SkyTrak 6036 Service Manual - Manual (Page 41)

Model 6036 S/N 9B0499 and Before 4-5
Section 4. Operator's Cab
4. Install the covers on the joystick assembly.
5. Install the lower panel.
b. Joystick Control Cables
Removal
1. Remove the lower panel which is below the
side console.
2. Remove the covers from the joystick assem-
bly, Fig. 4.5.
3. Loosen the lock screw until the control cable,
with lock screw and cable bushing, can be
removed from the slider.
4. Unthread cable bushing from cable and
remove lock screw from cable.
5. Remove the transmission cover.
6. Remove the clamp, Fig. 4.6, that secures the
control cable to the bracket on the forklift
frame.
7. Remove the cotter and clevis pin that attaches
the control cable to the spool on the main
control valve.
8. Remove the clevis and jam nut from cable
end.
9. Remove the cable from the forklift.
Installation
1. Route the control cable between the joystick
and the main control valve.
2. Secure the cable to the main control valve
spool, Fig. 4.6, with clevis and cotter pins.
3. At the other end of the cable, slip the lock
screw over the cable rod end.
4. Thread the cable bushing onto the cable rod
end and position it as shown in Fig. 4.5.
5. Insert the cable into the control slider. Then
thread the lock screw into the slider
6. Use a 5/8 inch open end wrench to hold the
slider in position and tighten the slider lock
screw; work carefully so you don’t rotate the
slider.
IMPORTANT: Do not exceed 55 lb-ft (75 N m).
7. Adjust the cable at both ends so that it oper-
ates properly.
8. Replace the covers on the joystick assembly.
9. Install the lower panel below the side console.
10. Install the transmission cover.
Fig. 4.7 Service Brake Pedal
4.3 MECHANICAL FOOT
CONTROLS
4.3.1 Service Brake Pedal
When you press the service brake pedal you
activate a brake valve that applies the hydraulic
service brakes. The service brake pedal pivots on
a shaft and is held in the raised position by a
spring.
a. Removal
1. Remove the lower panel below the control
console.
2. Remove the cotter pins and clevis, Fig. 4.7,
that secures the brake valve yoke to the brake
pedal.
NOTE: Brake valve push rod will slip out of brake
valve at this point. Remove push rod with yoke
attached.
3. Remove the spring from the pedal.
4. Remove one capscrew, washer and nut that
attaches pedal shaft to mounting frame. Slide
shaft out of pedal and remove pedal and flat
washers.
b. Installation
1. Lubricate the shaft, Fig. 4.7, with multi-
purpose lithium-based grease. Install shaft
through mounting frame, flat washer, pedal,
flat washer and mounting frame. Secure in
place with capscrew and nut.
YOKE
COTTER PIN
SPRING
SHAFT
ADJUSTING NUT
STOP SCREW
PEDAL
CLEVIS PIN
BRAKE VALVE
JAM NUT
BRAKE VALVE
PUSH ROD
Set stop screw
for 2" (51 mm)
clearance from
wall with pedal released and
1/2" (13 mm) minimum
clearance from wall with
pedal depressed.
MA0181