SkyTrak 6036 Service Manual - Manual (Page 96)

Section 8. Engine
8-10 Model 6036 S/N 9B0499 and Before
8.2.3 Integral Oil Cooler in Oil Filter
The oil filter for a turbocharged engine, Fig. 8.17,
has an integral oil cooler. Whenever you change
engine coolant, drain the oil cooler by removing
inlet or outlet connections, flush the cooler and
reconnect hose.
8.3 ENGINE ELECTRICAL
SYSTEM
The engine electrical system is described in
Section 10, Electrical System. These instructions
describe warning devices, wiring harnesses, circuit
breakers, the starting and charging circuits,
switches and solenoids, gauges and indicator
lights, and electrical troubleshooting.
8.4 ENGINE FUEL SYSTEM
The engine fuel system includes a fuel tank (1,
Fig. 8.18), a fuel level sender (2) and gauge, a fuel
pre-filter (3), a fuel pump, Fig. 8.10, a fuel filter
(22, Fig. 8.18), and fuel lines to and from the fuel
injection pump, and fuel lines from the fuel injec-
tion pump to and from the fuel injectiors back to
the fuel filter and fuel tank. A separate line runs
from the fuel filter to the Thermo Start plug, Fig.
8.14, in the intake manifold.
The threaded fuel fill opening in the top of the fuel
tank has a filler cap with a tether (3, Fig. 8.18). A
fuel level sender (2) and gauge are described in
Section 10, Electrical System.
A fuel supply hose carries fuel from the bottom of
the tank to the fuel pre-filter (21). The fuel then
flows through a fuel filter tube, a hose and a fuel
pump tube to the fuel lift pump, Fig. 8.10, which is
located on the left side of the engine.
A tube carries fuel under pressure from the fuel lift
pump to the fuel filter (22, Fig. 8.18). Fuel which
has been filtered by the fuel filter is directed
through tubes to the fuel injection pump and to the
Thermo Start plug, Fig. 8.14 in the intake manifold.
A tube from the fuel injection pump returns surplus
fuel to the fuel filter (22, Fig. 8.18) for recirculation
back to the fuel injection pump.
A tube from the fuel injectors returns surplus fuel
from the injectors to the fuel filter (22) and into a
line and hose which returns it to the fuel tank.
8.4.1 Type of Diesel Fuel to Use
Fuel represents a major portion of your forklift
operating costs; therefore, it is important to use it
efficiently. Don't let cost tempt you to use inferior
diesel fuel. The initial savings is a false economy
when you consider the damage poor fuel can do to
your forklift engine.
NOTE: Use only diesel fuel designed for diesel
engines. Some heating fuels contain harmful
chemicals which can seriously affect engine
efficiency and performance.
When operating in temperatures above 20 °F
(–6,7 °C), use diesel fuel No. 2D with a minimum
cetane rating of 45. When operating in tempera-
tures below 20 °F (–6,7 °C) use diesel fuel oil No.
1D with a minimum cetane rating of 50.
NOTE: When using diesel fuel with a sulfur
content below 1.3 percent, the oil filter change
interval must be reduced by 75 hours. The use of
fuel with a sulfur content above 1.3 percent is not
recommended.
8.4.2 Fuel Tank
The fuel tank (1, Fig. 8.18) is located directly
behind the front axle.
a. Removal
1. Have a dry chemical (Class B) fire extin-
guisher near the work area.
2. Disconnect the negative battery cable.
3. Using a hand operated pump, when available,
pump as much fuel as possible through the fill
cap or fuel level sensor openings in the fuel
tank. Pump the fuel oil into a marked and
approved receptacle for fuel oil.
Never drain or store fuel in an open container
due to the possibility of fire; discard the fuel in
an approved manner.
4. Prepare to drain remaining fuel by centering a
receptacle which can hold the remaining fuel
beneath the elbow (20, Fig 8.18) at the bottom
of the tank. Loosen hose clamp (5) at the
bottom of the tank, twist fuel supply hose (7)
off elbow (20), and drain fuel into receptacle.
Discard the fuel in an approved manner.
5. Loosen hose clamp (5) and twist the fuel
return hose (6) off elbow (4).
6. Disconnect wires 17 and 21 from fuel level
sender.
7. Lift and tilt the rear of the tank to remove it
from the forklift.
Caution !