SkyTrak 6036 Service Manual - Manual (Page 263)

Section 10. Electrical System
Model 6036 S/N 9B0499 and Before 10-69
Charging System—GENERAL
Trouble Probable Cause Remedy Reference
Starting System—THERMO START PLUG FOR COLD WEATHER STARTING
Intake manifold
remains cold after
ignition key switch
is momentarily
turned to THERMO
START position.
Intake manifold
remains
abnormally hot
during normal
engine operation.
1. Discharged batteries.
2. Broken wiring or circuit
breaker (10, Fig 10.5).
3. Loose connections.
4. Clogged or bent fuel line to
Thermo Start plug.
5. Defective plug.
6. Broken ignition switch.
Charge batteries only if
electrolyte is not frozen; if
frozen, remove batteries from
forklift, completely thaw and
then charge.
Replace wiring or circuit
breaker.
Tighten connections.
Clean or replace fuel line.
Replace Thermo Start plug.
Remove and test ignition
switch in all positions; replace
if defective.
See para. 10.6.2
See para. 10.4
See para. 10.5.5
See para. 10.5.5
See para. 10.5.5
See para. 10.7.1
Remove and test ignition
switch in all positions; replace
if defective. See para. 10.7.1
Visual Check 1. Check for loose or
corroded connections.
2. Check the condition and
adjustment of the
alternator belts.
3. Check the condition of the
batteries.
4. Check for voltage at the
terminals on the alternator.
Repair as necessary.
Install a new set of drive belts
if necessary; refer to
paragraph 8.1.2 for belt
adjustment instructions.
Refer to “Charging System—
Batteries”.
Refer to paragraph 10.6.1.b
for alternator troubleshooting
procedures.
See para. 10.6
See para. 8.1.2
and 10.6.1
See para. 10.6.2
See para. 10.6.1.b
Noise coming
from the
alternator. 1. Damaged or worn drive
belt.
2. Damaged or loose pulley
on the alternator.
3. Worn or damaged bearings
in the alternator.
Install new drive belt.
Remove the pulley and check
for damage to the rotor shaft
and pulley; install new parts
as required.
Disassemble the alternator
and replace bearings as
required.
See para. 8.1.2
and 10.6.1
See para. 8.1.2
and 10.6.1
See para. 10.6.1
Charging System—ALTERNATOR
Thermo Start plug is ON
continuously due to broken
ignition switch or a short
circuit in the wiring.