- Wheel Skidder:
- 515 (PIN: 4LR1-UP)
Introduction
This Special Instruction provides the necessary information that is required to install the 154-5634 Fuel Tank (Auxiliary) on the machine that is listed above.
The 154-5634 Fuel Tank (Auxiliary) will provide an additional 70 L (18.5 US gal) of fuel for the machine.
Do not perform any procedure that is outlined in this publication, until you understand the information that is contained in this document. Do not order parts until you understand the information that is contained in this document.
Machine Preparation
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Move the machine to a smooth, horizontal location that is away from operating machines and away from personnel.
- If the installation is done inside a building, the area should be well ventilated.
- Place the transmission direction control switch in the NEUTRAL position.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Lower the grapple and the decking blade to the ground.
- Stop the engine.
- Install the steering frame lock.
- Clean the machine in order to remove dirt and debris from the area that is needed to be worked on.
- Move the winch control lever to the BRAKE ON position.
- Move the control levers through the full range of travel. This will relieve any pressure that may be present in the implement hydraulic system.
Installation Procedure for 154-5634 Fuel Tank (Auxiliary)
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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. Read the article in the Service Magazine July 2,, "Welding On Fuel And Hydraulic Tanks". |
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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 Society2501 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 LaborWashington, D.C. 20210 |
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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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Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components. |
| Parts List for 154-5634 Fuel Tank (Auxiliary) | |||
| Item | Quantity | Part Number | Description |
| 1 | 1 | 154-5650 | Hose |
| 2 | 4 | 6V-8397 | O-Ring Seal |
| 3 | 1 | 6V-9836 | Tee |
| 4 | 1 | 155-5699 | Boss |
| 5 | 1 | 4D-7794 | Clip |
| 6 | 10 | 8T-4121 | Washer |
| 7 | 1 | 8T-4191 | Bolt |
| 8 | 1 | 154-5649 | Tube |
| 9 | 1 | 3K-0360 | O-Ring Seal |
| 10 | 1 | 6V-8723 | Elbow |
| 11 | 1 | 154-5648 | Fuel Tank |
| 12 | 1 | 9P-7121 | Fuel Tank Strainer |
| 13 | 1 | 5P-8501 | Padlock |
| 14 | 1 | 7X-7700 | Fuel Tank Cap |
| 15 | 1 | 5P-7244 | Warning Plate |
| 16 | 4 | 8T-9530 | Fastener Tack |
| 17 | 1 | 9R-2821 | Boss |
| 18 | 1 | 154-5645 | Bar |
| 19 | 1 | 154-5646 | Bar |
| 20 | 9 | 8T-4136 | Bolt |
| 21 | 1 | 154-5651 | Plate |
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| Illustration 1 | g00602747 |
154-5634 Fuel Tank (Auxiliary) | |
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| Illustration 2 | g00602758 |
Location of the 154-5634 Fuel Tank (Auxiliary) (1) 154-5650 Hose (2) 6V-8397 O-Ring Seal (3) 6V-9836 Tee (4) 155-5699 Boss (5) 4D-7794 Clip (6) 8T-4121 Washer (7) 8T-4191 Bolt (8) 154-5649 Tube (9) 3K-0360 O-Ring Seal (10) 6V-8723 Elbow (11) 154-5648 Fuel Tank (A) 179.9 ± 1.5 mm (7.08 ± .06 inch) (B) 215.2 ± 1.5 mm (8.47 ± .06 inch) (C) 33 ± 1.5 mm (1.3 ± .06 inch) (D) 21.5 ± 1.5 mm (.84 ± .06 inch) | |
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| Illustration 3 | g00603593 |
View A-A | |
- Install 154-5648 Fuel Tank (11) to the left side of the rear frame.
- Use Dimension (K), Dimension (L), and Dimension (M) to locate 154-5648 Fuel Tank (11) on the left side of the machine.
Show/hide table
Table 2 Recommended Welding Processes and Filler Metals Welding Process AWS Specification Welding Electrode SMAW (Stick Welding) A5.1 E7018 or Equivalent GMAW (MIG Welding) A5.18 ER70S-3 or Equivalent FCAW (Gas Shielding) A5.20 E70T-1 (1), E71T-1 (2) Show/hide table( 1 ) Use this electrode for welding on horizontal positions and flat positions. ( 2 ) Use this electrode for welding on all positions.
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| Illustration 4 | g00602789 |
Left Side of the Machine (12) 9P-7121 Fuel Tank Strainer . (13) 5P-8501 Padlock . (14) 7X-7700 Fuel Tank Cap . (15) 5P-7244 Warning Plate . (16) 8T-9530 Fastener Tack . (17) 9R-2821 Boss . (K) 669.8 ± 1.5 mm (26.37 ± .06 inch). (L) 162.6 ± 1.5 mm (6.40 ± .06 inch). | |
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| Illustration 5 | g00602935 |
View B-B (M) 182.6 mm (7.19 inch) | |
- Fillet weld 154-5648 Fuel Tank (11) from J to I. Refer to Illustration 3.
- Fillet weld 154-5648 Fuel Tank (11) from E to G. Refer to Illustration 5.
- Weld 154-5648 Fuel Tank (11) from F to H. Refer to Illustration 5.
- Attach 4D-7794 Clip (5) to 154-5649 Tube (8). Install 4D-7794 Clip (5) to 9R-2821 Boss (17) with one 8T-4191 Bolt (7) and one 8T-4121 Washer (6) .
- Bolt the 154-5651 Plate to the 154-5645 Bar and the 154-5646 Bar with five 8T-4136 Bolts and five 8T-4121 Washers (6). Bolt the assembly to 154-5648 Fuel Tank (11) with two 8T-4136 Bolts and two 8T-4121 Washers (6) for positioning.
- Tack weld 154-5646 Bar (19) to the frame. Refer to Illustration 7 (Dimension (O) ).
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| Illustration 6 | g00602777 |
View C-C through View E-E | |
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| Illustration 7 | g00602936 |
View C-C (18) 154-5645 Bar . (19) 154-5646 Bar . (N) 112 ± 1.5 mm (4.41 ± .06 inch). (O) 72 ± 1.5 mm (2.83 ± .06 inch). | |
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| Illustration 8 | g00602938 |
View D-D | |
- Tack weld 154-5645 Bar (18) to the frame. Refer to Illustration 7 (Dimension (N) ).
- Tack weld 155-5699 Boss (4) to the frame. Refer to Illustration 2 (Dimension (A) and Dimension (B) ).
- Tack weld 9R-2821 Boss (17) to the frame. Refer to Illustration 2 (Dimension (C) ).
- Unbolt and remove the 154-5651 Plate from 154-5645 Bar (18) and 154-5646 Bar (19). Fillet weld 154-5645 Bar (18) and 154-5646 Bar (19). Refer to Illustration 8. Fillet weld 155-5699 Boss (4) and 9R-2821 Boss (17). Refer to Illustration 4.
- Install one 154-5651 Plate (21) with nine 8T-4136 Bolts (20) and nine 8T-4121 Washers (6) .
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| Illustration 9 | g00602937 |
View E-E (6) 8T-4121 Washer . (20) 8T-4136 Bolt . (21) 154-5651 Plate . | |
- Install 5P-7244 Warning Plate (15) onto 154-5648 Fuel Tank (11) with four 8T-9530 Fastener Tack (16). Refer to Illustration 4.
- Drain the fuel tank.
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| Illustration 10 | g00603696 |
Main Fuel Tank | |