Komatsu 930E-2, Shop Manual

Page: 90 / 739

Removal
1. Raise truck body and install body-up cable.
2. Drain fuel from tank into clean containers.
3. Disconnect fuel tank wire harness and remove
clamps attached to tank. Remove ground wire
(19, Figure 4-1).
4. If equipped, close in-line shut-off valves. Remove
fuel supply (8) and return (7) hoses. Cap hoses
and tank fittings to prevent contamination.
5. Remove hydraulic filter assembly on frame side of
tank. Support filter assembly by placing a chain
over frame rail. (It is not necessary to remove
hydraulic hoses.)
The weight of the empty fuel tank is approximately
3590 lbs (1628 kg). Be certain to use lifting devices
with adequate capacity.
6. Attach lifting device to tank lift eyes (4).
7. Remove lower mount capscrews (16). Remove
upper mount capscrews (2) & mounting caps (3).
8. Lift tank assembly from brackets and move to work
area.
9. Remove fuel gauge sending unit (9), vent (5) on
top of tank, and other fittings as required to carry
out interior cleaning.
Installation
1. Thoroughly clean the frame mounting brackets
and mounting capscrew hole threads. Re-tap
threads if damaged.
The weight of the empty fuel tank is approximately
3590 lbs (1628 kg). Be certain to use lifting devices
with adequate capacity.
2. Lift the fuel tank into position over the frame
trunnion mounts and lower into position. Install
the mount caps (3, Figure 4-1) and capscrews (2)
and lockwashers, but do not tighten.
3. Install the four capscrews, lockwashers, and flat-
washers (16), flat washers (17), and rubber dam-
peners (18) in the lower mounts and tighten the
(4 x 0.750 UNC x 6.00 G8) lower mounting bolts
to 310
±
31 ft. lbs. (420
±
42 N.m) torque.
4. Tighten the trunnion mount capscrews (2) to 459
±
45 ft. lbs. (622
±
62 N.m) torque.
5. Connect hoses removed during removal proce-
dure. Install wire harness and clamps. Open the
in-line shut-off valves, if equipped.
Repair
If a tank has been damaged and requires structural
repair, carry out such repairs before final cleaning.
If a tank is to be weld repaired, special precautions
are necessary to prevent fire or explosion. Consult
local authorities if necessary, on safety regulations
before proceeding.
Cleaning
The fuel tank is provided with a drain and a cleaning
port in the side that allows steam or solvent to be
utilized in cleaning tanks that have accumulated for-
eign material.
It is not necessary to remove the tank from the truck
for cleaning of sediment, however rust and scale on the
walls and baffles may require complete tank removal.
This allows cleaning solutions to be in contact with all
interior surfaces by rotating the tank in various posi-
tions, etc.
Prior to a cleaning procedure of this type, all vents, fuel
gauge, and hose connections should be removed and
temporarily sealed. After all scale, rust, and foreign
material has been removed, the temporary plugs can
be removed.
A small amount of light oil should be sprayed into the
tank to prevent rust if the tank is to remain out of
service. All openings should be sealed for rust preven-
tion.
B4-2 Fuel Tank B04015