TH210 and TH215 Telehandlers Machine Systems Caterpillar

Fuel Tank - Remove

Usage:

Removal Procedure

Start By:

Drain the fuel tank. Refer to Operation and Maintenance Manual, "Fuel Tank Water and Sediment - Drain".
Remove the seat. Refer to Disassembly and Assembly Manual, "Seat - Remove and Install".
Remove the steering column. Refer to Disassembly and Assembly Manual, "Steering Column - Remove and Install".
Remove the drive shaft. Refer to Disassembly and Assembly Manual, RENR5155, "Drive Shaft - Remove and Install".

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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.

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Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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NOTICE

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.

Put identification marks on all lines, on all hoses, on all tubes and on all wires for installation purposes. Plug all lines, all hoses, and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the fuel system.

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Illustration 1	g00938972

Remove harness (1) for the joystick from bulkhead fitting (2) .

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Illustration 2	g00938976

Remove the screws and the washers that secure panel (3) to the cab. It will be necessary to remove the caps from the heads of the screws first. Place the caps in a safe place. Reuse the caps during the installation procedure. Make a note of the location of all the screws and washers for the purpose of installation.

Dislodge panel (3) from the panel's location in the cab.

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Illustration 3	g00938978

Remove bulkhead fitting (2) from panel (3) .

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Illustration 4	g00938980

Remove panel (3) from the cab. Move bulkhead fitting (2) aside.

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Illustration 5	g00938982

Remove stud (4), the guard and the washers from the frame of the cab.

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Illustration 6	g00938983

Remove handle (5) from the frame of the cab.

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Illustration 7	g00938984

Remove fuse panel (6) from panel (7) .

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Illustration 8	g00938985

Remove panel (8) from panel (7) .

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Illustration 9	g00938986

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Illustration 10	g00938988

Pull switch panel (9) out of panel (7). Disconnect electrical connectors (11) and electrical wires (10) from the switch panel before removing the switch panel from the cab. Place identification marks on all the electrical connectors and electrical wires in order to identify the correct positions of all the electrical connectors and the electrical wires for the purpose of installation.

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Illustration 11	g00938989

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Illustration 12	g00938991

Remove retaining nut (13) that secures engine start switch (12) to the rear of panel (7). Move the engine start switch aside. Note the orientation of the engine start switch with respect to the markings that identify the different positions of the engine start switch key for the purpose of installation. Refer to the white arrow in Illustration 12.

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Illustration 13	g00938993

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Illustration 14	g00938994

Pull switch panel (14) out of panel (7). Disconnect electrical connectors (15) from the switch panel before removing the switch panel from the cab. Place identification marks on the electrical connectors in order to identify the correct positions of all the electrical connectors for the purpose of installation.

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Illustration 15	g00938995

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Illustration 16	g00938997

Pull display (16) out of panel (7). Disconnect electrical connectors (17) from the display before removing the display from the machine. Place identification marks on the electrical connectors in order to identify the correct positions of all the electrical connectors for the purpose of installation.

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Illustration 17	g00939017

Loosen the clamps that secure hoses (18) in place. Disconnect the hoses from panel (7) .

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Illustration 18	g00939018

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Illustration 19	g00939019

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Illustration 20	g00939021

Remove the screws that secure panel (7) in position. For the locations of the screws, refer to the white arrows in Illustration 19 and Illustration 20. Make a note of the location of the screws for the purpose of installation.

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Illustration 21	g00939023

Lift the left hand side of panel (7) first before removing the panel from the cab.

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Illustration 22	g00939024

Remove the screws and the washers that secure panel (19) to panel (20). It will be necessary to remove the caps from the heads of the screws first. Place the caps in a safe place. Reuse the caps during the installation procedure. Make a note of the location of all the screws and washers for the purpose of installation.

Dislodge panel (19) from the panel's position on top of panel (20). Do not remove panel (19) .

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Illustration 23	g00939026

Remove the screws and the washers that secure panel (20) to the cab. It will be necessary to remove the caps from the heads of the screws first. Place the caps in a safe place. Reuse the caps during the installation procedure. Make a note of the location of all the screws and washers for the purpose of installation.

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Illustration 24	g00940117

Dislodge the bottom of panel (20) from the side of cab. Move the panel to one side. Do not remove the panel.

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Illustration 25	g00939028

Remove floormat (22) carefully from the cab. Take care to pull the floormat around parking brake control (21) .

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Illustration 26	g00939484

Disconnect electrical connector (23) for the fuel level sender.

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Illustration 27	g00939485

Disconnect fuel lines (24) from the fuel tank.

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Illustration 28	g00939486

Place a suitable floor jack with suitable cribbing under the fuel tank. Use the floor jack to support the weight of the fuel tank. The weight of the fuel tank is approximately 44 kg (97 lb).

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Illustration 29	g00939487
Inside of the cab

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Illustration 30	g00939488
Outside of the cab

Remove bolts (25) and the washers that secure the fuel tank to the machine.

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Illustration 31	g00939489

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Illustration 32	g00939625

Use the floor jack to carefully lower the fuel tank. Ensure that electrical connector (23) is not fouled by the frame of the cab.

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Illustration 33	g00939627

Carefully turn the fuel tank by approximately 90 degrees. Use the floor jack to carefully remove the fuel tank from the machine. Pass the filler tube of the fuel tank between the wheel and the frame of the cab. Refer to Illustration 33.