Fuel Tank - Remove and Install
Removal Procedure
Show/hide table
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| ZZ | 6V-9508 | Face Seal Plug | 3 |
| 6V-9829 | Cap | 3 | |
Start By:
- Tilt the cab. Refer to Disassembly and Assembly, "Cab - Tilt".
- Remove the gear pump. Refer to Disassembly and Assembly, "Gear Pump - Remove".
- Remove the air conditioner and heater. Refer to Disassembly and Assembly, "Air Conditioner and Heater - Remove".
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
Show/hide table
 |
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Turn the disconnect switch OFF when draining and/or removing any fuel system components. |
 |
Show/hide table
| 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. |
- Drain the fuel into a suitable container for storage or disposal. The capacity of the fuel tank is approximately 95 L (25 US gal).
- Remove bolts (1). Remove bolts (3). Position console (2) out of the way. Remove plate (4) .
Show/hide table
 | |
| Illustration 1 | g01067876 |
Show/hide table
 | |
| Illustration 2 | g01067887 |
- Remove bolts (6). Position console (5) out of the way.
Show/hide table
 | |
| Illustration 3 | g01067909 |
- Remove bolts (7). Remove plate (8). Remove plate (9) .
Show/hide table
 | |
| Illustration 4 | g01067918 |
- Remove bolts (12). Disconnect harness assemblies (10). Reposition block assembly (11) out of the way.
Show/hide table
 | |
| Illustration 5 | g01067933 |
- Disconnect hoses (13). Disconnect tube assembly (13A). Disconnect harness assembly (14) .
Show/hide table
 | |
| Illustration 6 | g01068050 |
- Disconnect hose assembly (15).
Show/hide table
 | |
| Illustration 7 | g01068056 |
- Remove bolts (17). Remove spring plate (16) .
Show/hide table
 | |
| Illustration 8 | g01068055 |
- Remove fuel tank (18) .
- Remove bolts (19). Remove fuel sender (20) .
Note: Remove harness assembly that was previously disconnected.
Show/hide table
 | |
| Illustration 9 | g01068176 |
- Remove fitting (21) and the grommet. Remove adapter (22) and adapter (23). Remove fitting (24) from fuel tank (18) .
Show/hide table
 | |
| Illustration 10 | g01068178 |
Installation Procedure
- Install fitting (24). Install adapter (23) and adapter (22). Install fitting (21) and the grommet into fuel tank (18) .
Show/hide table
| | |
| Illustration 11 | g01068178 |
- Install fuel sender (20). Secure the fuel sender with bolts (19) .
Note: Attach the harness assembly to the fuel tank.
Show/hide table
| | |
| Illustration 12 | g01068176 |
- Install fuel tank (18) into position.
- Install spring plate (16). Install bolts (17) .
Show/hide table
| | |
| Illustration 13 | g01068055 |
- Install hose assembly (15) .
Show/hide table
| | |
| Illustration 14 | g01068056 |
- Connect hoses (13). Connect tube assembly (13A) to the fuel tank. Connect harness assembly (14) .
Show/hide table
| | |
| Illustration 15 | g01068050 |
- Position block assembly (11). Secure block assembly (11) with bolts (12). Connect harness assemblies (10) .
Show/hide table
| | |
| Illustration 16 | g01067933 |
- Install plate (9). Install plate (8). Secure the plates with bolts (7) .
Show/hide table
| | |
| Illustration 17 | g01067918 |
- Move console (5) into position. Install bolts (6) .
Show/hide table
| | |
| Illustration 18 | g01067909 |
- Install plate (4). Move console (2) into position. Install bolts (3). Install bolts (1) .
Show/hide table
| | |
| Illustration 19 | g01067887 |
Show/hide table
| | |
| Illustration 20 | g01067876 |
- Fill the fuel tank with clean fuel. The capacity of the fuel tank is approximately 95 L (25 US gal).
End By:
- Install the air conditioner and heater. Refer to Disassembly and Assembly, "Air Conditioner and Heater - Remove".
- Install the gear pump. Refer to Disassembly and Assembly, "Gear Pump - Remove".
- Lower the cab. Refer to Disassembly and Assembly, "Cab - Tilt".
Caterpillar Information System:
16H Motor Grader Power Train Service Brake (Wheel Spindle) - Install
2004/04/26 Accelerator Hinge Pin Instructions Are Now Included with Parts Kit {1276}
SCJ and 8SC Series Alternators Alternator - Assemble
120M and 12M Motor Graders Steering Frame Lock
414E, 416E, 420E and 430E Backhoe Loaders MID 039 - CID 1957 - FMI 08
414E, 416E, 420E and 430E Backhoe Loaders MID 039 - CID 1957 - FMI 04
414E, 416E, 420E and 430E Backhoe Loaders MID 039 - CID 1957 - FMI 03
16H Motor Grader Power Train Service Brake (Wheel Spindle) - Remove
259B3 Compact Track Loader, 247B3 and 257B3 Multi Terrain Loaders and 216B3, 226B3, 236B3, 242B3 and 252B3 Skid Steer Loaders Machine Systems Control Valve (Work Tool) - Assemble
C27 and C32 Generator Set Engines Engine Design
16H Motor Grader Power Train Drive Chain - Install
AS2251 and AS2301 Asphalt Screed Fuel Pump Control
12M Motor Grader Seat
10-20B and 8-16B EXTEND A MAT SCREEDS Deflector Plate Adjustment (Strike-Off)
2004/05/03 New Transmission Solenoid Valve Groups Are Now Being Used {3174}
248B and 268B Skid Steer Loaders Machine Systems Control Valve (Work Tool)
793C, 793C XQ and 793D Off-Highway Truck Fast Fill Fluid Center Fluids Service System Troubleshooting
120M and 12M Motor Graders Equipment Lowering with Engine Stopped
8-16B and 10-20B Extend-A-Mat Screed Extender Carriage - Remove
C27 and C32 Engines for Caterpillar Built Machines Cylinder Head
120M and 12M Motor Graders Access Doors and Covers
770 and 772 Off-Highway Truck Engine Oil and Filter - Change
2004/06/14 New Cast Wheels Replace The Existing Cast Wheels {4201, 4209}
R2900G Load Haul Dump Power Train Gear Pump (Torque Converter Scavenge) - Disassemble