Procedure to Update the Low Pressure Fuel System on Certain 795F AC Off-Highway Trucks {1251, 1255, 1256, 1261, 1273, 1274, 1290, 1408, 1439} Caterpillar

Off Highway Truck

795F (S/N: SNT1-UP)

795F Series AC (S/N: ERM1-UP)

Introduction

The following instruction provided the needed information to update the low-pressure fuel system on certain 795F Off-Highway Trucks.

Safety

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death.

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Falling Hazard. May cause personal injury or death. Always attach safety lanyard to appropriate fixing point.

Required Parts

Prepare the Machine

Note: Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

1. Refer to Operation and Maintenance Manual, SEBU8349, "Prepare the Machine for Maintenance".

Procedure Engine Mounted Components

Engine ECM Harness Replacement

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Illustration 1	g03735398
View of the Engine ECM on the front of the Engine (A) 8T-9405 Bolt (B) 096-6166 Hard Washer (C) 316-0487 Spacer (D) 6V-1819 Bolt (E) 6V-5839 Washer (F) 190-4885 Spacer (G) 8T-0643 Bolt

1. Remove eight bolts (A), eight hard washers (B), spacer (C), bolt (D), two washers (E), spacer (F), and bolt (G). Retain all hardware.
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   Illustration 2	g03845739
   View of the Engine ECM on the front of the Engine

2. Disconnect atmospheric pressure sensor (H) and the rest of the connections for the harness assembly.
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   Illustration 3	g03737480
   View of the Engine ECM on the front of the Engine

3. Remove and discard the 376-1303 Engine Harness As.
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   Illustration 4	g03845740
   View of the Engine ECM on the front of the Engine (1) 454-8533 Control Harness As

4. Connect harness assembly (1) to the ECM and the mounting plate. Reuse the retained hardware from Step 1.

5. Connect harness assembly (1) to atmospheric pressure sensor (H) and the remaining connections for the engine harnesses.

Engine Jumper Harness Connection and Routing

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Illustration 5	g03737528

1. Cut a small hole in the boot of the front bulkhead connector in the left-hand engine harness.

   Note: Ensure that the hole is large enough for the new 454-8532 Sensor Harness As to pass through.

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   Illustration 6	g03737604
   (2) 454-8532 Sensor Harness As

2. Peel back the boot and pass harness assembly (2) through the boot.

   Connect the "T776" wire from harness assembly (2) to position "19". Connect the "L948" wire from harness assembly (2) to position "47".

   Slide the boot back over the connector.

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   Illustration 7	g03737603
   (2) 454-8532 Sensor Harness As (3) 7K-1181 Cable Straps

3. Route harness assembly (2) along the existing engine harness assembly. Secure harness assembly (2) by using cable straps (3).

   Note: Removing the intake tubes in order to access the existing engine harness adequately may be necessary. If needed, new 258-9926 Gaskets and 5H-6733 O-Ring Seals are included in the kit.

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   Illustration 8	g03737609

4. Cut a small hole in the boot of the rear bulkhead connector in the left-hand engine harness.

   Note: Ensure that the hole is large enough for the new 454-8532 Sensor Harness As to pass through.

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   Illustration 9	g03737614
   (2) 454-8532 Sensor Harness As

5. Peel back the boot and pass harness assembly (2) through the boot.

   If equipped with a 40 pin connector, connect the "T776" wire from harness assembly (2) to position "26". If equipped with a 70 pin connector, connect the "T776" wire from harness assembly (2) to position "40".

   Connect the "L948" wire from harness assembly (1) to position "11".

   Slide the boot back over the connector.

   Note: There may be an existing wire in these positions. If so, remove the wire from the connector, insulate the end, and route the wire out of the way. If there are existing wires and if the engine oil switch has not been updated to an oil level sensor, then refer to Service Magazine, SEPD1440, "An Improved Engine Oil Level Sensor is Available for Certain C175 Off-Highway Truck Engines" and update the sensor.

FTP Inlet Pressure Sensor Replacement

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Illustration 10	g03737730
View of the right-hand side of the engine (A) Harness assembly (B) Pressure sensor

1. Disconnect harness assembly (A) from pressure sensor (B).

2. Remove and discard pressure sensor (B).
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   Illustration 11	g03737877
   View of the right-hand side of the engine (4) 451-0503 Adapter (5) 228-7100 O-Ring Seal (6) 320-3061 Pressure Sensor Gp (7) 228-7101 O-Ring Seal

3. Install adapter (4) with O-ring seal (5) onto the manifold.

4. Install pressure sensor group (6) with O-ring seal (7) onto connector (4).

5. Replace the 297-5485 Connector Plug As on the harness assembly with a 281-8804 Connector Plug As. Refer to Step 5.a through Step 5.d.
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   Illustration 12	g03737870
   View of the harness assembly

   1. With the harness disconnected, remove the purple cap/wedge.
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      Illustration 13	g03737895
      View of the connector

   2. Carefully lift the connector tabs with a screwdriver while simultaneously pulling the individual wires from the connector.

      After the wires have been removed from the connector, discard the connector.

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      Illustration 14	g03737896
      (8) 281-8804 Connector Plug As

   3. Insert the retained wires into new connector plug assembly (8).

      Note: Ensure that the wires are placed in the correct position. Refer to Illustration 17.

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      Illustration 15	g03737939

   4. Secure the green cap/wedge onto the new connector plug assembly.
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   Illustration 16	g03737966
   View of the right-hand side of the engine (A) Harness assembly (6) 320-3061 Pressure Sensor Gp (8) 281-8804 Connector Plug As

6. Connect harness assembly (A) with new connector (8) to sensor (6) and secure the red locking tab.

Procedure - Chassis Wiring Updates

Note: Refer to Schematic, UENR2628 for additional wiring information.

Illustration 17	g06005858
Schematic for the Clean Fuel Module (CFM) Retrofit Kit

Illustration 18	g03738097
Typical view of the arrangement of the connection to a terminal

1. Prepare the machine for maintenance. Ensure that there is not any power to the breaker box.
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   Illustration 19	g03745007
   View of the breaker box assembly

2. Remove the cover from the breaker box assembly. Discard the cover and the hardware.
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   Illustration 20	g03745592
   (A) Terminal cover (1) 448-1224 Wire As (2) 9V-2818 Grommet (3) 204-2281 Cable Strap (4) 7K-1181 Cable Strap (5) 8T-4121 Hard Washer (6) 344-5675 Nut

3. Route wire assembly (1) with through the side of the breaker box assembly with grommet (2). Secure the end of wire assembly (1) with the 131-1497 Ring Terminal As to the junction block by using hard washer (5) and nut (6).

   Note: Refer to Illustration 18 for a typical view of a terminal connection.

4. Slide terminal cover (A) over the connection and secure terminal cover (A) with cable strap (4). Secure wire assembly (1) to the available cable assembly by using cable strap (3).
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   Illustration 21	g03845741
   (7) 449-0088 Cover As (8) 303-1256 Relay Gp (9) 7X-2534 Bolt (10) 9X-8256 Washer (11) 125-7875 Heat Shrink Tube (12) 267-2680 Fuse

5. Locate cover assembly (7). Secure relay group (8) to cover assembly (7) by using bolt (9) and washer (10).

6. Insert fuse (12) into relay group (8) on the switched side of the circuit. Fuse (12) should be in line with the exposed terminal as shown in Illustration 21.

   Note: Do not set any fuses in the remaining non-switched circuit and replace the fuse cover.

7. Attach 30 mm (1.18 inch) of heat shrink tube (11) to the unused terminal of relay group (8) as shown in Illustration 21.
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   Illustration 22	g03745647
   (B) 135-2543 Boot (1) 448-1224 Wire As (4) 7K-1181 Cable Strap (5) 8T-4121 Hard Washer (7) 449-0088 Cover As (8) 303-1256 Relay Gp (13) 264-3617 Lockwasher (14) 8T-4224 Hard Washer (15) 344-5674 Nut (16) 8T-4186 Bolt

8. Secure cover assembly (7) to the box assembly by using four bolts (16) and four hard washers (5).

   Connect the 131-1497 Ring Terminal As from wire assembly (1) to the stud on relay group (8) by using lockwasher (13), hard washer (14), and nut (15).

   Note: Refer to Illustration 18 for a typical view of a terminal connection.

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   Illustration 23	g03745736
   (4) 7K-1181 Cable Strap (8) 303-1256 Relay Gp (10) 9X-8256 Washer (17) 1H-3244 Lockwasher (18) 455-9413 Chassis Harness As (19) 344-5673 Nut

9. Connect the 131-1496 Terminal As from harness assembly (18) to the top stud on relay group (8) by using lockwasher (17), washer (10), and nut (19).

   Note: Refer to Illustration 18 for a typical view of a terminal connection.

   Slide the boot over the connection and secure the boot with cable strap (4).

10. Connect the plug connection from harness assembly (18) to the top of relay group (8).
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    Illustration 24	g03745745
    (3) 204-2281 Cable Strap (7) 449-0088 Cover As (18) 455-9413 Chassis Harness As (20) 449-0087 Cover (21) 8T-4200 Bolt (22) 8T-4224 Hard Washer (23) 8T-4908 Bolt (24) 204-8000 Cable Tie Mounting

11. Secure cover (20) to the top of cover assembly (7) by using three bolts (21), four hard washers (22), bolt (23), and cable tie mounting (24).

    Secure harness assembly (18) to cable tie mounting (24) with cable strap (3).

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    Illustration 25	g03835763
    View of cover (20) ( A) 11.5 mm (0.45 inch) (B) 100 mm (4.0 0 inch)

12. Cover (20) may interfere with intake tube. If interference occurs modify cover as shown in Illustration 25.
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    Illustration 26	g03746657
    (3) 204-2281 Cable Strap (18) 455-9413 Chassis Harness As

13. Route harness assembly (18) up the left-hand side of the frame and toward the rear of the machine. Follow the existing harness assemblies. Secure harness assembly (18) by using cable straps (3), as needed.
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    Illustration 27	g03746695
    (3) 204-2281 Cable Strap (18) 455-9413 Chassis Harness As

14. Continue to route harness assembly (18) along the left-hand side of the frame, following the existing harness assemblies. Secure harness assembly (18) with cable straps (3), as needed.

15. Remove the "R997" wire from Position 7 of the Engine Interface Connector. Insert the "R997" wire into Position 1 of the CFM harness connector "CK-C5".

    Remove the "J843" wire from Position 32 of the Engine Interface Connector. Insert the "J843" wire into Position 2 of the CFM harness connector "CK-C5".

    Insert wire "R997" from CFM harness into Position 7 of the Engine Interface harness.

    Insert wire "L948" from CFM harness into Position 11 of the Engine Interface harness.

    40 Pin connector, insert wire "T776" into Position 26 of the Engine Interface harness.

    70 Pin connector, insert wire "T776" into Position 40 of the Engine Interface harness.

    Insert wire "J843" into Position 32 of the Engine Interface harness.

    Note: There may be an existing wire in these positions. If so, remove the wire from the connector, insulate the end, and route the wire out of the way. If there are existing wires and if the engine oil switch has not been updated to an oil level sensor, then refer to Service Magazine, SEPD1440, "An Improved Engine Oil Level Sensor is Available for Certain C175 Off-Highway Truck Engines" and update the sensor.

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    Illustration 28	g03746703
    (3) 204-2281 Cable Strap (4) 7K-1181 Cable Strap (18) 455-9413 Chassis Harness As (25) 8T-4179 Bolt (26) 8T-4223 Hard Washer (27) 320-3061 Pressure Sensor Gp

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    Illustration 29	g03746704
    (3) 204-2281 Cable Strap (4) 7K-1181 Cable Strap (18) 455-9413 Chassis Harness As (27) 320-3061 Pressure Sensor Gp

16. Continue to route harness assembly (18) along the left-hand side of the frame, following the existing harness assemblies. Secure harness assembly (18) with cable straps (3), as needed.

    Secure the available terminal from harness assembly (18) to the ground boss with bolt (25) and hard washer (26).

17. Secure pressure sensor group (27) to the top of the CFM pump manifold, if installed.

    Continue to route harness assembly (18) along the left-hand side of the frame, following the existing harness assemblies to the fuel tank. Secure harness assembly (18) with cable straps (3) and cable straps (4), as needed.

    Connect the two receptacles from harness assembly (18) to the CFM connections.

    Note: Step 17 to be completed after the CFM Pump has been installed.

Procedure - Pump Preparation

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Illustration 30	g03779463
View of the CFM pump

1. Locate the CFM pump.
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   Illustration 31	g03868420
   (1) 320-3061 Pressure Sensor Gp (2) 228-7101 O-Ring Seal

2. Secure pressure sensor group (1) to the CFM pump with O-ring seal (2). Tighten sensor group (1) tp 10 ± 2 N·m (89 ± 18 lb in).

CFM Pump Cover Modification (If Needed)

If the CFM pump group does not have a pigtail to connect the wire harness assembly, a new hole in the cover must be drilled. Refer to the instructions below.

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Illustration 32	g03742838
(AA) 48 mm (1.88 inch) (AB) 32 mm (1.25 inch) (AC) 25 mm (0.98 inch) Diameter hole

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Illustration 33	g03742479
(1) Grommet (part of the wiring group)

1. Drill a 25 mm (0.98 inch) diameter hole in the cover for the CFM pump group. Refer to Illustration 32 for the hole location.

   Insert grommet (1) into the drilled hole. Insert the wiring harness through grommet (1) and connect to the pump group.

Procedure - Pump Fuel Line Installation

The following instruction include information needed for installation with and without a fuel heater. Refer to the appropriate section.

Installation Without a Fuel Heater

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Illustration 34	g03846280
(A) Hose assembly (B) Connector (C) Ball valve (D) Bracket assembly (E) Elbow (F) Tube assembly (G) Elbow (H) Bracket assembly (J) Filter group (K) Sensor (L) Filter base (M) Wire harness

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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

1. Disconnect hose assembly (A).

2. Remove and discard the following components:

   • Connector (B)

   • Ball valve (C)

   • Bracket assembly (D)

   • Elbow (E)

   • Tube assembly (F)

   • Elbow (G)

   • Bracket assembly (H)

   • Filter groups (J)

   • Sensor (K)

   Retain the following components:

   • Sensor (K)

   • Filter bases (L)

   • Harness assembly (M)

   Discard any associated mounting hardware.

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   Illustration 35	g03743836
   View of the side and front of the fuel tank (1) 125-9738 Block (2) 452-8100 Bracket As

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   Illustration 36	g03743837
   View of the side of the fuel tank (1) 125-9738 Block (AA) 104 mm (4.09 inch) (AB) 160 mm (6.30 inch) (AC) 75 mm (2.95 inch)

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   Illustration 37	g03744099
   View of the front of the fuel tank (2) 452-8100 Bracket As (AD) 23 mm (0.91 inch) from side of tank (AE) 173 mm (6.81 inch) from bottom of tank

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   Personal injury or death can result from an explosion. Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force. Do not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions such as filling the tank with either carbon dioxide or water.

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   NOTICE
   The fuel tank must be drained of all fuel so that there is no residual oil left in the fuel tank.

3. Locate and weld two blocks (1) and bracket assembly (2) onto the fuel tank.

   Do Not Weld an Empty Fuel Tank.

   Reference: Special Instruction, REHS1841, "General Welding Procedures"

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   Illustration 38	g03846420
   View of the front of the fuel tank (2) 452-8100 Bracket As (N) Elbow

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   NOTICE
   The hose assembly that connects to the bottom of the rear most steering accumulator must be adjusted in order to prevent damage to the hose assembly from bracket assembly (2).

   Note: Ensure that there is no hydraulic oil pressure in the system. Refer to Operation and Maintenance Manual, SEBU8349, "Prepare the Machine for Maintenance".

4. Loosen elbow (N) on the bottom of the rear most steering accumulator. Rotate elbow (L) clockwise approximately 10 degrees in order to avoid the hose assembly from contact with bracket assembly (2). Retighten elbow (N) after reorientation.
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   Illustration 39	g03868523
   (1) 125-9738 Block (3) 449-9892 Bracket As (4) 8T-4196 Bolt (5) 198-4777 Hard Washer

5. Secure bracket assembly (3) to two blocks (1) by using four bolts (4), and four hard washers (5).

   Note: Cable tie mountings (7) are for the wiring harness assembly.

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   Illustration 40	g03868455
   (P) Chassis harness (R) Water separator harness (7) 204-8000 Cable Tie Mounting (11) 8T-4121 Hard Washer (15) 8T-4136 Bolt (37) 8T-4137 Bolt (38) 125-8534 Plate As (39) 130-5300 Clip (40) 204-2281 Cable Strap

6. Connect chassis harness (P) to water separator harness (R). Secure harnesses using three cable tie mounts (40), six hard washers (11), four bolts (15), two bolts (37), plate assembly (38), clip (39), four cable straps (40), and grommet (41) as shown in Illustration 40.
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   Illustration 41	g03846321
   (L) Filter base (8) 321-1326 Filter Base As (9) 225-6948 O-Ring Seal (10) 8T-4182 Bolt (11) 8T-4121 Hard Washer (12) 344-5675 Nut (13) 9S-4181 O-Ring Plug (14) 238-5084 O-Ring Seal

7. Preassemble the filter bases, using two existing filter bases (L) and new filter base (8).

   Secure three filter base assemblies together by using four O-ring seals (9), eight bolts (10), 16 hard washers (11), and eight nuts (12).

   Secure two O-ring plugs (13) and two O-ring seals (14) to left-hand filter base assembly (8).

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   Illustration 42	g03869089
   (2) 452-8100 Bracket As (8) 321-1326 Filter Base As (11) 8T-4121 Hard Washer (14) 238-5084 O-Ring Seal (15) 8T-4136 Bolt (16) 228-7093 O-Ring Seal (17) 8C-5723 Connector (18) 239-1834 Tee (19) 159-4724 Ball Valve (21) 438-5386 Water Separator and Fuel Filter As (42) 8T-7927 Connector (43) 228-7094 O-Ring Seal

8. Secure assembled filter base assemblies (8) to bracket assembly (2) by using nine bolts (15) and nine hard washers (11).

   Secure three fuel filter assemblies (21) to filter bases (8).

9. Secure connector (17) with O-ring seal (14) and O-ring seal (16) to the rear most port of right-hand filter base assembly (8).

   Secure tee (18) with O-ring seal (14) and O-ring seal (16) to the forward most port of right-hand filter base assembly (8).

10. Secure ball valve (19) with O-ring seal (14) to tee (18).

    Secure connector (42) with O-ring seal (14) and O-ring seal (43) to ball valve (19).

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    Illustration 43	g03868889
    (R) Water separator harness (8) 321-1326 Filter Base As (10) 8T-4182 Bolt (11) 8T-4121 Hard Washer (12) 344-5675 Nut (40) 204-2281 Cable Strap (41) 132-5789 Clip

11. Secure water separator harness (R) to an unused hole on filter base assembly (8) using bolt (10), two hard washers (11), nut (12), cable strap (40), and clip (41).
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    Illustration 44	g03869012

12. Install water sensor into the first fuel filter.
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    Illustration 45	g03744314
    (2) 452-8100 Bracket As (6) 8T-4186 Bolt (11) 8T-4121 Hard Washer (22) 452-8101 Guard As (23) 6P-6256 Spring Retainer

13. Secure guard assembly (22) to bracket assembly (2) by using four bolts (6), four hard washers (11), and four spring retainers (23).
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    Illustration 46	g03744332
    View of the 457-5703 Fuel Pump Gp

14. Locate the fuel pump group. Remove and discard the shipping hardware from the fuel pump group.
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    Illustration 47	g03744575
    (3) 449-9892 Bracket As (11) 8T-4121 Hard Washer (24) 457-5703 Fuel Pump Gp (25) 183-8004 Bolt (26) 450-0342 Sleeve (27) 8T-4178 Bolt

15. Secure fuel pump group (24) to bracket assembly (3) by using bolt (25), sleeve (26), two bolts (27), and two hard washers (11).
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    Illustration 48	g03744595
    View of the fuel pump group

16. Remove and discard two plugs from the manifold on the fuel pump group.
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    Illustration 49	g03744719
    (14) 238-5084 O-Ring Seal (16) 228-7093 O-Ring Seal (24) 457-5703 Fuel Pump Gp (28) 6V-9008 Elbow (29) 6V-9005 Elbow (30) 8D-8428 Adapter (31) 214-7566 O-Ring Seal (32) 229-5465 Fitting (33) 6V-0852 Dust Cap

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    Illustration 50	g03744746
    (A) 25 Degrees (28) 6V-9008 Elbow

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    Illustration 51	g03870280
    (B) 26 Degrees (29) 6V-9005 Elbow

17. Secure elbow (28) with O-ring seal (14) and O-ring seal (16) to the top of fuel pump group (24).

    Note: Ensure that elbow (28) is aligned 25 degrees from the face of the pump manifold. Refer to Illustration 50.

    Secure adapter (30), O-ring seal (14), fitting (31), O-ring seal (32), and dust cap (33) to the side of fuel pump group (24).

18. Secure elbow (29) with O-ring seal (14) and O-ring seal (16) to the existing ball valve on the side of the fuel tank.

    Note: Ensure that elbow (29) is aligned 26 degrees upward from the top surface of the ball valve. Refer to Illustration 51.

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    Illustration 52	g06005872
    (A) Hose assembly (28) 6V-9008 Elbow (29) 6V-9005 Elbow (34) 449-9888 Hose As (42) 8T-7927 Connector

19. Secure hose assembly (A) to connector (42).

    Note: Hose assembly (A) was disconnected in Step 1.

20. Connect hose assembly (34) between elbow (28) and elbow (29).
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    Illustration 53	g03870090

21. Hose assembly (A) has excess length and will need to be installed so that there are no hose rubs. Refer to Illustration 53.

    Note: Hose assembly (A) is not included in the KIT, refer to HIS (Hydraulic Information System) for details.

22. Hose assembly (A) can be discarded and replaced by hose assembly (44). Hose assembly (44) is shorter in length and will not need to be “snaked”.

23. Use existing routing and clipping from hose assembly (A) for hose assembly (44).
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    Illustration 54	g03744807
    (14) 238-5084 O-Ring Seal (16) 228-7093 O-Ring Seal (17) 8C-5723 Connector (18) 239-1834 Tee (20) 6V-8635 Connector (35) 463-8693 Hose As (36) 463-8692 Hose As

24. Secure two connectors (20) with two O-ring seals (14) and two O-ring seals (16) to the bottom of the fuel pump group.

    Connect hose assembly (35) to forward most connector (20) and to connector (17).

    Secure hose assembly (36) to rear most connector (20) and to tee (18).

Installation With a Fuel Heater

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Illustration 55	g03747632
(A) Hose assembly (B) Connector (C) Ball valve (D) Bracket assembly (E) Tube assembly (F) Elbow (G) Hose assembly (H) Bracket assembly (J) Filter group (K) Clip

1. Remove and discard the following components:

   • Hose assembly (A)

   • Connector (B)

   • Ball valve (C)

   • Bracket assembly (D)

   • Tube assembly (E)

   • Elbow (F)

   • Hose assembly (G)

   • Bracket assembly (H) and associated hardware

   • Two filter groups (J) and associated hardware

   • Clip (K) and associated hardware

   Note: Hose assembly (A) must also be disconnected at the right-hand side of the engine. Retain all mounting hardware associated with hose assembly (A).

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   Illustration 56	g03743836
   View of the side and front of the fuel tank (1) 125-9738 Block (2) 452-8100 Bracket As

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   Illustration 57	g03743837
   View of the side of the fuel tank (1) 125-9738 Block (AA) 104 mm (4.09 inch) (AB) 160 mm (6.30 inch) (AC) 75 mm (2.95 inch)

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   Illustration 58	g03744099
   View of the front of the fuel tank (2) 452-8100 Bracket As (AD) 23 mm (0.91 inch) from side of tank (AE) 173 mm (6.81 inch) from bottom of tank

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   Personal injury or death can result from an explosion. Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force. Do not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions such as filling the tank with either carbon dioxide or water.

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   NOTICE
   The fuel tank must be drained of all fuel so that there is no residual oil left in the fuel tank.

2. Locate and weld two blocks (1) and bracket assembly (2) onto the fuel tank.

   Do Not Weld an Empty Fuel Tank.

   Reference: Special Instruction, REHS1841, "General Welding Procedures"

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   Illustration 59	g03744081
   View of the front of the fuel tank (2) 452-8100 Bracket As (L) Elbow

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   NOTICE
   The hose assembly that connects to the bottom of the rear most steering accumulator must be adjusted in order to prevent damage to the hose assembly from bracket assembly (2).

   Note: Ensure that there is no hydraulic oil pressure in the system. Refer to Operation and Maintenance Manual, SEBU8349, "Prepare the Machine for Maintenance".

3. Loosen elbow (L) on the bottom of the rear most steering accumulator. Rotate elbow (L) clockwise approximately 10 degrees in order to avoid the hose assembly from contact with bracket assembly (2). Retighten elbow (L) after reorientation.
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   Illustration 60	g03743902
   (1) 125-9738 Block (3) 449-9892 Bracket As (4) 8T-4196 Bolt (5) 198-4777 Hard Washer (6) 8T-4186 Bolt (7) 230-7732 Cable Tie Mounting

4. Secure bracket assembly (3) to two blocks (1) by using two bolts (4), four hard washers (5), two bolts (6), and two cable tie mountings (7).

   Note: Cable tie mountings (7) are for the wiring harness assembly.

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   Illustration 61	g03744148
   (8) 321-1326 Filter Base As (9) 225-6948 O-Ring Seal (10) 8T-4182 Bolt (11) 8T-4121 Hard Washer (12) 344-5675 Nut (13) 9S-4181 O-Ring Plug (14) 238-5084 O-Ring Seal

5. Preassemble the filter bases.

   Secure three filter base assemblies (8) together by using four O-ring seals (9), eight bolts (10), 16 hard washers (11), and eight nuts (12).

   Secure two O-ring plugs (13) and two O-ring seals (14) to left-hand filter base assembly (8).

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   Illustration 62	g06005881
   (2) 452-8100 Bracket As (8) 321-1326 Filter Base As (11) 8T-4121 Hard Washer (14) 238-5084 O-Ring Seal (15) 8T-4136 Bolt (16) 228-7093 O-Ring Seal (17) 8C-5723 Connector (18) 239-1834 Tee (19) 159-4724 Ball Valve (21) 438-5386 Water Separator and Fuel Filter As (41) 8T-7927 Connector

6. Secure assembled filter base assemblies (8) to bracket assembly (2) by using nine bolts (15) and nine hard washers (11).

   Secure three fuel filter assemblies (21) to filter bases (8).

7. Secure connector (17) with O-ring seal (14) and O-ring seal (16) to the rear most port of right-hand filter base assembly (8).

   Secure tee (18) with O-ring seal (14) and O-ring seal (16) to the forward most port of right-hand filter base assembly (8).

8. Secure ball valve (19) with O-ring seal (14) to tee (18).

   Secure connector (41) with O-ring seal (14) and O-ring seal (16) to ball valve (19).

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   Illustration 63	g03744314
   (2) 452-8100 Bracket As (6) 8T-4186 Bolt (11) 8T-4121 Hard Washer (22) 452-8101 Guard As (23) 6P-6256 Spring Retainer

9. Secure guard assembly (22) to bracket assembly (2) by using four bolts (6), four hard washers (11), and four spring retainers (23).
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   Illustration 64	g03744332
   View of the 457-5703 Fuel Pump Gp

10. Locate the fuel pump group. Remove and discard the shipping hardware from the fuel pump group.
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    Illustration 65	g03744575
    (3) 449-9892 Bracket As (11) 8T-4121 Hard Washer (24) 457-5703 Fuel Pump Gp (25) 183-8004 Bolt (26) 450-0342 Sleeve (27) 8T-4178 Bolt

11. Secure fuel pump group (24) to bracket assembly (3) by using bolt (25), sleeve (26), two bolts (27), and two hard washers (11).
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    Illustration 66	g03744595
    View of the fuel pump group

12. Remove and discard two plugs from the manifold on the fuel pump group.
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    Illustration 67	g03744813
    (L) Elbow (existing) (14) 238-5084 O-Ring Seal (16) 228-7093 O-Ring Seal (24) 457-5703 Fuel Pump Gp (28) 6V-9008 Elbow (29) 8D-8428 Adapter (30) 214-7568 O-Ring Seal (31) 6V-3965 Fitting (32) 6V-0852 Dust Cap

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    Illustration 68	g03747716
    (A) 5 Degrees (28) 6V-9008 Elbow

13. Secure elbow (28) with O-ring seal (14) and O-ring seal (16) to the top of fuel pump group (24).

    Note: Ensure that elbow (28) is aligned 5 degrees from the face of the pump manifold. Refer to Illustration 68.

    Secure adapter (29), O-ring seal (14), fitting (30), O-ring seal (31), and dust cap (32) to the side of fuel pump group (24).

14. Reorient existing elbow (L) 90 degrees to face away from the fuel tank.
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    Illustration 69	g03747743
    (L) Elbow (existing) (3) 449-9892 Bracket As (11) 8T-4121 Hard Washer (28) 6V-9008 Elbow (33) 449-9897 Hose As (34) 452-8102 Hose As (35) 7D-7233 Clip (36) 3J-5251 Pipe (37) 8T-4172 Bolt

15. Secure hose assembly (33) between elbow (28) and elbow (L).

16. Secure hose assembly (34) between the thermal compensator valve and the adapter on the core assembly. Secure hose assembly (34) to the side of bracket assembly (3) by using clip (35), pipe (36), bolt (37), and hard washer (11).
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    Illustration 70	g03747745
    (14) 238-5084 O-Ring Seal (16) 228-7093 O-Ring Seal (17) 8C-5723 Connector (18) 239-1834 Tee (20) 6V-8635 Connector (38) 463-8693 Hose As (39) 463-8692 Hose As

17. Secure two connectors (20) with two O-ring seals (14) and two O-ring seals (16) to the bottom of the fuel pump group.

    Connect hose assembly (38) to forward most connector (20) and to connector (17).

    Secure hose assembly (39) to rear most connector (20) and to tee (18).

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    Illustration 71	g03747797
    (20) 6V-8635 Connector (40) 463-8691 Hose As

18. Secure one end of hose assembly (40) to connector (20).

    Secure the other end of hose assembly (40) to the right-hand side of the engine, where the previous hose assembly was connected. Use the retained clipping and hardware to secure the hose routing.

    Note: Refer to Step 1.

Engine Software

1. The updated fuel system requires an update to the software. Connect a laptop computer to the Caterpillar Diagnostic Connector behind the seats of the cab. Open Cat ET.

   Obtain the latest correct software from the “Service Software Files” link on the home page of the Service Information System.

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   Illustration 72	g03749242
   Typical view

2. Navigate to the "Engine Configuration Parameters" and change the status of the "Electric Fuel Transfer Pump Installation Status" to "Installed".