SkyTrak 6036 Service Manual - Manual (Page 291)

Section 10. Electrical System
10-29 Model 6036/6036T S/N 9B0500 thru 14833
EMERGENCY BRAKE
P
P
TRAVEL
SELECT
LEVER
STEERING
SELECT
SWITCH
PARK
LOCK
SWITCH
RANGE
SELECT
LEVER
Fig. 10.21 Control Panel
WINDSHIELD
WASHER/WIPER
CONTROL
OH0043
a. Removal
1. Engage the park lock, place the travel select
lever in neutral, and turn the ignition switch to
OFF.
2. Disconnect negative (–) cable (2, Fig. 10.16)
from the batteries.
3. Unlock and open the right engine access door
to gain access to the fuel injection pump.
4. Tag and remove electric wires or pull electrical
connector apart for S/N 3617 & after turbo
engines.
5. A plunger and spring may fall from the sole-
noid when it is removed from the fuel injection
pump except for S/N 3617 & after turbo
engines see step 6. Be prepared to catch
these parts when you remove the solenoid.
Use an appropriate wrench to turn the sole-
noid counterclockwise.
6. S/N 3617 & after turbo remove the solenoid
from the backside of the injector pump by
removing the two bolts holding the solenoid to
the mounting plate. Remove the nut holding
the linkage to the arm on the pump. Save all
the hardware for reassembly.
7. Discard the O-ring.
b. Disassembly
Do not disassemble the fuel run solenoid.
c. Cleaning and Drying
Without submerging the electrical components,
clean the fuel run solenoid using a approved
solvent and dry using a clean lint-free cloth.
d. Inspection and Replacement
1. Prepare to test the fuel run solenoid by
assembling the valve at a bench.
2. Energize the solenoid using 12 Vdc to see if
the plunger retracts. Replace fuel run sole-
noid if it doesn’t retract.
e. Installation
1. Clean exterior of fuel injection pump.
2. Install a new O-ring on the fuel run solenoid.
3. Remove protective plug from fuel injection
pump.
4. With spring and plunger in solenoid, turn fuel
run solenoid into fuel injection pump, being
careful to avoid cross threading. Tighten until
snug. S/N 3617 & after turbo see step 5.
5. S/N 3617 & after turbo line up the holes in the
solenoid with the holes in the mounting plate
and secure in place with the two bolts. As-
semble the linkage end of the solenoid to the
arm on the injector pump with the hex nut.
Tighten all hardware securely.
6. Connect electric wires and connect negative
cable to batteries.
7. Close and lock the engine access door.
8. Prepare to test fuel run solenoid by clearing
personnel and any obstructions from the area
around the forklift.
9. Start the engine.
• If engine starts the solenoid is functioning.
• If engine fails to start, solenoid may have
a poor ground connection. Check voltage
at solenoid.
10. Check for fuel oil leakage around solenoid.