2002/11/25 An Improved Hose Assembly for Machines with Dual Fuel Tanks is now Used {1710} Caterpillar


An Improved Hose Assembly for Machines with Dual Fuel Tanks is now Used {1710}
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2002/11/25 [SEPD0657]
FUEL SYSTEM
TANK GP-FUEL
2002/11/25 An Improved Hose Assembly for Machines with Dual Fuel Tanks is now Used {1710}
Load Haul Dump:
R1600 (S/N: 9EW)
R1700G (S/N: 8XZ)

Reference: Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures".

Reference: Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety".

Reference: Service Magazine, SEPD0025, 2 July 1990, "Welding On Fuel And Hydraulic Tanks".

Description of Change: An improved hose assembly for machines with dual fuel tanks is now used.

Adaptable To: The 0DE5343 Hose As replaces the former 0DE4435 Hose As and the 0DE4189 Hose As. The 0DE5343 Hose As is effective with R1700G (S/N: 8XZ307-UP). The 0DE5343 Hose As is adaptable to R1600 (S/N: 9EW1-UP) and R1700G (S/N: 8XZ1-306). Refer to "Improved Dual Fuel Tank Hose Installation Procedure for the R1600 LHD" and "Improved Dual Fuel Tank Hose Installation Procedure for the R1700G LHD" for the machine that is being serviced.

------ WARNING! ------

Personal injury or death can result from an explosion.

Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force.

Do Not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions. Such as; filling the tank with either carbon dioxide or water.

Read the article in the Service Magazine, July 2, 1990, "Welding On Fuel And Hydraulic Tanks".

----------------------

------ WARNING! ------

Personal injury can result from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas.

----------------------

------ WARNING! ------

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.

Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.

U.S. Department of Labor
Washington, D.C. 20210
----------------------


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "AVSpare Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in AVSpare machines.

Dispose of all fluids according to local regulations and mandates.


Improved Dual Fuel Tank Hose Installation Procedure for the R1600 LHD

Table 1
Parts Required    
Item     Qty     Part Number     Description    
5     2     9EQ2781     Mounting Flange    
6     9     8T-4223     Hard Washer    
7     8     5P-2566     Bolt    
8     2     4J-0524     O-Ring Seal    
9     4     1P-4579     Half Flange    
10     1     0DE5343     Hose As    
11     1     8T-8917     Bolt    
12     1     168-6890     Clip    
13     1     168-6891     Clip    
14     1     6V-1574     Grommet    

  1. Remove the engine.

  1. Drain each fuel tank into a suitable container for storage or disposal.



    Illustration 1g00929413

    View of the fuel hose and fittings to be removed

    (1) 9S-7296 Flared Elbow

    (2) 0DE4435 Hose As

    (3) 009-4440 Connector

  1. Remove the inspection cover from the top of each fuel tank.

  1. Remove the following parts: 0DE4435 Hose As (2), 9S-7296 Flared Elbow (1) and 009-4440 Connector (3) .

  1. Discard the following parts: 0DE4435 Hose As (2), 9S-7296 Flared Elbow (1) and 009-4440 Connector (3) .



    Illustration 2g00929045

    View of the socket to be cut off flush

    (4) Socket

  1. Manufacture a suitable plug and install inside socket (4) to prevent grinding and welding debris from entering the fuel tank.

    Note: Protect exposed wiring and hose assemblies from heat and sparks generated by grinding and generated by welding.

    Note: Prior to grinding and welding, refer to Service Magazine, SEPD0025, 2 July 1990, "Welding On Fuel And Hydraulic Tanks". This publication can be found on the AVSpare Service Information System (SIS).

    Note: Prior to grinding and welding, refer to Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety".

  1. Cut off shaded section of socket (4) .

  1. Repeat Step 6 through 7 for the other side fuel tank.



    Illustration 3g00929417

    View of the mounting flange to be welded to the fuel tank

    (5) 9EQ2781 Mounting Flange

    (A) Grind existing weld for flange placement typical both sides

    (W1) Seal weld all round 4 mm (0.16 inch) fillet weld

    (W2) Seal weld all round 6 mm (0.24 inch) fillet weld

  1. Grind the area smooth for placement of 9EQ2781 Mounting Flange (5) .

  1. Seal weld 9EQ2781 Mounting Flange (5) in position on the fuel tank. Refer to Illustration 3. Refer to Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures".

  1. Remove the manufactured plug installed in Step 6.

  1. Repeat Step 9 through 11 for the other side fuel tank.



    Illustration 4g00929420

    View of 0DE5343 Hose As installation

    (6) 8T-4223 Hard Washer

    (7) 5P-2566 Bolt

    (8) 4J-0524 O-Ring Seal

    (9) 1P-4579 Half Flange

    (10) 0DE5343 Hose As

    (11) 8T-8917 Bolt

    (12) 168-6890 Clip

    (13) 168-6891 Clip

    (14) 6V-1574 Grommet

  1. Install 0DE5343 Hose As (10). Refer to Illustration 4.

  1. Install the inspection covers to the top of the fuel tanks that were removed in Step 3.

  1. Install the engine.

  1. Fill the fuel tanks with fuel.

Improved Dual Fuel Tank Hose Installation Procedure for the R1700G LHD

Table 2
Parts Required    
Item     Qty     Part Number     Description    
8     2     9EQ2781     Mounting Flange    
9     9     8T-4223     Hard Washer    
10     8     5P-2566     Bolt    
11     2     4J-0524     O-Ring Seal    
12     4     1P-4579     Half Flange    
13     1     0DE5343     Hose As    
14     1     8T-8917     Bolt    
15     1     168-6890     Clip    
16     1     168-6891     Clip    
17     1     6V-1574     Grommet    

  1. Remove the engine.

  1. Drain each fuel tank into a suitable container for storage or disposal.



    Illustration 5g00929437

    View of the fuel hose and fittings to be removed

    (1) 009-4440 Connector

    (2) 0DE4189 Hose As

    (3) 5S-7379 Bolt

    (4) 8T-4896 Hard Washer

    (5) 7D-4092 Clip

    (6) 2P-1312 Elbow

  1. Remove the inspection cover from the top of each fuel tank.

  1. Remove the following parts: 5S-7379 Bolts (3), 8T-4896 Hard Washers (4), 7D-4092 Clips (5), 0DE4189 Hose As (2), 009-4440 Connector (1) and 2P-1312 Elbow (6) .

  1. Discard the following parts: 5S-7379 Bolts (3), 8T-4896 Hard Washers (4), 7D-4092 Clips (5), 0DE4189 Hose As (2), 009-4440 Connector (1) and 2P-1312 Elbow (6) .



    Illustration 6g00929438

    View of the socket to be cut off flush

    (7) Socket

  1. Manufacture a suitable plug and install inside socket (7) to prevent grinding and welding debris from entering the fuel tank.

    Note: Protect exposed wiring and hose assemblies from heat and sparks generated by grinding and generated by welding.

    Note: Prior to grinding and welding, refer to Service Magazine, SEPD0025, 2 July 1990, "Welding On Fuel And Hydraulic Tanks". This publication can be found on the AVSpare Service Information System (SIS).

    Note: Prior to grinding and welding, refer to Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety".

  1. Cut off shaded section of socket (4) .

  1. Repeat Step 6 through 7 for the other side fuel tank.



    Illustration 7g00929439

    View of the mounting flange to be welded to the fuel tank

    (8) 9EQ2781 Mounting Flange

    (A) Grind existing weld for flange placement typical both sides

    (W1) Seal weld all round 4 mm (0.16 inch) fillet weld

    (W2) Seal weld all round 6 mm (0.24 inch) fillet weld

  1. Grind the area smooth for placement of 9EQ2781 Mounting Flange (8) .

  1. Seal weld 9EQ2781 Mounting Flange (8) in position on the fuel tank. Refer to Illustration 7.

  1. Remove the manufactured plug installed in Step 6.

  1. Repeat Step 9 through 11 for the other side fuel tank.



    Illustration 8g00929441

    View of 0DE5343 Hose As installation

    (9) 8T-4223 Hard Washer

    (10) 5P-2566 Bolt

    (11) 4J-0524 O-Ring Seal

    (12) 1P-4579 Half Flange

    (13) 0DE5343 Hose As

    (14) 8T-8917 Bolt

    (15) 168-6890 Clip

    (16) 168-6891 Clip

    (17) 6V-1574 Grommet

  1. Install 0DE5343 Hose As (13). Refer to Illustration 8.

  1. Install the inspection covers to the top of the fuel tanks that were removed in Step 3.

  1. Install the engine.

  1. Fill the fuel tanks with fuel.

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