SkyTrak 6036 Service Manual - Manual (Page 203)

Section 10. Electrical System
Model 6036 S/N 9B0499 and Before 10-9
10.5 STARTING CIRCUIT
When you turn the ignition key to start the engine
with the transmission in neutral, the starting circuit
actuates a starter relay, a starter solenoid, a
starter and a fuel run solenoid. The fuel run
solenoid opens a valve which supplies fuel to the
injection pump.
When starting in a cold environment, turning the
key to a position between run and start for a few
moments before starting, will supply current to a
thermo start plug in the intake manifold. The plug
ignites a fuel-air mixture in the intake manifold to
facilitate cold weather starting.
The starting circuit functions as follows:
1. Current from the batteries (1, Fig. 10.7) flows
through the positive battery cable (2) to the
starter solenoid (3).
2. It then flows to circuit breaker (4) and to
terminal “1” of the ignition switch (5).
3. When the key (6) is turned to the START
position, current flows through contacts in the
ignition switch to the park lock brake switch
(7).
4. If the park lock brake is set, current flows
through contacts in the brake switch to the
neutral start switch (8).
5. If the transmission select lever is in neutral,
current flows through contacts in the neutral
start switch to energize the coil of the starter
relay (9). The relay closes contacts which
allow current to energize the starter solenoid
(3) and operate the starter.
6. When the solenoid and related mechanisms
cause the starter pinion to engage a gear on
the flywheel, the starter motor rotates the
gear, crankshaft and related components in
the engine.
7. When the ignition key was turned in step 3,
the fuel run solenoid opened a valve to supply
fuel to the fuel injection pump. As the starter
rotated the engine components, the fuel
injection pump and related lines and injectors
supplied fuel to the cylinders.
8. When the pistons compress this injected fuel,
ignition occurs, the engine runs and the starter
pinion retracts.
9. As the engine runs, it operates an alternator
which recharges the battery which was used
during the starting cycle.
3
4
6
1
5
2
4 Disconnect wiring from all of the circuit break-
ers in the bracket.
5. Remove two nuts, lock washers and two
washers and slide bracket over the studs.
b. Installation of Circuit Breaker Bracket and
Individual Circuit Breaker
1. Slide circuit breaker bracket over two studs
and secure using two washers, lock washers
and hex nuts.
2. Position the terminal marked “BAT” on the
circuit breaker terminal plate to your right and
snap each circuit breaker into bracket using a
small slot screwdriver.
3. Secure tagged wiring to respective terminals
using lock washers and hex nuts.
4. Connect battery ground cable to the battery.
5. Check operation of circuits.
1. Circuit breaker, 6 A, protects steering select
valve circuit
2. Circuit breaker, 10 A, protects horn and backup
alarm (and optional cab heater fan) circuit
3. Circuit breaker, 6 A, protects instrument panel,
park lock solenoid switch
4. Circuit breaker, 40 A, protects ignition system
feed for entire electrical system
5. Circuit breaker, 6 A, protects enclosed cab
windshield washer/wiper and circulation fan
circuits (this breaker is optional and will not be
found on forklifts with an open cab)
6. Circuit breaker, 15 A, protects the optional
lighting package
OA0482
Fig. 10.6 Circuit Breakers