SkyTrak 6036 Service Manual - Manual (Page 256)

Section 10. Electrical System
10-62 Model 6036 S/N 9B0499 and Before
3. Connect negative (–) cable (2, Fig. 10.38) to
the batteries.
4. Start the engine and inspect for oil leaks.
5. Close and lock right engine access door.
10.13.2 Steering and Emergency
Hydraulic Pump
(S/N 7P0013 and Before)
The emergency hydraulic pump, Fig. 10.68,
performs three functions:
• When starting the engine, the emergency
steer pump supplies oil pressure as the
engine is being started;
• When oil pressure at the engine rises
above 4 psi (0,3 bar), the emergency steer
pump ceases operation because the
engine is turning fast enough for the
tandem pump to supply sufficient hydraulic
oil pressure for forklift operation.
• If engine oil pressure again falls below 4
psi (0,3 bar), the switch will close and the
emergency steer pump will resume
operation for as long as the battery retains
a sufficient charge.
a. Removal
1. Disconnect negative (–) cable (2, Fig. 10.38)
from the batteries.
2. Remove hydraulic tank cover.
3. Disconnect red electrical cable from solenoid
(4, Fig. 10.68) by removing nut.
4. Tag and disconnect yellow ground wire from
solenoid (4) by removing nut.
5. Tag and disconnect yellow ground wire from
housing of motor (1) by removing screw.
6. Tag, disconnect, and plug the hydraulic supply
hose at the pump. Cap or plug the hose end
and pump ports.
7. Tag, disconnect, and plug the hydraulic
pressure hose at the pump. Cap or plug the
hose end and pump ports.
8. Prepare to remove pump and motor assembly
by supporting assembly while an assistant
removes two 3/8-16 UNC hex head
capscrews.
9. Lift assembly from the forklift.
b. Disassembly
1. Disconnect black electric terminal cable (5,
Fig. 10.68) by removing nuts at the solenoid
(4) and at the housing of the motor (1).
2. Remove solenoid (4) by removing two 1/4-20
by 1/4" Torx head screws.
3. In warranty the pump and motor assembly is
replaced as a complete unit. Out of warranty
the pump and motor can be serviced as
separate items. If further disassembly is
required, mark the orientation of the pump to
the motor and remove four screws which
secure the pump (2) to the motor (1).
4. Lift pump (2) from motor (1).
5. Remove coupling (6) from pump (2).
c. Cleaning and Drying
Without submerging the motor (1, Fig. 10.68) in
the cleaning solvent, clean the pump and motor
assembly in an approved cleaning solvent and
blow dry.
d. Inspection and Replacement
1. Inspect the pump and motor assembly.
2. Discard the complete pump or motor if the
pump (2, Fig. 10.68) or motor (1) is damaged
or defective.
3. Test the coil of the solenoid (4) for continuity.
Discard solenoid if it is damaged or defective.
4. Test solenoid operation using short heavy
gauge wires connected to a fused or protected
6 A minimum output, 12 Vdc power supply.
Discard solenoid if it fails to operate.
5. Test pump motor operation using short heavy
gauge wires connected to a fused or protected
6 A minimum output, 12 Vdc power supply.
Discard motor if it fails to run.
e. Assembly
1. If pump and motor was disassembled, install
coupling (6, Fig. 10.68) in pump (2).
2. Refer to the orientation marks made in para-
graph b, place the pump (2) in position on the
motor (1) and secure with four screws.
3. Position solenoid (4) on housing of motor (1)
and install two 1/4-20 by 1/4" Torx hd screws.
4. Torque bottom nut on the ground terminal on
the housing of the motor (1) to 100 lb/in (11,3
N m) maximum.
5. Connect black electric terminal cable (5) by
installing nuts at the solenoid (4) and at the
ground terminal on the housing of the motor
(1). Torque this top nut on the ground terminal
on the housing of the motor to 35 lb/in (3,9
N m) maximum.