Procedure to Prevent Fuel Tank Group Rust on Certain D6K and D6K2 Track-Type Tractors {1261, 1263, 1273} Caterpillar


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Procedure to Prevent Fuel Tank Group Rust on Certain D6K and D6K2 Track-Type Tractors {1261, 1263, 1273} [M0123551]
FUEL SYSTEM
FILTER GP-FUEL
Procedure to Prevent Fuel Tank Group Rust on Certain D6K and D6K2 Track-Type Tractors {1261, 1263, 1273}
Track-Type Tractor
D6K (S/N: 6S61-133,3000-3014; 7P61-101,3000; MP71-241,3000-3098; ZLJ1-112,3000-3001)
D6K2 (S/N: EL71-1012,3000-3455; MGM1-529,3000-3205; DFR1-712,3000-3039; JTR1,200-1341,3000-3057)

Reference: Disassembly and Assembly, M0066516, "D6K Track Type Tractor", "Fuel Tank - Remove and Install".

Reference: Disassembly and Assembly, M0080783, "D6K2 and D4 Track-Type Tractors", "Fuel Tank - Remove and Install".

Reference: Operation and Maintenance Manual, SEBU9352, "D6K2 and D4 Track-Type Tractor", "Fuel System Filter (In-Line) - Replace".

Reference: Operation and Maintenance Manual, M0070790, "D4 and D6K Track-Type Tractor", "Fuel System Primary and Secondary Filters - Replace."

Reference: Operation and Maintenance Manual, SEBU9352, "D6K2 and D4 Track-Type Tractor", "Fuel System Primary and Secondary Filters - Replace."

Reference: Special Instruction, SEHS9031, "Storage Procedure for AVSpare Products."

The rework procedure helps to clean and prevent the fuel tank group from rusting.

------ WARNING! ------

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.


------ WARNING! ------

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.


------ WARNING! ------

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.


------ WARNING! ------

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.


------ WARNING! ------

Personal injury or death can result from sudden movement.

Prevent possible injury by performing the following procedures before work begins:

Move the product or equipment to a smooth, level surface.

When applicable, lower equipment/work tools to the ground.

Engage the parking brake, system brakes and/or hydraulic lockout control. When applicable, stop the engine and remove the ignition key.

Release system pressure from pressurized systems.

If applicable, block the wheels/tracks.

Turn the battery disconnect switch to the OFF position and if applicable, remove the battery disconnect key. If not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. 

Attach a “Do Not Operate” or similar warning tag at the battery disconnect switch location and as defined by site rules and/or local regulations.




Illustration 1g06276183

------ WARNING! ------

Access to this service point may require climbing on the equipment. Slipping or falling while climbing on the equipment could result in personal injury or death. Refer to the Operation and Maintenance Manual, Mounting and Dismounting topic for safety information.


------ WARNING! ------

Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness.


------ WARNING! ------

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to do the job.

Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.


------ WARNING! ------

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.


------ WARNING! ------

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.


------ WARNING! ------

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.


------ WARNING! ------

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.


------ WARNING! ------

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.

Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.



NOTICE

Do not pre-fill the fuel filter with fuel before you install the fuel filter. Contaminated fuel WILL DAMAGE the fuel system components.



NOTICE

AVSpare STRONGLY recommends the use of high efficiency fuel filters. High efficiency fuel filters are designed in order to better protect diesel engines that have higher injection pressures and closer tolerances. Use of fuel filters that are NOT high efficiency fuel filters will result in shortened fuel system component life. AVSpare high efficiency fuel filters are the preferred filters for AVSpare engines.


Table 1
Required Parts 
Item  Qty  Part Number  Part Name 
525-6206  Water Separator Element 
360-8960  Filter 
479-4133  Fuel Filter Element 

The most efficient and cost-effective way to clean the rust from fuel tank is to use solvent. Follow the rework procedure given below to clean the fuel tank using solvent.

Note: Ensure that proper procedures are followed for long-term storage period of the machine. Use Volatile Corrosion Inhibitor (VCI) in fuel tank for long period of storage time. VCI oil is compatible with fuel.Refer to Special Instruction, SEHS9031, "Storage Procedure for AVSpare Products".

Note: Ensure proper handling of the Diesel Exhaust Fluid in the DEF tank only.

Machine Preparation

For D6K Track-Type Tractor, refer to Operation and Maintenance Manual, M0070790, "D4 and D6K Track-Type Tractor", "Prepare the Machine for Maintenance".

For D6K2 Track-Type Tractor, refer to Operation and Maintenance Manual, SEBU9352, "D6K2 and D4 Track-Type Tractor", "Prepare the Machine for Maintenance".

Rework Procedure



Illustration 2g06604098
Some parts are removed for clarity
(A) Fuel tank group
(1) 525-6206 Filter
(2) 360-8960 Fuel Filter Element
(3) 479-4133 Water Separator Element

  1. Remove fuel tank group (A) from the machine.

    Note: Refer to Disassembly and Assembly , "Fuel Tank - Remove and Install" of your machine.

  2. Fill fuel tank group (A) partially with solvent, Evapo-rust, Mirachem 250, or equivalent.

    Note: The solvent is reusable.

  3. This process requires 2 hours minimum for the solvent to clean the surfaces of fuel tank group (A).

  4. Rotate fuel tank group (A) to treat all the surfaces with the solvent.

    Note: Keep fuel tank group (A) in each position for 2 hours minimum.

  5. Drain and retain the solvent from fuel tank group (A) and reuse the solvent for another wash.

  6. Clean fuel tank group (A) with clear water.

  7. Dry fuel tank group (A).

  8. Spray fuel tank group (A) with 516-0277 Oil (Volatile Corrosion Inhibitor (VCI)).

    Note: VCI oil is compatible with fuel.

  9. Install fuel tank group (A) on the machine.

    Note: Refer to Disassembly and Assembly , "Fuel Tank - Remove and Install" of your machine.

  10. Remove the existing In-Line filter and replace with filter (1).

    Note: Refer to Operation and Maintenance Manual , "Fuel System Filter (In-Line) - Replace" of your machine.

  11. Remove existing primary and secondary filters , and replace with fuel filter element (2) and water separator element (3).

    Note: Refer to Operation and Maintenance Manual , "Fuel System Primary and Secondary Filters - Replace" of your machine.

  12. Refill fuel tank group (A) with fuel.

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