SkyTrak 6036 Service Manual - Manual (Page 103)

Section 8. Engine
Model 6036 S/N 9B0499 and Before 8-17
rigid spacer.
Tighten securing nuts evenly to 12 lb-ft (16 N m).
a. How to Locate Faulty Atomizer(s)
A faulty atomizer can cause:
• Misfiring
• Knocking in one (or more) cylinders
• Engine overheating
• Loss of power
• Smoky exhaust (black)
• Increased fuel consumption
The particular faulty atomizer or atomizers may be
determined by releasing the pipe union nut on each
atomizer in turn, with the engine running at a fast
"tick-over". If after slackening a pipe union nut the
engine revolutions remain constant, this denotes a
faulty atomizer.
To test the atomizer:
1. Withdraw this complete unit from the cylinder
head.
2. Invert the atomizer with the nozzle facing
outwards and then retighten the unions.
3. Slacken the unions of the other atomizer pipes
(to avoid the possibility of engine starting).
4. Use the starter to turn the engine over until fuel
sprays from the nozzle. Examine the shape of
the spray. If the spray is unduly "wet" or
"streaky" or obviously to one side, or if the
nozzle "dribbles" it may only be necessary to
probe the nozzle holes to remove carbon.
Caution !
Be careful to keep hands and face from coming
in contact with spray as it will cause fuel oil to
penetrate the skin.
IMPORTANT: Do not attempt to adjust injection
pressure without a testing pump and pressure
gauge. It is impossible to adjust the setting of at-
omizers with any degree of accuracy without the
proper equipment.
A perfect atomizer, when tested by pumping fuel
through it in the open air gives a short "pinging"
sound as the fuel emerges from the holes. After
the atomizer has been in service for some time,
the "pinging" changes to a crackling sound. It is
not until the atomizer sounds "dead" that its condi-
tion is likely to affect the running of the engine.
b. Atomizer Identification
Currently, the atomizer code is stamped on the
atomizer body.
c. How to Replace an Atomizer
1. Remove the fuel leak off pipe.
2. Remove the high pressure pipe union nuts
from the atomizer and fuel injection pump and
release the pipe.
3. Remove the atomizer flange nuts and remove
the atomizer and seat washer.
4. Put new atomizer with new seat washer, in
position. Be sure atomizer is not tilted and
tighten the flange nuts evenly by small
amounts to 12 lb-ft (16 N m).
5. Connect high pressure fuel pipe and tighten
nut to 15 lb-ft (20 N m).
6. Connect the leak off pipe.
7. Run the engine and check for fuel and air
leakage.
8. Bleed the fuel system by following the proce-
dures in 8.1.5, Bleeding Fuel System.
8.5 ENGINE EXHAUST
SYSTEM
• Exhaust fumes contain carbon monoxide, a
colorless, odorless gas which is fatal when
inhaled in a confined area. Avoid breathing
exhaust fumes and be sure engine operation
will not cause a concentration of toxic emis-
sions.
• Exhaust system components get very hot
and can cause serious burns.
The exhaust system is supported by the engine to
minimize the transfer of noise and vibration into
the operators cab. The tail pipe on current forklifts
is directed to the right side of the forklift which is
more remote from the operators cab.
Annoying rattles and noise vibrations in the ex-
haust system are usually caused by misalignment
of parts. When aligning the system, leave all bolts
or nuts loose until all parts are properly aligned,
then tighten working from front to rear.
Warning !