Fast Fill System-Fuel {1273, 1279, 1710} Caterpillar

Articulated Truck

725 (S/N: B1L1-UP; AFX1-UP)

725C (S/N: LFB1-UP; TFB1-UP)

730 (S/N: AGF1-UP; B1M1-UP)

730 EJECTOR (S/N: B1W1-UP)

730C (S/N: LFF1-UP; TFF1-UP)

730C EJECTOR (S/N: LFH1-UP; TFH1-UP)

735 (S/N: B1N1-UP; AWR1-UP)

735B (S/N: L4D1-UP; T4P1-UP)

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)

740B (S/N: L4E1-UP; T4R1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

Excavator

385B (S/N: BKF1-UP; ANS1-UP; BKX1-UP)

385C (S/N: EDA1-UP; KBC1-UP; SBE1-UP; T2E1-UP; T2F1-UP; JCM1-UP; MNZ1-UP)

5090B (S/N: CLD1-UP; SJY1-UP)

5110B (S/N: AAA1-UP; AAK1-UP; AAT1-UP)

5130B (S/N: 4CS1-UP)

Off-Highway Truck/Tractor

769D (S/N: BBB1-UP)

773E (S/N: BDA1-UP)

776D (S/N: AFS1-UP)

777D (S/N: AGC1-UP; AGY1-UP)

Quarry Truck

771D (S/N: BCA1-UP)

775E (S/N: BEC1-UP)

Wheel Dozer

814F (S/N: BGF1-UP)

844 (S/N: BBN1-UP; 2KZ1-UP)

844H (S/N: BTW1-UP)

854G (S/N: A4W1-UP)

Wheel Loader

988G (S/N: BNH1-UP; 2TW1-UP)

988H (S/N: BXY1-UP)

990 Series II (S/N: BCR1-UP)

990H (S/N: BWX1-UP)

992G (S/N: AZX1-UP)

994D (S/N: 3TZ1-UP)

994F (S/N: 4421-UP)

Introduction

This special instruction contains information describing the parts and service information in order to install a bolt on fast fuel system in a fuel tank.

Caterpillar has introduced a new fast fill fuel kit that does not depend on tank pressure to shut off fuel flow. Instead, a hydraulic valve controls shut off, rather than a traditional pressure sensing nozzle. This system allows for improved contamination control. The nonpressurized fast fill system provides a positive shutoff to eliminate spills and overfills. Also, the maximum fill rate is 570 L (150 US gal) per minute.

Parts Information

285-1202 Fast Fill Fuel Adapter Gp

Illustration 1	g03354300

Safety Section

Welding on Fuel Tanks

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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.

Do Not Weld an Empty Fuel Tank.

An empty fuel tank cannot be cleaned sufficiently in order to ensure that all the flammable vapors have been removed. Vapors remain even after cleaning with steam or washing with a caustic solution. Also, when caustic solutions are heated, caustic solutions can also be explosive. In order to prepare a fuel tank for welding, use one of the following procedures:

• Fill the tank with carbon dioxide.

• Fill the tank with water.

Filling the Fuel Tank with Carbon Dioxide

Use the following procedure in order to prepare the tank for welding:

1. Cover all openings or plug all openings, except for the filler hole.

2. Fill the tank with carbon dioxide from a CO₂ fire extinguisher.

3. Put a board, or some other object with a flat surface, over the filler hole in order to keep the carbon dioxide in the tank.

4. Weld the tank by using the welding practices that are detailed in this document.

Filling the Fuel Tank with Water

Use the following procedure in order to prepare the tank for welding:

1. Cover all openings or plug all openings, except for the filler hole.

2. Fill the tank with water.

   Note: The water must be kept at the top of the filler hole at all times. This procedure will ensure that there are no vapors that have collected in empty cavities.

3. Weld the tank by using the welding practices that are detailed in this document.

Note: After welding on the tank, the fuel tank must be drained. Fill the fuel tank with a mixture of fuel and methyl alcohol (methanol). A ratio of 0.5 L (0.13 US gal) methanol to 38 L (10.04 US gal) of fuel is satisfactory. The methanol will mix with the water. The methanol and water will burn with the fuel.

General Welding Procedures

Proper Cleaning for Inspection

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When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the rear tow points. Install the rear tow point pins through the ends of the retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

Before you inspect the area, clean the area with an appropriate high-pressure washer. Be careful not to damage wires or other components. Use an appropriate degreaser to remove any oil or grease from the frame assembly. If necessary, use a wire brush or a scraper to remove excessive dirt and grease. Make sure that the substances that follow are removed from the area that will be inspected.

• Oil

• Grease

• Dirt

Preparing the Area for Welding

Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.

• Oil

• Grease

• Paint

• Dirt

If the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding process.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the weld splatter.

Weld Specifications and Qualifications

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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 kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator for breathing protection.

Qualifications

Welders must be qualified for fillet welding and groove welding. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to "American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process and GMAW process. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that are listed below:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This procedure will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses from the weld splatter.

Welding Specifications

Low Hydrogen Electrodes for the SMAW Process

The tables that follow list the mechanical properties of welds that are deposited by low hydrogen electrodes.

Low hydrogen electrodes must be stored in an electrode oven at 120 °C (248 °F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the specifications of the manufacturer.

The table that follows shows setting for the welding current for the electrode diameter.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.

Flux Cored Welding Electrode for the FCAW Process

An alternative process, use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the shielding gases of the manufacturer. This process is specified for inside welding. The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical properties:

The table that follows lists the mechanical properties of welds that are deposited by the flux cored welding electrode.

The table that follows shows setting for the welding current for the flux cored welding electrode that has a diameter of 1.3 mm (.051 inch).

Note: The settings for the welding current can vary due to the position of the weld. Also, the settings for the welding current can vary with the manufacturer of the welding electrode.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The volume of the fillet weld should not exceed 8.0 mm (0.315 inch).

Arc Welding Electrodes for the GMAW Process

The table that follows lists the mechanical properties of welds that are deposited by the GMAW Process.

The welding parameters will vary with the position of the weld and with different electrode manufacturers.

General Repair for Cracked Welds

1. Remove any components that prevent access to the cracked weld.

2. Clean the weld of the following substances: oil, grease and dirt.

3. Use the dye penetrant to inspect the entire area for possible cracks.

4. Protect machined surfaces from sparks and weld deposits.

5. Use an air carbon arc torch or use a grinder in order to remove cracks. Use a grinder to remove cracks that extend through the castings. Remove at least 50.8 mm (2.0 inch) of material past each end of the crack. When the crack is removed, the bottom of the groove should have an angle of 90 degrees in order to ensure sufficient penetration. The side walls of the groove should extend upward at an angle of 45 degrees.

6. Use the dye penetrant to inspect the gouged area in order to ensure that the crack has been removed. Be sure to clean the prepared groove before welding.

7. Use Welding in order to repair the prepared groove by using passes that do not exceed two times the electrode diameter. If the alternate welding process is selected, the size of the weld pass should not exceed 7.88 mm (0.31 inch) by volume. Do not allow any slag inclusion when multiple pass welding is used.

8. Clean the weld and inspect the weld. The weld must be free from the following imperfections: cracks, porosity, undercut and incomplete fusion. All quality of the weld must conform to ANSI/AWS standard 14.3.

9. Tank should be tested before the fast fill assembly is installed.

Installation

Fast Fill Assembly

Fuel Tank

1. Lock and tag out the vehicle.

2. Determine the fuel level with the tank full on a level surface. This observation is used to adjust the fast fuel system shutoff.

3. Determine if the fuel tank has bolt on adapter plates (A) and (B) already installed.

   Note: On all fuel tanks, leave an air space equal to 5% of the total capacity of the tank. The air space must be left to account for the thermal expansion of the fuel.

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   Illustration 2	g03355493
   (A) 221-5303 Plate (B) 221-5304 Plate

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   Illustration 3	g02339317
   221-5303 Plate

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   Illustration 4	g02339322
   221-5304 Plate

4. If the adapters are on the tank, continue with step 5. If the adapters do not exist on the tank, continue to Step 1 of the (Removal and Installation Procedure) section.

   Note: If fuel tanks have adapter plates with 50.4 mm (2 inch) NPTF threads, these plates must be replaced with 221-5303 Plate and 221-5304 Plate for installation of fast fuel kit. Proceed to step 1 of the (Removal and Installation Procedure) section.

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   Illustration 5	g03355493

5. Drain the tank and remove the cover plates (A) and (B).

   Note: The baffling inside the fuel tank could make a difficult routing of the signal line from the vent assembly to the receiver. The vent assembly should be located on the highest area of the fuel tank. If no clear path from the vent to the receiver exists, a new vent location may be required. Proceed to step 1 of the (Removal and Installation Procedure) section.

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   Illustration 6	g03358011

6. Estimate the 224-7696 Hose length. Measure the distance from the 317-3252 Fuel Tank Vent As to the 252-5806 Shutoff Valve Assembly.

   Note: The overall length (C) is the distance from the vent assembly to the inlet valve assembly, with an additional 610 mm (24 inch). The extra length is to aid in assembly.

7. Fabricate the signal line 224-7696 Hose with end fittings 253-1371 Permanent Coupling As. Before installing, test the hose assembly to ensure that there are no leaks at the hose coupling joint.

8. Install 5P-2618 Connector to the vent assembly with 1J-9671 O-Ring Seal. Tighten to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft).

9. Connect the 224-7696 Hose to the 317-3252 Fuel Tank Vent As. Tighten to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft).

10. Insert the 317-3252 Fuel Tank Vent As with 1H-8128 O-Ring Seal and the 224-7696 Hose through the vent hole.
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    Illustration 7	g03495336
    (1) 317-3252 Fuel Tank Vent As (3) 224-7696 Hose (5) 221-5303 Plate (6) 221-5304 Plate

11. Lower the signal line until the signal line is visible through the receiver plate (6) .
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    Illustration 8	g03359055
    (4) 105-3484 Bolt

12. Tighten bolts (4) on the vent assembly to a torque of 13 ± 3 N·m (9.6 ± 2.2 lb ft).
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    Illustration 9	g03493623
    (2) 252-5806 Shutoff Valve Assembly (3) 224-7696 Hose (6) 221-5304 Plate (7) 8T-4136 Bolt (8) 8M-2772 Receiver Cover Clip

13. Carefully pull signal line (3) through the plate (6).

    Note: Allow no debris to enter the tank.

    Note: Avoid twisting, kinking, or damaging the signal line during installation.

14. Install 5P-2618 Connector to the inlet valve assembly with 1J-9671 O-Ring Seal. Tighten to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft).

15. Attach the signal line (3) to the valve assembly (2) .

16. Tighten signal line (3) to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft).

17. Install the valve assembly (2) and 5H-6734 O-Ring Seal onto the adapter plate (6).

18. Install receiver cover clip (8) to the valve assembly (2) using bolts (7).

19. Tighten bolts (7) to a torque of 13 ± 3 N·m (9.6 ± 2.2 lb ft).
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    Illustration 10	g03494003
    (9) 1P-4582 Half Flange (10) 6V-8200 Bolt (11) 8T-4223 Hard Washer (12) 376-1308 Receiver (13) 4J-0527 O-Ring Seal

20. Install receiver (12) and the o-ring seal (13) to the valve using half flange (9), bolt (10) and washer (11).

21. Tighten bolts to a torque of 100 ± 20 N·m (73.76 ± 14.75 lb ft).

Removal and Installation Procedure

Remove

Tank Preparation

1. Remove the following items from the fuel tank: panels, decking, hoses and fittings.

2. Unbolt the fuel tank from the vehicle and lower the fuel tank to the ground.

3. Clean the fuel tank and mark the fuel tank for location of the vent and the receiver.
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   Illustration 11	g03494198

4. Cut a 130 mm (5.12 inch) (C) hole in the tank for the vent assembly adapter plate.

5. Cut a 155 mm (6.10 inch) (D) hole in the tank for the receiver assembly adapter plate.

6. Ground all sharp edges that were previously cut.
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   Illustration 12	g03494219
   (1) 317-3252 Fuel Tank Vent As (2) 252-5806 Shutoff Valve Assembly (3) 224-7696 Hose

7. Estimate the signal line (3) length. Measure the distance from the vent (1) to the valve assembly (2).

   Note: The overall length (E) is the distance from the vent assembly to the inlet valve assembly plus an additional 610 mm (24 inch). The extra length is to aid in assembly.

8. Fabricate the signal line 224-7696 Hose with end fittings 253-1371 Permanent Coupling As. Before installing, test the hose assembly to ensure that there are no leaks at the hose coupling joint.

9. Install 5P-2618 Connector to the vent assembly with 1J-9671 O-Ring Seal. Tighten to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft).
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   Illustration 13	g03494377
   (5) 221-5303 Plate

10. Weld a 4 mm (0.16 inch) bead around plate (5) to the fuel tank at location (F).
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    Illustration 14	g03494398
    (6) 221-5304 Plate

11. Weld a 4 mm (0.16 inch) bead around plate (6) to the fuel tank at location (G).
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    Illustration 15	g03495399
    (1) 317-3252 Fuel Tank Vent As (3) 224-7696 Hose (5) 221-5303 Plate

12. Connect the signal line (3) to the vent (1). Tighten to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft).

13. Insert the vent assembly (1) with 1H-8128 O-Ring Seal and the signal line (3) through the vent hole plate (5).
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    Illustration 16	g03495858
    (1) 317-3252 Fuel Tank Vent As (3) 224-7696 Hose (5) 221-5303 Plate (6) 221-5304 Plate

14. Lower the signal line (3) until the line is visible through the receiver mount area (6).
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    Illustration 17	g03495860
    (4) 105-3484 Bolt

15. Tighten bolts (4) on the vent assembly to a torque of 13 ± 3 N·m (9.6 ± 2.2 lb ft).
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    Illustration 18	g03495896
    (2) 252-5806 Shutoff Valve Assembly (3) 224-7696 Hose (6) 221-5304 Plate (7) 8T-4136 Bolt (8) 8M-2772 Receiver Cover Clip

16. Carefully pull the signal line (3) through the adapter plate opening (6).

    Note: Allow no debris to enter the tank.

    Note: Avoid twisting, kinking, or damaging the signal line during installation.

17. Install 5P-2618 Connector to the inlet valve assembly with 1J-9671 O-Ring Seal. Tighten to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft).

18. Attach the signal line (3) to the valve assembly (2).

19. Tighten the signal line (3) to a torque of 3.4 ± 1 N·m (2.5 ± 0.7 lb ft)

20. Install the valve assembly (2) and 5H-6734 O-Ring Seal onto the adapter plate (6).

21. Install receiver cover clip (8) to the valve assembly (2) using bolts (7).

22. Tighten bolts (7) to a torque of 13 ± 3 N·m (9.6 ± 2.2 lb ft)
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    Illustration 19	g03495999
    (9) 1P-4582 Half Flange (10) 6V-8200 Bolt (11) 8T-4223 Hard Washer (12) 376-1308 Receiver (13) 4J-0527 O-Ring Seal

23. Install receiver (12) and the o-ring seal (13) to the valve using half flange (9), bolt (10) and washer (11).

24. Tighten bolts to a torque of 100 ± 20 N·m (73.76 ± 14.75 lb ft).

Test and Adjust Section

Instructions for Test and Adjust

Fuel Shutoff Level Test

1. Turn on the fluid pump. After the nozzle is attached to the inlet receiver, move the handle upward to the ON position.

2. The Nozzle handle will move downward to the OFF position when the tank is full. The fuel flow will be shut off to the tank. Turn off the fluid pump and remove the nozzle.
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   Illustration 20	g03496018
   (A) Spacers

3. If the fuel level is low, compared to the fluid level as measured before retrofitting, unbolt the vent assembly and remove bottom spacers (A). Start from the lower portion of the vent in order to obtain the required fuel level.

   Note: Each spacer removed will bring the fluid level up an additional 25 mm (1 inch). Be sure to tighten all spacers, if necessary.

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   NOTICE
   DO NOT remove excess spacers to achieve a higher fuel level than what was noted prior to retrofitting, over fill may result.

4. After removing the required spacers to adjust the fluid height, reconnect and tighten the vent assembly to the top of the fuel tank.

   Note: Check that all fittings and spacers are tight.

5. Reconnect the fueling nozzle to the inlet receiver.

6. Turn on the fluid pump.

7. Move the nozzle handle to ON.

   Note: The nozzle will automatically shut off at the new full level.

8. Turn off the fluid pump and remove the refueling nozzle.

9. Check all connections for leaks at the following locations:vent, inlet valve, boss fittings and receiver. Tighten any fasteners or fittings if necessary.