SkyTrak 8042 Service Manual - Manual (Page 345)

Engine: Cummins 4BT3.9 and 4BTA3.9
7A.22 Model 8042, 10042, 10054 Legacy Rev. 10/03
b. Disassembly
The fuel/hydraulic oil reservoir is a one-piece unit and
cannot be disassembled. The fuel level indicator and
hydraulic filters can be removed and reused on the new
replacement reservoir. Dispose of the old reservoir
according to local regulations concerning hazardous
materials disposal.
c. Cleaning and Drying
If contaminated fuel, hydraulic oil or foreign material is in
the tank, the tank can usually be cleaned.
d. If a leak is suspected between the fuel and hydraulic oil
tank, contact JLG Service Department at:
Domestic: 1-877-554-5438
International: 1-717-485-6657
To clean the fuel/hydraulic oil tank:
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
2. Depending on which side of the tank is contaminated
(fuel or hydraulic oil), remove the fuel or oil tank
drain plug, and safely drain any fuel or hydraulic oil
into a suitable container. Dispose of fuel or hydraulic
oil properly.
3. Clean the fuel/hydraulic oil 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. For the fuel tank side, 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.
e. Inspection
Note: If a leak is suspected between the fuel and hydraulic
oil tank, contact JLG Service Department at:
Domestic: 1-877-554-5438
International: 1-717-485-6657
1. Inspect the fuel/hydraulic oil tank thoroughly for any
cracks, slices, leaks or other damage.
2. With the fuel/hydraulic oil tank removed from the
vehicle, 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 tank for leaks by applying a soap
solution to the exterior and look for bubbles to
appear at the cracked or damaged area.
f. Assembly
The fuel/hydraulic oil reservoir is a one piece-unit and
cannot be disassembled. The fuel level indicator and
hydraulic filters can be removed and reused on the new
replacement tank. Dispose of the old tank according to
local regulations concerning hazardous materials disposal
regulations.
g. Fuel/Hydraulic Oil Tank Installation
1. Attach the tank (1) to a suitable lifting device at the
lift point (2).
2. Place the tank carriage bolts (3) into the slotted
holes in frame.
3. Position the tank (1) and insert carriage bolts (3)
through tank attachment holes. Install lock-
washers (4) and finger tighten nuts (5) onto carriage
bolts. Slide tank and carriage bolts toward the front
of vehicle, until carriage bolts are bottomed out into
the slotted frame holes.
4. Install plugs (6, 7 and 8) using new o-ring seals.
5. Install the hydraulic oil temperature sensor (9) in the
tank and connect to the engine harness connector.
6. Install the fuel line fittings (10) to the tank.
7. Install the fuel supply (11) and return line (12) hoses
to the fuel tank. Secure with clamps (13).
8. Install the hydraulic fuel strainer (14) in the tank.
9. Connect the lower hydraulic oil strainer hose (15) to
the strainer (14) and secure using clamp (16).
10. Install lower tank fitting (17) and connect hydraulic
return hose fitting (18).
11. Install the hydraulic fluid level sight-glass (19) using
special designed and drilled capscrews and gaskets.
12. Connect the tee fitting (20) to the tank.
DANGER:
NEVER weld in, on, near or
around the fuel/hydraulic oil reservoir. Fuel and
hydraulic fluid and fumes can cause the reservoir
to explode. This can result in death or serious
personal injury.
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.