Lull 944E-42 Service Manual - Manual (Page 227)

7.25 Model 644E-42/944E-42 Rev. 6/04
Engine: Cummins 4BT 3.9, B4.5T and QSB 4.5T
c. Cleaning and Drying
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned. Replace a leaking or
damaged tank. DO NOT attempt to repair, plug or patch
a leaking or damaged fuel tank. The tank is manufactured
using an injection molding process and cannot be
repaired. Contact JLG Service Department at:
(877) 554-5438 or (717) 485-6657
To clean the fuel tank:
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
2. Invert and tilt the tank from side to side. Safely drain
any fuel into a suitable container. Dispose of fuel
properly.
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes. Invert
the tank, tilt it from side to side, and drain the water.
4. If necessary, add a diesel fuel emulsifying agent to
the tank. Refer to the engine manufacturer for the
correct emulsifying agent-to-water mixture ratio.
Refill the tank with water, and agitate the mixture for
10 minutes. Drain the tank completely.
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the tank
and allow it to dry completely.
d. Inspection
1. Inspect the fuel tank thoroughly for any cracks,
slices, leaks or other damage. Replace a leaking or
damaged tank. DO NOT attempt to repair, plug or
patch a leaking or damaged fuel tank. The tank is
manufactured using an injection molding process
and cannot be repaired. Contact JLG Service
Department at: (877) 554-5438 or (717) 485-6657
2. With the fuel tank removed from the vehicle, plug all
openings except one elbow fitting. Install the elbow
fitting and apply approximately 1 to 1-1/2 psi
(7 to 10 kPa) of air pressure through the elbow.
Check the tank for leaks by applying a soap solution
to the exterior of the tank, or by submerging the tank
in water and looking for bubbles to appear at the
cracked or damaged area.
e. Assembly and Replacement
1. Install the fuel sender, with gasket, (6) to the fuel
tank (1). Secure with the five previously removed
capscrews (5), and torque to 1.5-2.5 lb-ft (2-3 Nm).
Do not overtighten.
2. Install the 3/8" NPT square head drain plug (7).
3. Replace the fuel tank (1) onto tank support (part of
cab structure.) Attach the fuel level gauge wire (4).
Secure fuel tank retaining panel (2), with two (3)
previously removed capscrews. Torque capscrews to
38-59 lb-ft (50-80 Nm).
4. Reconnect the fuel hoses (8 and 9). Torque the hose
clamps to 4 lb-in (0,46 Nm).
7.8.3 Fuel Level Sender and Gauge
The fuel level sender and gauge assembly is described in
Section 9.14.17, “Fuel Level Gauge and Fuel Level
Sender.”
WARNING:
NEVER drain or store fuel in
an open container due to the possibility of
explosion or fire. Discard the fuel in an
approved manner.