0499 and Before4. If gauge shows no indication, look for anempty fuel tank, no current to ignition

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-4712. Flasher Mount13. Flasher14. Machine Screw, rd hd, #10-24 x 3/4 (2)15. Locknut, #

Section 10. Electrical System10-48Model 6036 S/N 9B0499 and BeforeLighting System CircuitsUse with Fig. 10.53 Lighting SystemWire No. Color Gauge From

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-49Fig. 10.55 Directional Signal Switch Lever andEmergency Flasher Control TabPush the

Section 10. Electrical System10-50Model 6036 S/N 9B0499 and Beforea. How to Operate the Emergency FlashersTo operate the emergency flashers, pull flas

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-516. Insert assembled anchor screws into slots inswitch. Do not tighten.7. Bend strap

Section 10. Electrical System10-52Model 6036 S/N 9B0499 and Before3. Work the opening in the boot into the grooveof the plunger so the metal of the pl

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-53The 6 A rated switch has a built-in circuit breaker.a. Removal1. Disconnect negative

Section 10. Electrical System10-54Model 6036 S/N 9B0499 and BeforeFig. 10.62 Windshield Wiper Motor Removal and Disassembly1. Flange Head Capscrews (4

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-5510.10.3 Windshield Wiper Motor (Enclosed Cab Only)The windshield wiper motor is

Model 6036 S/N 9B0499 and Before3-7Section 3. BoomPAD, #10 GA SHIM,INSERT (4),LOCK WASHER (8),FLAT WASHER (8),3/8-16 X 3/4"CAPSCREW (8)Fig. 3.10

Section 10. Electrical System10-56Model 6036 S/N 9B0499 and Beforec. Disassembly1. To facilitate reassembly, place parts on aclean bench or in a clean

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-57g. Reassembly1. Solder the coil leads and cable assembly tothe parking switch as sho

Section 10. Electrical System10-58Model 6036 S/N 9B0499 and Beforee. Installation1. Position the fan and install four screws, Fig.10.66.2. Connect wir

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-59123456789101112131416151718192021232414Fig. 10.67 Removal of Optional Cab Heater Swi

Section 10. Electrical System10-60Model 6036 S/N 9B0499 and Beforenut (9) to provide the desired projection of theswitch stem through the suspension s

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-6110.13 EMERGENCY BRAKING AND STEERING SYSTEM10.13.1 Low Oil Pressure SwitchThe

Section 10. Electrical System10-62Model 6036 S/N 9B0499 and Before3. Connect negative (–) cable (2, Fig. 10.38) tothe batteries.4. Start the engine an

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-63f. Installation1. Lower the pump and motor assembly intoposition and secure to machi

Section 10. Electrical System10-64Model 6036 S/N 9B0499 and Before3. Reconnect wiring to solenoid and motor.4. Position the appropriate yellow ground

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-65Trouble Probable Cause Remedy ReferenceWarning Devices—HORNHorn doesn'tsound wh

Section 3. Boom3-8Model 6036 S/N 9B0499 and Beforepads and the intermediate boom. The gapshould be 0.07 to 0.13" (1,8 to 3,3 mm) andequal on all

Section 10. Electrical System10-66Model 6036 S/N 9B0499 and BeforeNo voltage at theseoperations caused by abroken wire or switch, or acircuit breaker

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-671. Battery is discharged.2. Defective starting motorconnections or loosebattery conn

Section 10. Electrical System10-68Model 6036 S/N 9B0499 and Before1. Discharged batteries.2. Bad connections, wires,cables or other parts in thestarti

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-69Charging System—GENERALTrouble Probable Cause Remedy ReferenceStarting System—THERMO

Section 10. Electrical System10-70Model 6036 S/N 9B0499 and BeforeWarning !• Wear safety glasses when working near batteries.• Keep batteries out of t

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-71Trouble Probable Cause Remedy ReferenceCharging System—BATTERIES (cont'd)Discha

Section 10. Electrical System10-72Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause Remedy ReferenceSwitches and Solenoids—IGNITION (KEY) SWITCH

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-73Trouble Probable Cause Remedy ReferenceSwitches and Solenoids—PARK LOCK SWITCH &

Section 10. Electrical System10-74Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause Remedy ReferenceGauges and Indicator Lights—WARNING LIGHTSBul

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-75Coolanttemperaturewarning bulblights when theengine is runningbut notoverheated.1. R

Model 6036 S/N 9B0499 and Before3-9Section 3. Boom3.1.4 Chain ReplacementTwo chains extend the inner boom and one chainretracts it.Extend ChainsIMPORT

Section 10. Electrical System10-76Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause Remedy ReferenceGauges and Indicator Lights—FUEL LEVEL GAUGEN

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-77Trouble Probable Cause Remedy ReferenceOptional Light Circuit—MOMENTARY BRAKE LIGHT

Section 10. Electrical System10-78Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause Remedy ReferenceOptional Light Circuit—HEADLIGHT AND REAR WOR

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-79Trouble Probable Cause Remedy ReferenceWindshield Washer/Wiper for Enclosed Cab—GENE

Section 10. Electrical System10-80Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause Remedy ReferenceWindshield Washer/Wiper for Enclosed Cab—GENE

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-81Trouble Probable Cause Remedy ReferenceWindshield Washer/Wiper for Enclosed Cab—GENE

Section 10. Electrical System10-82Model 6036 S/N 9B0499 and BeforeTrouble Probable Cause Remedy ReferenceCab Heater for Enclosed Cab—CAB HEATER SWITCH

Section 10. Electrical SystemModel 6036 S/N 9B0499 and Before10-8310.15 SPECIFICATIONSRATING ...

Section 3. Boom3-10Model 6036 S/N 9B0499 and Before3.1.5 Chain Lubrication250 Hour Intervals1. Remove the rear boom cover from the outerboom.2. Extend

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

Model 6036 S/N 9B0499 and Before3-11Section 3. BoomAdjustment is accomplished using extend chainadjustment locknuts, Fig. 3.14.a. Chain Locknut Functi

Effectivity PageJanuary, 1997 - 001 - Original Issue.February 11, 2005 - B - Replaced all branding with JLG.Model 6036 S/N 9B0499 and Before A

Section 3. Boom3-12Model 6036 S/N 9B0499 and Beforeintermediate boom raises up, thereby providingclearance for removing the bottom pad.3. Inspect the

Model 6036 S/N 9B0499 and Before3-13Section 3. BoomB C A A B (FIG. 3.13)4. With the boom extended fully, apply MPG tothe extend chain us

Section 3. Boom3-14Model 6036 S/N 9B0499 and BeforeFig. 3.19 Counterbalance Valves on Boom HoistCylindersAfter the boom has been retracted fully, proc

Model 6036 S/N 9B0499 and Before3-15Section 3. Boomadjusting screw on each cartridge simulta-neously into the cartridge very slowlyclockwise. Hydraul

Section 3. Boom3-16Model 6036 S/N 9B0499 and Before3.4 TROUBLESHOOTINGReferenceRemedyProbable CauseTroubleBroken hydraulic line and/orconnection leak

Model 6036 S/N 9B0499 and Before3-17Section 3. BoomMaximum lift height - boom extended 36 ft. 1 in. (11 m) 35 ft. 5 in. (10,8 m)Maximum lift height -

This Page Left Blank Intentionally

Model 6036 S/N 9B0499 and Before4-1Section 4. Operator's CabNRFDANGERFig. 4.1 Seat4.2 MECHANICAL HANDCONTROLSMechanical hand controls in the oper

4-2Model 6036 S/N 9B0499 and BeforeSection 4. Operator's Cabterminates at a linkage which moves a spool in thetransmission control valve.a. Trans

Model 6036 S/N 9B0499 and Before4-3Section 4. Operator's Cabb. Transmission CableRemoval1. Remove lower panel below control console.2. Remove the

Effectivity PageModel 6036 S/N 9B0499 and BeforeB

4-4Model 6036 S/N 9B0499 and BeforeSection 4. Operator's CabFig. 4.5 Joystick Assembly With Covers Removed5. Assemble the other end of each cable

Model 6036 S/N 9B0499 and Before4-5Section 4. Operator's Cab4. Install the covers on the joystick assembly.5. Install the lower panel.b. Joystick

4-6Model 6036 S/N 9B0499 and BeforeSection 4. Operator's CabFig. 4.8 Throttle PedalLIMIT STOP SCREWLOCKNUTWASHERCLAMPCABLE SUPPORTTHROTTLE CABLES

Model 6036 S/N 9B0499 and Before4-7Section 4. Operator's Cab2. Adjust the limit stop screw until it touches thepedal.3. Tighten the locknut to 12

4-8Model 6036 S/N 9B0499 and BeforeSection 4. Operator's Cab3/16" (5 mm) GAPPIVOT BOLTTENSIONWASHERLOCK PINSBOTTOM NUTLOCKPLATE4.4 REAR VIEW

This Page Left Blank Intentionally

Section 5. Wheel Assembly, Tires, and Axle5-1Model 6036/6036T S/N 9B0499 and BeforeSECTION 5WHEEL ASSEMBLY, TIRES, AND AXLECONTENTSPar. Title Page5.1

Section 5. Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0499 and Before5-2Warning !The forklift may have standard or optional wheelsand tires

Section 5. Wheel Assembly, Tires, and Axle5-3Model 6036/6036T S/N 9B0499 and BeforeWHEELASSEMBLYsolution from the tire.These instructions cover tire r

Section 5. Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0499 and Before5-4FIXED SIDE FLANGEAND TIRE SEATEMBOSSED VALVE HOLERIM BASELOOSE SIDE

Model 6036 S\N 9B0499 and BeforeSECTION CONTENTSSection Subject PageSection 1 Safety Practices ...

Section 5. Wheel Assembly, Tires, and Axle5-5Model 6036/6036T S/N 9B0499 and Before5. Use a suitable hoist or jack to raise the axleuntil the tire cle

Section 5. Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0499 and Before5-6VALVE CORECORE EJECTOR BODYCORE REMOVERHANDLECLIP-ON CHUCKFigure 5.

Section 5. Wheel Assembly, Tires, and Axle5-7Model 6036/6036T S/N 9B0499 and Before9. Remove the valve stem from the rim base.10. Refer to paragraph 5

Section 5. Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0499 and Before5-818. Insert the valve core in the stem and pressur-ize the tire as f

Section 5. Wheel Assembly, Tires, and Axle5-9Model 6036/6036T S/N 9B0499 and Before6. Lubricate a new rubber O-ring. Place O-ringin groove on one sid

Section 5. Wheel Assembly, Tires, and AxleModel 6036/6036T S/N 9B0499 and Before5-105.1.15 Installing a Wheelon the Forklift1. Be sure you’ve read and

Section 5. Wheel Assembly, Tires, and Axle5-11Model 6036/6036T S/N 9B0499 and BeforeCaution !The use of non-original equipment replacementparts is not

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-12larly over the breather, drain the hypoid gearlubricant and inspect inte

Section 5. Wheel Assembly, Tires, and Axle5-13Model 6036 S/N 9B0499 and Before3. Place adequate support under the frame sothat it will remain in place

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-14Flange—Front Axle and Service Brakes2. Screw, self-locking3. Planetary G

This Page Left Blank Intentionally

Section 5. Wheel Assembly, Tires, and Axle5-15Model 6036 S/N 9B0499 and Beforec. Cleaning and Drying1. Clean the groove under drive flange washer (9,F

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-16Flange and Wheel End Without Service Brakes1. Wheel End Assembly2. Screw

Section 5. Wheel Assembly, Tires, and Axle5-17Model 6036 S/N 9B0499 and BeforeWarning !Wear safety glasses at all times when assem-bling and disassemb

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-18Fig. 5.10 Axle Steering Joints14. Locknut15. Washer, flat16. Fitting, gr

Section 5. Wheel Assembly, Tires, and Axle5-19Model 6036 S/N 9B0499 and BeforeFig. 5.11 Retaining Ring Inspection5. Tap the spindle with a soft-faced

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-204. Replace roller bearing cups (24) or cones (23)if any are worn, pitted

Section 5. Wheel Assembly, Tires, and Axle5-21Model 6036 S/N 9B0499 and Beforeturn and align any hole in the nut with amajor spline on the spindle. M

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-22Fig. 5.13 Exploded View of Park Lock1. Screw, socket head cap (4)2. Plat

Section 5. Wheel Assembly, Tires, and Axle5-23Model 6036 S/N 9B0499 and Beforec. Cleaning and Drying1. Clean all parts with approved petroleum basedcl

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-24Fig. 5.15 Front Axle Differential Carrier Assembly23. Screw, differentia

Section 1. Safety PracticesModel 6036 S\N 9B0499 and Before1-11.1 INTRODUCTIONPractically all SERVICE work involves the need todrive the forklift. Th

Section 5. Wheel Assembly, Tires, and Axle5-25Model 6036 S/N 9B0499 and Before1. Differential Carrier Assembly (includesitems 2 thru 39)2. Ring, adjus

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-26• Do not attempt carrier and differential removaland installation and di

Section 5. Wheel Assembly, Tires, and Axle5-27Model 6036 S/N 9B0499 and BeforeARROW DOWNTO FILL/CHECK OIL LEVELARROW DOWNTO FILL/CHECK OIL LEVELFILLFI

Section 5. Wheel Assembly, Tires, and AxleModel 6036 S/N 9B0499 and Before5-28Oil Capacity of Wheel EndFront-54 oz. (1,6 liter)Special TRAK Wet Disc B

This Page Left Blank Intentionally

Section 6. Drive Shafts and Drop BoxModel 6036 S/N 9B0499 and Before6-1CONTENTSPar Title Page6.1 DRIVE SHAFT ASSEMBLIES 6-16.1.1 Drive Shaft Servicing

Section 6. Drive Shafts and Drop Box6-2Model 6036 S/N 9B0499 and BeforeFig. 6.1 Drive Shafts and Drop BoxMA 0301REAR AXLEASSEMBLYMA 0302PARKLOCKAXLE I

Section 6. Drive Shafts and Drop BoxModel 6036 S/N 9B0499 and Before6-3Drive Shaft–Transmission to Drop Gear Box1. Position the drive shaft assembly o

Section 6. Drive Shafts and Drop Box6-4Model 6036 S/N 9B0499 and Before9. Clean the exterior of the drop gear box andmove it to a clean work area.b. I

Section 6. Drive Shafts and Drop BoxModel 6036 S/N 9B0499 and Before6-5Fig. 6.2 Exploded View of Drop Gear BoxSCREW &WASHERPA0261END YOKEOIL SEALV

1-2Model 6036 S\N 9B0499 and BeforeSection 1. Safety PracticesWhyImproper clothing can catch on controlsor moving parts and cause accidentsand/or inju

This Page Left Blank Intentionally

Model 6036 S/N 9B0499 and Before7-1Section 7. Transmission7.1 TRANSMISSION PREVENTIVE 7-1MAINTENANCE7.1.1 Daily or 10 Hour Intervals 7-17.1.2 First 5

7-2Model 6036 S/N 9B0499 and BeforeSection 7. Transmission3. Remove sump plug and screen with gasketfrom housing, Fig. 7.3. Allow the transmissionto

Model 6036 S/N 9B0499 and Before7-3Section 7. Transmission7.4 HOW TO BACK FLUSHOIL COOLERThe transmission oil cooler, Fig. 7.4, is mountedbehind the

7-4Model 6036 S/N 9B0499 and BeforeSection 7. Transmission7.9 TROUBLESHOOTINGTroubleProbable Cause RemedyLow Clutch Pressure Low oil levelFill to prop

Model 6036 S/N 9B0499 and Before7-5Section 7. Transmission7.10 SPECIFICATIONSFilter CapacityConverter:Outlet oil temperature1 quart (0,95 liter)180 t

This Page Left Blank Intentionally

Section 8. EngineModel 6036 S/N 9B0499 and Before8-18.1 ENGINE PREVENTIVE 8-2MAINTENANCE8.1.1 Daily Before Operation 8-28.1.2 First 50 Hours, 250 Hour

Section 8. Engine8-2Model 6036 S/N 9B0499 and Before8.1 ENGINE PREVENTIVEMAINTENANCE8.1.1 Daily Before Operation1. Open fuel fill access door with a k

Section 8. EngineModel 6036 S/N 9B0499 and Before8-34. Remove the air cleaner cover wing nut, cover,and primary element, Fig. 8.5.Wear safety glasses

Section 1. Safety PracticesModel 6036 S\N 9B0499 and Before1-3WhyMany cuts, abrasions, and/or injuriesare caused by defective or impropertools.Well ma

Section 8. Engine8-4Model 6036 S/N 9B0499 and Before2. Level forklift, lower the carriage to ground,shut off engine, and engage park lock.3. Place a r

Section 8. EngineModel 6036 S/N 9B0499 and Before8-53. Loosen drain cock on bottom of fuel pre-filterand allow water to completely drain from it.4. Ti

Section 8. Engine8-6Model 6036 S/N 9B0499 and BeforeINJECTOR HIGH PRESSURELINE FITTINGSFig. 8.13 Injector High Pressure Line Fittings5. Loosen any two

Section 8. EngineModel 6036 S/N 9B0499 and Before8-78.1.7 2,500 Hour Intervals1. Inspect and service proprietary equipmentsuch as starter motor, alter

Section 8. Engine8-8Model 6036 S/N 9B0499 and BeforeDo not use a lubricating oil to the MIL-L-2104Cspecification in naturally aspirated engines for th

Section 8. EngineModel 6036 S/N 9B0499 and Before8-9An approved antifreeze as described inparagraph 2 protects against corrosion andalso raises the bo

Section 8. Engine8-10Model 6036 S/N 9B0499 and Before8.2.3 Integral Oil Cooler in Oil FilterThe oil filter for a turbocharged engine, Fig. 8.17,has an

Section 8. EngineModel 6036 S/N 9B0499 and Before8-11Fig. 8.18 Engine Fuel System1. Fuel Tank2. Fuel Level Sender3. Filler Cap with Tether4. Elbow, 90

Section 8. Engine8-12Model 6036 S/N 9B0499 and Beforeb. Disassembly1. Remove five capscrews, fuel level sender (2,Fig. 8.18) and gasket from fuel tank

Section 8. EngineModel 6036 S/N 9B0499 and Before8-13a. Removal1. Remove fuel pre-filter inlet and outlet tubes(11, Fig. 8.18).2. Support filter with