Remove/install fuel tank

AR47.10-P-4100GLC

Remove/install fuel tank

21.2.12

 

Remove/install

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground cable from battery

AR54.10-P-0003GL



Notes on battery

All models

AH54.10-P-0001-01A

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

2

Lift/jack up vehicle

AR00.60-P-1000G

3

Detach underride guard (14)

4

Unscrew cap (20).

 Inspect seal (17), replace if necessary.

5

Drain fuel tank (1)

 If fuel tank (1) is emptied by opening drain plug (10), it is necessary to replace seal (9). The seal can be lubricated to ease assembly.

AR47.10-P-4001B



*BF47.10-P-1001-01A

6

Loosen clamp (22) on hose connection (21)

7

Detach left vent hose (12) from fitting (23) on fuel tank (1)

 Close off fitting (23).

8

Detach right vent hose (11) from fitting (24) on fuel tank (1)

 Close off fitting (24).

9

Detach return line from fitting (25) for the fuel tank (1)

 Close off fitting (25) and return line.

10

Remove center cover (15) in cargo area

11

Remove maintenance window cover (4)

12

Detach vent hose (5) from fuel level sensor (B4)

 Close off connection at fuel level indicator sensor (B4).

13

Remove electrical lines (6) on fuel level sensor (B4)

14

Remove stationary heater fuel metering pump (Y23)

15

Remove underride guard bracket (13) from frame

16

Remove tensioning straps (7)

17

Remove fuel tank (1) downwards

 Allow escaping fuel to drain into a suitable container.



Disposing fuel tanks

OS47.10-P-0001-01A

18

Remove fuel line (26) from the suction jet pump (27)

 Only when replacing new fuel tank (1).

 An excessively high loosening torque and retightening torque for the nuts can cause twisting of the swirl pot in the fuel tank (1). The suction jet pump (27) will therefore no longer lie at its lowest point which can lead to premature failure of fuel transmission and immobility cases, although the fuel tank (1) still has sufficient fuel in it.

 Installation: Tighten nut on fuel line (26) with a torque of 45 Nm.

19

Install in the reverse order

20

Read out fault memory and erase

Stored faults which may be caused by removed cables or by a simulation, must be processed and erased in the fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Model
461, 463

BF47.10-P-1001-01A

Fuel tank capacity

Total filling capacity

Liters

96

Reserve capacity

Liters

20