SkyTrak 6036 Service Manual - Manual (Page 138)

Section 8B Cummins Engine
8B-18 Model 6036/6036T S/N 9B0500 thru 14833
Warning
NOTE: When using diesel fuel with a sulfur
content below 1.3 percent, the filter change interval
must be reduced by 75 hours. The use of fuel with
a sulfur content above 1.3 percent is not recom-
mended.
8B.11.2 Fuel Tank
The fuel tank (1, Fig. 8B.39) is located directly
behind the front axle.
a. Removal
1. Have a dry chemical (Class B) fire extinguisher
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.
4. Prepare to drain remaining fuel by centering a
receptacle which can hold the remaining fuel
beneath the elbow (14, Fig 8B.39) at the
bottom of the tank. Loosen hose clamp (5) at
the bottom of the tank, twist fuel supply hose
(7) off elbow (14), and drain fuel into recep-
tacle. Discard the fuel in an approved manner.
Remove elbow (14) 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 (2).
7. Lift and tilt the rear of the tank to remove it
from the forklift.
b. Disassembly
1. Remove five capscrews, washers, fuel level
sender (2, Fig. 8B.39) and gasket from fuel
tank.
2. Remove fuel supply elbow (4) and rubber
bushing (13) from fuel tank.
Never drain or store fuel in an open container
due to the possibility of fire; discard the fuel in
an approved manner.
c. Cleaning and Drying
If contaminated fuel or foreign material is in the
tank, the tank can usually be cleaned. Replace
tank if tank is damaged or if there are leaks in
unreparable areas.
Clean the tank as follows:
1. Have a dry chemical (Class B) fire extinguisher
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.
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 10,3 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 bushing (13, Fig. 8A.39), fuel
supply and return elbows (4 and 14) in tank.
2. Position fuel level sender gasket and fuel level
sender (2) tank.
3. Loosely install the screw and washer which
secures the ground wire to the sender and fuel
tank.
4. Install the other four screws and washers and
alternately torque the five screws which secure
the sender to the fuel tank from 10 to 14 lb-
inch (1 to 2 Nm). Use No. 10-24 screws.
5. Install the wire and nut on the center terminal
of the sender.