Procedure to Replace the 321-4673 Fuel Tank As on Certain AD30 Underground Articulated Trucks{1273} Caterpillar

Underground Articulated Truck:

AD30 (S/N: DXR307-558)

Introduction

This special instruction covers the procedure to replace the 321-4673 Fuel Tank As with the 432-2200 Fuel Tank As on AD30 S/N:DXR307-558 Underground Articulated Trucks. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

ReferenceDisassembly and Assembly, RENR6919, "AD30 Underground Articulated Truck Machine Systems".

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Parts Required

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

6. Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

Procedure for Machines Fitted with Standard Fuel Fill

Remove and Disassemble the 321-4673 Fuel Tank As

1. Remove the 321-4673 Fuel Tank As . Refer to Disassembly and Assembly, "Fuel Tank - Remove".

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Illustration 1	g03376556
Bottom view of the 321-4673 Fuel Tank As (1) Cover (2) Valve (3) Drain plug (4) Plug

2. Remove and retain Item (1) through Item (4). Retain the bolts and washers for assembly purposes, discard the gasket.

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Illustration 2	g03376557
Top view of the 321-4673 Fuel Tank As (5) Cover As

3. Remove and retain cover assembly (5), the bolts, and the washers for assembly purposes.

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Illustration 3	g03376558
Top view of the 321-4673 Fuel Tank As (6) Cap (7) Adapter (8) Cover (9) Sender (10) Strainer (11) Bolt (12) Gasket (13) Gasket

4. Remove and retain Item (6) through Item (11). Retain the bolts and the washers for assembly purposes, discard the gaskets.

5. Discard the 321-4673 Fuel Tank As .

Assemble and Install the 432-2200 Fuel Tank As

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Illustration 4	g03376561
Bottom view of the 432-2200 Fuel Tank As (1) Cover (2) Valve (3) Drain plug (4) Plug (14) 1P-9390 Outlet Gasket

1. Install 1P-9390 Outlet Gasket (14) and Item (1) through Item (4) that were retained.

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Illustration 5	g03376558
Top view of the 432-2200 Fuel Tank As (6) Cap (7) Adapter (8) Cover (9) Sender (10) Strainer (11) Bolt (12) 6C-3060 Gasket (13) 309-2371 Gasket

2. Install 6C-3060 Gasket (12), 309-2371 Gasket (13), and Item (6) through Item (11) that were retained.

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Illustration 6	g03376564
Top view of the 432-2200 Fuel Tank As (5) Cover As

3. Install cover assembly (5) using the bolts and washers that were retained.

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Illustration 7	g03376562
432-2200 Fuel Tank As (15) 9X-8257 Washer (16) 8T-4779 Bolt (17) 7X-2563 Bolt (18) 8T-5439 Hard Washer

4. Install the 432-2200 Fuel Tank As using Item (15) through Item (18). Refer to Illustration 7 and Disassembly and Assembly, "Fuel Tank - Install".

Procedure for Machines Fitted with the Fast Fill Fuel Adapter

Remove and Disassemble the 321-4673 Fuel Tank As

1. Remove the 321-4673 Fuel Tank As . Refer to Disassembly and Assembly, "Fuel Tank - Remove".

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Illustration 8	g03377156
Bottom view of the 321-4673 Fuel Tank As (1) Cover As (2) Gasket (3) Hose As

2. Remove and retain cover assembly (1), the bolts, and washers.

3. Disconnect hose assembly (3) and discard gasket (2) .

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Illustration 9	g03377157
Bottom view of the 321-4673 Fuel Tank As (4) Valve (5) Drain Plug (6) Plug

4. Remove and retain two valves (4), drain plug (5), and plug (6) .

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Illustration 10	g03377158
Top view of the 321-4673 Fuel Tank As (7) Cover As (8) Cover As

5. Remove and retain cover assembly (7), cover assembly (8), the bolts, and the washers.

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Illustration 11	g03377160
Top view of the 321-4673 Fuel Tank As (9) Vent As (10) Gasket

6. Remove and retain vent assembly (9), the bolts, and the washers.

7. Discard gasket (10) .

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Illustration 12	g03377161
Top view of the 321-4673 Fuel Tank As (11) Cap (12) Adapter (13) Strainer (14) Sender (15) Gasket

8. Remove and retain Item (11) through Item (14), the bolts, and the washers.

9. Discard gasket (15) .

10. Discard the 321-4673 Fuel Tank As .

Assemble and Install the 432-2200 Fuel Tank As

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Illustration 13	g03377161
Top view of the 432-2200 Fuel Tank As (11) Cap (12) Adapter (13) Strainer (14) Sender (15) 6C-3060 Gasket

1. Install Item (11) through Item (15) using the bolts and the washers retained.

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Illustration 14	g03377160
Top view of the 432-2200 Fuel Tank As (9) Vent As (10) 309-2371 Gasket

2. Install vent assembly (9) and 309-2371 Gasket (10) using the bolts and the washers retained.

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Illustration 15	g03377158
Top view of the 432-2200 Fuel Tank As (7) Cover As (8) Cover As

3. Install cover assembly (7) and cover assembly (8) using the bolts and the washers retained.

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Illustration 16	g03377157
Bottom view of the 432-2200 Fuel Tank As (4) Valve (5) Drain Plug (6) Plug

4. Install two valves (4), drain plug (5), and plug (6) .

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Illustration 17	g03377156
Bottom view of the 432-2200 Fuel Tank As (1) Cover As (2) 1P-9390 Outlet Gasket (3) Hose As

5. Connect hose assembly (3) .

6. Install cover assembly (1) and 1P-9390 Outlet Gasket (2) using the bolts and the washers retained.

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Illustration 18	g03377164
(16) 9X-8257 Washer (17) 8T-4779 Bolt (18) 7X-2563 Bolt (19) 8T-5439 Hard Washer

7. Install the 432-2200 Fuel Tank As using Item (16) through Item (19). Refer to Illustration 18 and Disassembly and Assembly, "Fuel Tank - Install".