JLG 534D-10 - Manual (Page 118)

Engine
7.10 534D-9, 534D-10 & 544D
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the battery negative (-) cable from the
battery negative (-) terminal.
5. Remove the fuel tank/hydraulic oil reservoir cover.
Note: If replacing the tank, remove all internal and
external components from the old tank, and retain for
use on the replacement tank.
Note: Have a dry chemical (Class B) fire extinguisher
near the work area.
6. Remove fuel tank drain plug, and drain fuel into an
approved and suitable container. Dispose of fuel
properly.
7. Label, disconnect and cap the fuel lines from the
bottom of the fuel tank.
8. Disconnect the fuel gauge harness.
9. Remove screws securing fuel sender to the tank.
Remove fuel sender from tank.
10. Remove the four mounting bolts under the fuel tank.
11. Lift the empty fuel tank from the side of the machine.
b. Disassembly
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed and
reused on the new replacement tank. Dispose of the old
tank according to local regulations concerning hazardous
materials disposal.
c. Cleaning and Drying
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned.
Note: If a leak is suspected in the fuel tank, contact JLG
Service Department.
To clean the fuel tank:
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
2. Remove the fuel tank drain plug, and 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 and
drain the water. Dispose of contaminated water
properly.
4. Add a diesel fuel emulsifying agent to the tank. Refer
to the manufacturer’s instructions 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. Dispose of
contaminated water properly.
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.
d. Assembly
The fuel level indicator can be removed and reused on the
new replacement tank. Dispose of the old tank according
to local regulations concerning hazardous materials
disposal regulations.
e. Inspection
Note: If a leak is suspected in the fuel tank, contact a
JLG Service Department.
1. Inspect the fuel tank thoroughly for any cracks,
slices, leaks or other damage.
2. With the fuel tank removed from the machine, plug
all openings except one elbow fitting. Install the
elbow fitting, and apply approximately 1-1.5 psi
(7-10 kPa) of air pressure through the elbow. Check
the reservoir for leaks by applying a soap solution to
the exterior and look for bubbles to appear at the
cracked or damaged area.
f. Fuel Tank Installation
1. Set fuel tank in its original orientation at the side of
the machine.
2. Install the four fuel tank mounting bolts.
3. Install the fuel sender with new gasket into the fuel
tank and secure with screws. DO NOT overtighten.
4. Connect the previously labeled fuel hoses to their
appropriate locations. Secure with clamps.
5. Connect the fuel gauge harness.
6. Fill the fuel tank according to specifications.Refer to
Section 2.4, “Fluid and Lubricant Capacities.”
7. Check fuel tank for leaks.
8. Connect the battery negative (-) cable to the battery
negative (-) terminal.
9. Install the fuel tank/hydraulic oil reservoir cover.
10. Close and secure the engine cover.
7.9.3 After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Operator &
Safety Manual.