Installation of New Fuel Tank on D-Series Compactors{1273} Caterpillar

Paving Compactor:

CP-533D (S/N: 6AZ1-307)

CP-563D (S/N: 5LZ1-308)

CS-531D (S/N: 4MZ1-325)

CS-533D (S/N: 5CZ1-359)

CS-563D (S/N: 2RZ1-504)

CS-573D (S/N: 2YZ1-184)

CS-583D (S/N: 3GZ1-472)

Introduction

This Special Instruction provides information for the proper replacement of the fuel tank on D-Series soil compactors.

Rework Procedure

1. Drain the fuel into a suitable container. The fuel tank capacity is 265 L (70 US gal).

2. Remove the radiator, the oil cooler and the hydraulic oil tank. Refer to Service Manual Module, Disassembly and Assembly, KENR7023.

3. Remove the fuel tank. Refer to Service Manual Module, Disassembly and Assembly, KENR7023.

   Note: Note the location of the battery cables and the electrical harness.

4. Remove the following items from the original fuel tank assembly. Use these items for the installation of the new fuel tank.
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   Table 1

   Remove these items from the original fuel tank.
   Item	Quantity	Part Number	Description
   2	1	6V-7238	Shutoff Valve
   3	2	8T-4986	Hose Clamps
   4	1	9G-5127	Breather
   5	1	9P-7121	Fuel Strainer
   7	1	123-6319	Fuel Tank Cap Assembly
   11	1	144-9420	Fuel Level Sender As
   12	1	156-2779	Hose
   13	4	156-5114	Angles
   14	1	177-2174	Fuel Filler As
   16	5	6V-4298	Bolts
   17	5	8T-0328	Hard Washers
   18	2	8T-4121	Hard Washers

   The following table lists the new parts that are required for the new 143-7666 Fuel Tank As .

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   Table 2

   Required Parts
   Item	Quantity	Part Number	Description
   1	3	6S-8620	Hose Clamps
   6	3	9R-7240	Gaskets
   8	1	143-7666	Fuel Tank As
   9	1	144-5339	Fuel Tube
   10	1	144-5340	Plate As
   15	1	3K-0360	O-Ring Seal
   16	10	6V-4298	Bolts
   17	10	8T-0328	Hard Washers
   19	2	8T-4195	Bolts
   20	620 mm (24 inch)	5P-1518	Hose
   21	1	152-0270	Hose As
   22	1	152-0269	Hose As
   23	4	6V-8397	O-Ring Seals
   24	1	6V-8636	Connector
   25	1	3J-1907	O-Ring Seal

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Illustration 1	g00851473

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Illustration 2	g00851648

5. Combine the parts from table 1 and table 2 in order to prepare the new 143-7666 Fuel Tank As for installation.

6. Install the new 143-7666 Fuel Tank As . Refer to Service Manual Module, Disassembly and Assembly, KENR7023.

   Note: Route the electrical harness and the battery cable around the fuel tank. Improper routing may cause serious damage.

7. Reinstall the following items: hydraulic oil tank, oil cooler and radiator. Refer to Service Manual Module, Disassembly and Assembly, KENR7023.

8. Fill the fuel tank with fuel.

9. Before you start the machine, prime the fuel system and check for leaks in the fuel system.