SkyTrak 6036 Service Manual - Manual (Page 108)

Section 8A Perkins Engine
8A-16 Model 6036/6036T S/N 9B0500 thru 14833
Warning
Never drain or store fuel in an open container
due to the possibility of fire; discard the fuel in
an approved manner.
d. Inspection and Replacement
1. Plug all outlets before removing a fuel tank for
a suspected fuel leak; make sure that one of
the fuel hoses isn’t leaking onto the tank.
2. To test a fuel tank which is out of the forklift,
plug all openings except a supply or return
elbow. Apply a small amount of air pressure
to tank through this elbow (approximately 1 to
1-1/2 psi (7,0 to 10,33 kPa). Test tank for
leaks by applying soap solution to exterior of
tank or by submerging tank in water and
looking for bubbles.
3. For a short term repair you may be able to
repair a small leak by installing a sheet metal
screw with a neoprene gasket in the opening.
Replace tank for long term repair.
e. Assembly
1. Install rubber bushings (18, Fig. 8A.26), fuel
supply and return elbows (4 and 19) in tank.
Reconnect both supply and return hoses (6
and 7) and clamp to elbows.
2. Position fuel level sender gasket and fuel level
sender (2) in tank.
3. Loosely install the screw which secures the
ground wire to the sender and fuel tank.
4. Install the other four screws and alternately
torque the five screws which secure the
sender to the fuel tank from 10 to 14 lb-in
(1 to 2 Nm). Use No. 10-24 screws.
5. Install the wire and nut on the center terminal
of the sender.
8A.13.3 Fuel Level Sender and Gauge
The fuel level sender and gauge assembly is
described in Section 10, Electrical System.
Fig. 8A.27 Fuel Pre-Filter
1. Fuel Pre-Filter
2. Plug
3. Washer
4. Prepare to drain remaining fuel by centering a
receptacle which can hold the remaining fuel
beneath the elbow (19, Fig 8A.26) at the
bottom of the tank. Loosen hose clamp (5) at
the bottom of the tank, twist fuel supply hose
(7) off elbow (19), and drain fuel into recep-
tacle. Discard the fuel in an approved man-
ner. Remove elbow (19) from bottom of the
tank to drain remaining fuel from tank.
5. Loosen hose clamp (5) and twist the fuel
return hose (6) off elbow (4).
6. Disconnect wires from fuel level sender.
7. Lift and tilt the rear of the tank to remove it
from the forklift.
b. Disassembly
1. Remove five capscrews, fuel level sender
(2, Fig. 8A.26) and gasket from fuel tank.
2. Remove fuel supply elbow (4) and rubber
bushing (18) from fuel tank.
c. Cleaning and Drying
If contaminated fuel or foreign material is in the
tank, the tank can usually be cleaned. Replace
tank if it is damaged or if there are leaks in
unreparable areas.
Clean the tank as follows:
1. Have a dry chemical (Class B) fire extin-
guisher near the work area.
2. Disconnect the negative (–) battery cable.
3. Remove and disassemble fuel tank as de-
scribed in paragraphs a and b. Invert, rock
and drain tank.
4. Clean tank with high pressure washer or flush
with hot water for five minutes. Invert, rock
and drain tank completely.
5. If necessary, add a diesel fuel emulsifying
agent to the tank, refill with water, and agitate
mixture for 10 minutes. Drain tank completely.
Refer to manufacturer’s instructions for correct
emulsifying agent to water mixture.
6. When empty, refill to overflowing with water.
Completely flush and empty tank.
1
4
5
5
4
3
2
6
3
2
MA0341
4. Nut
5. Ferrule
6. Drain Cock