2005/10/24 Caterpillar

Load Haul Dump:

R2900G (S/N: GLK1-UP)

Additional venting for dual fuel tanks is available. The additional venting improves filling the left side fuel tank when using the fast-fill system. Refer to the following procedure.

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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.

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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

Removal procedure:

1. Turn the battery disconnect switch to the OFF position.

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Illustration 1	g01203034
Right side view (1) 9EP8863 Cover - Inspection (2) Existing disposal hose

2. Remove inspection cover (1) from the top of the fuel tank. Cover the opening.

3. Remove existing disposal hose (2) from the fuel tank vent assembly. Discard disposal hose (2) .

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Illustration 2	g01203035
Left side view (3) Existing disposal hose (4) 9EQ2618 Cover - Inspection

4. Remove existing disposal hose (3) from the fuel tank vent assembly. Retain disposal hose (3) for assembly.

5. Remove inspection cover (4) from the top of the fuel tank. Cover the opening.

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Illustration 3	g01203036
(1) 9EP8863 Cover - Inspection (4) 9EQ2618 Cover - Inspection (A) 65 mm (2.56 inch) (B) Drill a 25 mm (0.984 inch) hole. (C) 25 mm (1.00 inch) (D) 60 mm (2.36 inch) (E) 50 mm (1.97 inch)

6. Drill a 25 mm (0.984 inch) hole in inspection covers (1) and (4) removed in Step 2 and Step 5.

Note: Install 7T-2853 Fitting into the top of each cover with the thread facing outward.

7. Install a 7T-2853 Fitting in each hole (B). Weld the 7T-2853 Fitting to the cover.

Installation procedure for machines GLK1-565:

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Illustration 4	g01188910
Rear frame plan view of GLK1-565 (1) 9EP8863 Cover - Inspection (3) Existing disposal hose (4) 9EQ2618 Cover - Inspection (5) 0DE6051 Hose As (6) 6D-4244 Clip (7) 4L-6454 Bolt (8) 6V-8801 Nut (9) 8T-4896 Hard Washer (10) 1P-9390 Gasket (11) 1P-7625 Elbow (12) 8L-2786 O-Ring Seal (13) 6DE7820 Adapter (14) Existing vent assembly (15) 9Y-3349 Disposal Hose

Note: Check two gaskets (10) for wear or for damage. Replace the gaskets if necessary.

1. Install modified inspection covers (1) and (4) .

2. Install items (5) through (12) .

3. Install 6DE7820 Adapter (13) between existing vent assembly (14) and the fuel tank.

4. Install 9Y-3349 Disposal Hose (15) .

5. Install disposal hose (3) that was retained for assembly.

Installation procedure for machines GLK566-UP:

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Illustration 5	g01204345
Rear frame plan view of GLK566-UP (1) 9EP8863 Cover - Inspection (3) Existing disposal hose (4) 9EQ2618 Cover - Inspection (6) 6D-4244 Clip (7) 4L-6454 Bolt (8) 6V-8801 Nut (9) 8T-4896 Hard Washer (10) 1P-9390 Gasket (11) 1P-7625 Elbow (12) 8L-2786 O-Ring Seal (13) 6DE7820 Adapter (14) Existing vent assembly (15) 9Y-3349 Disposal Hose (16) 5P-8113 Elbow (17) 7F-2060 Locknut (18) 2P-1282 Union (19) 0DE5962 Hose As (20) 4M-0061 Bolt (21) 8T-4224 Hard Washer (22) 0DE6047 Hose As (23) 0DE6049 Hose As (24) Existing hole (25) Radiator shroud (right side) (26) Radiator shroud (left side) (E) 20 mm (0.79 inch) (F) 40 mm (1.57 inch) (G) 40 mm (1.57 inch) (H) Drill a 22.23 mm (0.875 inch) hole.

Note: Check two gaskets (10) for wear or for damage. Replace the gaskets if necessary.

1. Install modified inspection covers (1) and (4) .

2. Drill two holes (H) in the radiatotor shrouds.

3. Using the two holes drilled in Step 2, install items (16), (17) and (18) .

4. Install hose assemblies (19), (22) and (23). Refer to Illustration 5.

5. Install 6DE7820 Adapter (13) between existing vent assembly (14) and the fuel tank.

6. Install 9Y-3349 Disposal Hose (15) .

7. Install disposal hose (3) that was retained for assembly.