- Off-Highway Truck/Tractor
- 797F (S/N: LAJ1-UP; WSP1-UP)
Introduction
The following instruction provided the needed information to update the low-pressure fuel system on certain 797F 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. |
| NOTICE |
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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. |
Required Parts
| Required Parts - Engine Mounted Components | ||
| Qty | Part Number | Description |
| 8 | Gasket | |
| 12 | O-Ring Seal | |
| 1 | Control Harness As | |
| 1 | Sensor Harness As | |
| 15 | Cable Strap | |
| 1 | Adapter | |
| 1 | O-Ring Seal | |
| 1 | Pressure Sensor Gp | |
| 1 | O-Ring Seal | |
| 1 | Connector Plug As | |
| Required Parts - Chassis Wiring (S/N: LAJ1-230) (1) | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | Wire As | |
| 2 | 1 | Grommet | |
| 3 | 5 | Cable Strap | |
| 4 | 6 | Hard Washer | |
| 5 | 3 | Nut | |
| 6 | 4 | Bolt | |
| 7 | 1 | Relay Gp | |
| 8 | 1 | Bolt | |
| 9 | 3 | Washer | |
| 10 | 1 | Heat Shrink Tube
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| 11 | 1 | Fuse | |
| 12 | 1 | Lockwasher | |
| 13 | 10 | Hard Washer | |
| 14 | 1 | Nut | |
| 15 | 2 | Bolt | |
| 16 | 1 | Bolt | |
| 17 | 1 | Nut | |
| 18 | 1 | Chassis Harness As | |
| 19 | 1 | Lockwasher | |
| 20 | 1 | Nut | |
| 21 | 1 | Cover | |
| 22 | 4 | Nut | |
| 23 | 2 | Cable Tie Mounting | |
| 24 | 49 | Cable Strap | |
| 25 | 1 | Cable Tie Mounting | |
| 26 | 1 | Bolt | |
| 27 | 1 | 293-9452 | Cable Tie Mounting |
| (1) | Caterpillar strongly recommends that machines (S/N: LAJ1-230) perform the update outlined in Special Instruction, REHS9332, "Procedure to Relocate the Circuit Breaker Group on the 797F Off-Highway Truck". For machines that have already done the procedure outlined in REHS9332, refer to section "Machines LAJ 00231–Up" of this document with its corresponding parts list, to update the chassis wiring. |
| Required Parts - Chassis Wiring (S/N: LAJ231 - Up) | ||
| Qty | Part Number | Description |
| 1 | Wire As | |
| 1 | Grommet | |
| 5 | Cable Strap | |
| 6 | Hard Washer | |
| 3 | Nut | |
| 1 | Cover As | |
| 1 | Relay Gp | |
| 1 | Bolt | |
| 2 | Washer | |
| 1 | Heat Shrink Tube
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| 1 | Fuse | |
| 1 | Lockwasher | |
| 5 | Hard Washer | |
| 1 | Nut | |
| 3 | Bolt | |
| 2 | Bolt | |
| 1 | Cable Tie Mounting | |
| 1 | Chassis Harness As | |
| 1 | Lockwasher | |
| 1 | Nut | |
| 1 | Cover | |
| 3 | Bolt | |
| 3 | Cable Tie Mounting | |
| 50 | Cable Strap | |
| 1 | Cable Tie Mounting | |
| 1 | Bolt | |
| 4 | Hard Washer | |
| Required Parts - Pump Preparation | ||
| Qty | Part Number | Description |
| 1 | Pressure Sensor Gp | |
| 1 | O-Ring Seal | |
| Required Parts - Pump Fuel Line Installation (Without Heater) | ||
| Qty | Part Number | Description |
| 1 | O-Ring Plug | |
| 1 | O-Ring Seal | |
| 1 | Fuel Pump Gp | |
| 2 | O-Ring Seal | |
| 2 | Bolt | |
| 10 | Hard Washer | |
| 4 | Nut | |
| 2 | Bolt | |
| 2 | Bolt | |
| 1 | Bolt | |
| 4 | O-Ring Seal | |
| 3 | Elbow | |
| 3 | O-Ring Seal | |
| 1 | Hose As(1) | |
| (1) | Hose assembly is not serviceable, and is not included in the kit. Refer to Hydraulic Information System (HIS) for instructions to build the hose assembly. |
| Required Parts - Pump Fuel Line Installation (With Heater) | ||
| Qty | Part Number | Description |
| 1 | O-Ring Plug | |
| 1 | O-Ring Seal | |
| 1 | Fuel Pump Gp | |
| 2 | O-Ring Seal | |
| 2 | Bolt | |
| 13 | Hard Washer | |
| 4 | Nut | |
| 2 | Bolt | |
| 2 | Bolt | |
| 1 | Bolt | |
| 1 | O-Ring Seal | |
| 1 | Elbow | |
| 1 | O-Ring Seal | |
| 1 | Elbow | |
| 5 | O-Ring Seal | |
| 1 | Bracket As | |
| 2 | Taperlock Stud | |
| 2 | Nut | |
| 2 | Hard Washer | |
| 2 | Bolt | |
| 2 | Elbow | |
| 4 | O-Ring Seal | |
| 2 | Connector | |
| 1 | Hose As(1) | |
| 1 | Hose As(1) | |
| 1 | Hose As(1) | |
| 1 | Bracket As | |
| 1 | Clip | |
| 1 | Bolt | |
| (1) | Hose assembly is not serviceable, and is not included in the kit. Refer to Hydraulic Information System (HIS) for instructions to build the hose assembly. |
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.
- Refer to Operation and Maintenance Manual, SEBU8417, "Prepare the Machine for Maintenance".
Procedure Engine Mounted Components
| Required Parts - Engine Mounted Components | |||
| Item | Qty | Part Number | Description |
| - | 8 | Gasket | |
| - | 12 | O-Ring Seal | |
| 1 | 1 | Control Harness As | |
| 2 | 1 | Sensor Harness As | |
| 3 | 15 | Cable Strap | |
| 4 | 1 | Adapter | |
| 5 | 1 | O-Ring Seal | |
| 6 | 1 | Pressure Sensor Gp | |
| 7 | 1 | O-Ring Seal | |
| 8 | 1 | Connector Plug As | |
Engine ECM Harness Replacement
- 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 g03735430 View of the Engine ECM on the front of the Engine - Disconnect the atmospheric pressure sensor 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 - Remove and discard the 376-1303 Engine Harness As.
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Illustration 4 g03737512 View of the Engine ECM on the front of the Engine
(1)454-8533 Control Harness As - Connect harness assembly (1) to the ECM and the mounting plate. Reuse the retained hardware from Step 1.
- Connect harness assembly (1) to the atmospheric pressure sensor and the remaining connections for the engine harnesses.
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| Illustration 1 | g03735398 |
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View of the Engine ECM on the front of the Engine (A) (B) (C) (D) (E) (F) (G) | |
Engine Jumper Harness Connection and Routing
- 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 - 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 - Route harness assembly (2) along the existing engine harness assembly. Secure harness assembly (2) by using cable straps (3).
Note: Removing the intake tubes 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 - 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 - Peel back the boot and pass harness assembly (2) through the boot.
Connect the "T776" wire from harness assembly (2) to position "26". 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.
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| Illustration 5 | g03737528 |
FTP Inlet Pressure Sensor Replacement
- Disconnect harness assembly (A) from pressure sensor (B).
- 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 - Install adapter (4) with O-ring seal (5) onto the connector.
- Install pressure sensor group (6) with O-ring seal (7) onto adapter (4).
- 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.
- With the harness disconnected, remove the purple cap/wedge.
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Illustration 13 g03737895 View of the connector - 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 - Insert the retained wires into new connector plug assembly (8).
Note: Ensure that the wires are placed in the correct position.
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Illustration 15 g03737939 - Secure the green cap/wedge onto the new connector plug assembly.
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Illustration 12 g03737870 View of the harness assembly Show/hide table
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 - With the harness disconnected, remove the purple cap/wedge.
- Connect harness assembly (A) with new connector (8) to sensor (6) and secure the red locking tab.
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| Illustration 10 | g03737730 |
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View of the right-hand side of the engine (A) Harness assembly (B) Pressure sensor | |
Procedure - Chassis Wiring Updates
Machines LAJ 00001–00230
Note: Caterpillar strongly recommends that machines (S/N: LAJ1-230) perform the update outlined in Special Instruction, REHS9332, "Procedure to Relocate the Circuit Breaker Group on the 797F Off-Highway Truck".
Note: For machines that have already done the procedure outlined in REHS9332, refer to section "Machines LAJ 00231–Up" of this document to update the chassis wiring.
Note: Refer to Schematic, UENR2575 for additional wiring information.
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| Illustration 17 | g03737995 |
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Schematic for the Clean Fuel Module (CFM) Retrofit Kit | |
| Required Parts - Chassis Wiring (S/N: LAJ1-230) | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | Wire As | |
| 2 | 1 | Grommet | |
| 3 | 5 | Cable Strap | |
| 4 | 6 | Hard Washer | |
| 5 | 3 | Nut | |
| 6 | 4 | Bolt | |
| 7 | 1 | Relay Gp | |
| 8 | 1 | Bolt | |
| 9 | 3 | Washer | |
| 10 | 1 | Heat Shrink Tube
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| 11 | 1 | Fuse | |
| 12 | 1 | Lockwasher | |
| 13 | 10 | Hard Washer | |
| 14 | 1 | Nut | |
| 15 | 2 | Bolt | |
| 16 | 1 | Bolt | |
| 17 | 1 | Nut | |
| 18 | 1 | Chassis Harness As | |
| 19 | 1 | Lockwasher | |
| 20 | 1 | Nut | |
| 21 | 1 | Cover | |
| 22 | 4 | Nut | |
| 23 | 2 | Cable Tie Mounting | |
| 24 | 49 | Cable Strap | |
| 25 | 1 | Cable Tie Mounting | |
| 26 | 1 | Bolt | |
| 27 | 1 | 293-9452 | Cable Tie Mounting |
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| Illustration 18 | g03738097 |
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Typical view of the arrangement of the connection to a terminal | |
- Prepare the machine for maintenance. Ensure that there is not any power to the breaker box.
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Illustration 19 g06112195 View of breaker box location
(A) Cover - Remove cover (A) and retain mounting hardware (F).
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Illustration 20 g06140204 View of box after rework and hole locations
(A) Cover
(AA)60 mm (2.36inch)
(AB)24.5 mm (0.96 inch)
(B)9 mm diameter hole
(BB)80 mm (3.15 inch) - Drill four
9 mm holes (B) in cover (A) in locations shown in illustration 20.Show/hide table
Illustration 21 g06140186 View of relay mount hole location
(A) Cover
(CC)40 mm (1.57 inch)
(DD)44 mm (1.73inch)
(E)6.6 mm (0.26 inch) diameter hole - Drill one
6.6 mm hole (E) in cover (A) in location shown in illustration 21.Show/hide table
Illustration 22 g06112501 View of breaker box with cover removed
(1)448-1224448-1224 Wire As
(2)9V-2818 Grommet
(3)7K-1181 Cable Strap
(4)8T-4121 Hard Washer
(5)344-5675 Nut - Route wire assembly (1) through the side of the breaker box assembly with grommet (2). Secure the ring terminal end of wire assembly (1) to the junction block by using hard washer (4) and nut (5).
Note: Refer to Illustration 18 for a typical view of a terminal connection.
- Secure terminal cover to wire assembly (1) with cable strap (3).
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Illustration 23 g06140192 View of relay on breaker box cover
(A) Cover
(7)303-1256 Relay Gp
(8)7X-2534 Bolt
(9)9X-8256 Washer
(10)125-7875 Heat Shrink Tube
(11)267-2680 Fuse
(17)5C-2890 - Position relay (7) onto cover (A) and secure with one bolt (8), two washers (9), and one nut (17).
- Insert fuse (11) into relay group (7).
Note: Do not set any fuses in the remaining not-switched circuit and replace the fuse cover.
- Attach
30 mm (1.18 inch) of heat shrink tube (10) to the unused terminal of relay group (7).Show/hide table
Illustration 24 g06140189 View of relay connected to harnesses
(1)448-1224 Wire As
(3)7K-1181 Cable Strap
(7)303-1256 Relay Gp
(9)9X-8256 Washer
(12)9F-5644 Lockwasher
(13)8T-4224 Hard Washer
(14)344-5674 Nut
(18)455-9414 Chassis Harness As
(19)1H-3244 Lockwasher
(20)344-5673 Nut - Position terminal end of wire assembly (1) onto relay (7). Secure with one lockwasher (12), one washer (13), and one nut (14).
Note: Refer to Illustration 18 for a typical view of a terminal connection.
- Secure terminal cover of wire assembly (1) with one cable strap (3).
- Connect plug of harness (18) to relay (7).
- Position terminal end of harness (18) onto relay (7). Secure with one lockwasher (19), one washer (9), and one nut (20).
Note: Refer to Illustration 18 for a typical view of a terminal connection.
- Secure terminal cover of harness (18) with one cable strap (3).
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Illustration 25 g06140206 View of breaker box after update
(A) Cover
(F) Retained Hardware
(6)8T-4189 Bolt
(13)8T-4224 Hard Washer
(16)8T-4908 Bolt
(18)455-9414 Chassis Harness As
(21)449-0087 Cover
(22)5P-7970 Nut
(24)204-2281 Cable Strap
(27)293-9452 Cable Tie Mounting - Position cover (21) on cover (A). Secure with eight washers (13), four bolts (6), and four nuts (22).
- Secure cover (A) to breaker box with retained hardware (F), one cable mount (27), one washer (13), and one bolt (16).
- Secure harness (18) to cable mount (27) with one cable strap (24).
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Illustration 26 g06113019 View of harness routing
(18)455-9414 Chassis Harness As
(24)204-2281 Cable Strap - Route harness assembly (18) along the left-hand side of the frame by following the existing harness assemblies. Secure harness assembly (18) by using cable straps (24), as needed.
- Go to step 13 of section "Machines LAJ 00231–Up" in this document to continue routing harness (18).
Machines LAJ 00231–Up
Note: Refer to Schematic, UENR2575 for additional wiring information.
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| Illustration 27 | g03737995 |
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Schematic for the Clean Fuel Module (CFM) Retrofit Kit | |
| Required Parts - Chassis Wiring (S/N: LAJ231 - Up) | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | Wire As | |
| 2 | 1 | Grommet | |
| 3 | 5 | Cable Strap | |
| 4 | 6 | Hard Washer | |
| 5 | 3 | Nut | |
| 6 | 1 | Cover As | |
| 7 | 1 | Relay Gp | |
| 8 | 1 | Bolt | |
| 9 | 2 | Washer | |
| 10 | 1 | Heat Shrink Tube
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| 11 | 1 | Fuse | |
| 12 | 1 | Lockwasher | |
| 13 | 5 | Hard Washer | |
| 14 | 1 | Nut | |
| 15 | 3 | Bolt | |
| 16 | 2 | Bolt | |
| 17 | 1 | Cable Tie Mounting | |
| 18 | 1 | Chassis Harness As | |
| 19 | 1 | Lockwasher | |
| 20 | 1 | Nut | |
| 21 | 1 | Cover | |
| 22 | 3 | Bolt | |
| 23 | 3 | Cable Tie Mounting | |
| 24 | 50 | Cable Strap | |
| 25 | 1 | Cable Tie Mounting | |
| 26 | 1 | Bolt | |
| 27 | 4 | Hard Washer | |
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| Illustration 28 | g03738097 |
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Typical view of the arrangement of the connection to a terminal | |
- Prepare the machine for maintenance. Ensure that there is not any power to the breaker box.
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Illustration 29 g03749994 View of the breaker box assembly - Remove the cover from the breaker box assembly. Discard the cover and the hardware.
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Illustration 30 g03750008 (A) 8N-0869 Terminal Cover
(1)448-1224 Wire As
(2)9V-2818 Grommet
(3)7K-1181 Cable Strap
(4)8T-4121 Hard Washer
(5)344-5675 Nut - 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 (4) and nut (5).
- Slide terminal cover (A) over the connection and secure terminal cover (A) with cable strap (3).
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Illustration 31 g03750418 (6) 449-0088 Cover As
(7)303-1256 Relay Gp
(8)7X-2534 Bolt
(9)9X-8256 Washer
(10)125-7875 Heat Shrink Tube
(11)267-2680 Fuse - Locate cover assembly (6). Secure relay group (7) to cover assembly (6) by using bolt (8) and washer (9).
- Insert fuse (11) into relay group (7).
Note: Do not set any fuses in the remaining not-switched circuit and replace the fuse cover.
- Attach
30 mm (1.18 inch) of heat shrink tube (8) to the unused terminal of relay group (7).Show/hide table
Illustration 32 g06132539 (B) 135-2543 Boot
(1)448-1224 Wire As
(3)7K-1181 Cable Strap
(6)449-0088 Cover As
(7)303-1256 Relay Gp
(12)264-3617 Lockwasher
(13)8T-4224 Hard Washer
(14)344-5674 Nut
(15)8T-4189 Bolt
(16)8T-4908 Bolt
(17)345-3753 Cable Tie Mounting
(27)5P-4116 Hard Washer - Secure cover assembly (6) to the box assembly by using three bolts (15), one bolt (16), one cable tie mounting (17), and four hard washers (27).
Connect the 131-1497 Ring Terminal As from wire assembly (1) to the stud on relay group (7) by using lockwasher (12), hard washer (13), and nut (14).
Note: Refer to Illustration 28 for a typical view of a terminal connection.
Slide the boot over the connection and secure the boot with cable strap (3).
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Illustration 33 g03750011 (3) 7K-1181 Cable Strap
(7)303-1256 Relay Gp
(9)9X-8256 Washer
(18)455-9414 Chassis Harness As
(19)1H-3244 Lockwasher
(20)344-5673 Nut - Connect the 131-1496 Terminal As from harness assembly (18) to the top stud on relay group (7) by using lockwasher (19), washer (9), and nut (20).
Note: Refer to Illustration 28 for a typical view of a terminal connection.
Slide the boot over the connection and secure the boot with cable strap (3).
- Connect the plug connection from harness assembly (18) to the top of relay group (7).
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Illustration 34 g03750012 (6) 449-0088 Cover As
(13)8T-4224 Hard Washer
(16)8T-4908 Bolt
(17)345-3753 Cable Tie Mounting
(18)455-9414 Chassis Harness As
(21)449-0087 Cover
(22)8T-4200 Bolt
(23)204-8000 Cable Tie Mounting
(24)204-2281 Cable Strap - Secure cover (21) to the top of cover assembly (6) by using three bolts (22), four hard washers (13), bolt (16), and cable tie mounting (23).
Secure harness assembly (18) to cable tie mounting (23) with cable strap (24). Secure harness assembly (18) to cable tie mounting (17) by using two cable straps (24).
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Illustration 35 g03750780 (18) 455-9414 Chassis Harness As
(23)204-8000 Cable Tie Mounting
(24)204-2281 Cable Strap - Route harness assembly (18) along the left-hand side of the frame. Secure harness assembly (18) to first available boss by using cable tie mounting (23), cable strap (24), and the existing hardware.
Route harness assembly (18) along the left-hand side of the frame by following the existing harness assemblies. Secure harness assembly (18) by using cable straps (24), as needed.
Note: Make a loop in harness assembly (18) to account for excess wire length. Refer to Illustration 35.
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Illustration 36 g03750857 (C) Bolt
(D) Washer
(18)455-9414 Chassis Harness As
(24)204-2281 Cable Strap - Continue to route harness assembly (18) up the left-hand side of the frame. Secure the terminal connection from harness assembly (18) to the available ground boss by using existing bolt (C) and existing washer (D).
Note: Ensure that the ground boss is clean. Use sand paper, as needed.
Route harness assembly (18) toward the rear of the machine. Use cable straps (24) to secure harness assembly (18), as needed.
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Illustration 37 g03750784 (18) 455-9414 Chassis Harness As
(24)204-2281 Cable Strap - 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 (24), as needed.
- 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 terminal "T-2" into Position 7 of the Engine Interface harness.
Insert terminal "T-3" into Position 11 of the Engine Interface harness.
Insert terminal "T-5" into Position 26 of the Engine Interface harness.
Insert terminal "T-6" 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 38 g03751103 (4) 8T-4121 Hard Washer
(5)344-5675 Nut
(15)8T-4189 Bolt
(18)455-9414 Chassis Harness As
(23)204-8000 Cable Tie Mounting
(24)204-2281 Cable Strap
(25)381-2621 Cable Tie Mounting - Route harness assembly (18) down the frame to the fuel filters. Secure harness assembly with cable straps (24), as needed.
- Secure harness assembly (18) to the rear filter base by using two bolts (15), four hard washers (4), two nuts (5), cable tie mounting (23), cable tie mounting (25), and two cable straps (24).
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Illustration 39 g03751277 (3) 7K-1181 Cable Strap
(4)8T-4121 Hard Washer
(18)455-9414 Chassis Harness As
(23)204-8000 Cable Tie Mounting
(24)204-2281 Cable Strap
(26)8T-4196 Bolt - 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 (24) and cable straps (3), as needed.
Secure harness assembly (18) to the bracket assembly for the fuel filters by using bolt (26), hard washer (4), cable tie mounting (23), and cable strap (24).
- Connect harness assembly (18) to the pressure sensor on the top of the fuel pump.
Connect harness assembly (18) to the available connector on the fuel pump.
Procedure - Pump Preparation
| Required Parts - Pump Preparation | |||
| Item | Qty | Part Number | Description |
| 1 | 1 | Pressure Sensor Gp | |
| 2 | 1 | O-Ring Seal | |
- Locate the CFM pump.
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Illustration 41 g06020604 (1) 320-3061 Pressure Sensor Gp
(2)228-7101 O-Ring Seal - Secure pressure sensor group (1) to the CFM pump with O-ring seal (2).
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| Illustration 40 | g03738953 |
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View of the CFM pump | |
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.
- Drill a
25 mm (0.98 inch) diameter hole in the cover for the CFM pump group. Refer to Illustration 42 for the hole location.Insert grommet (1) into the drilled hole. Insert the wiring harness through grommet (1) and connect to the pump group.
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| Illustration 42 | g03742838 |
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(AA) (AB) (AC) | |
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| Illustration 43 | g03742479 |
| (1) Grommet (part of the wiring 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
| Required Parts - Pump Fuel Line Installation (Without Heater) | |||
| Item | Qty | Part Number | Description |
| 1 | 1 | O-Ring Plug | |
| 2 | 1 | O-Ring Seal | |
| 3 | 1 | Fuel Pump Gp | |
| 4 | 2 | O-Ring Seal | |
| 5 | 2 | Bolt | |
| 6 | 10 | Hard Washer | |
| 7 | 4 | Nut | |
| 8 | 2 | Bolt | |
| 9 | 2 | Bolt | |
| 10 | 1 | Bolt | |
| 11 | 1 | Sleeve | |
| 12 | 4 | O-Ring Seal | |
| 13 | 3 | Elbow | |
| 14 | 3 | O-Ring Seal | |
| 15 | 1 | Hose As(2) | |
| (1) | Part of the |
| (2) | Hose assembly is not serviceable, refer to Hydraulic Information System (HIS) |
- Remove and discard the following components:
- Adapter (A)
- Elbow (B)
- Tube assembly (C)
- Two bolts (D)
- Two washers (E)
- Plate (F)
- Half flange (G)
- Half flange (H)
- Grommet (J)
- Elbow (K)
- Three bolts (L)
- Three washers (M)
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Illustration 45 g03749391 ( N) Ball valve
(P) Connector
(R) Hose assembly - Disconnect hose assembly (R) from connector (P).
Remove ball valve (N) and connector (P). Retain ball valve (N). Discard connector (P).
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Illustration 46 g03749401 (1) 9S-4181 O-Ring Plug
(2)238-5084 O-Ring Seal - Secure O-ring plug (1) with O-ring seal (2) to the rear filter base.
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Illustration 47 g03749404 (3) 457-5703 Fuel Pump Gp
(4)225-6948 O-Ring Seal
(5)6V-1819 Bolt
(6)8T-4121 Hard Washer
(7)8T-4133 Nut
(8)8T-5005 BoltShow/hide table
Illustration 48 g03749461 (3) 457-5703 Fuel Pump Gp
(6)8T-4121 Hard Washer
(9)8T-6685 Bolt
(10)5N-8427 Bolt
(11)450-0342 Sleeve - Secure fuel pump group (3) to the front filter base by using two O-ring seals (4), two bolts (5), eight hard washers (6), four nuts (7), and two bolts (8).
Secure fuel pump group (3) from the top by using two bolts (9), two hard washers (6), bolt (10), and sleeve (11).
Note: Tighten the two bolts (5), two bolts (8), two bolts (9), and one bolt (10) by hand before you start the torque sequence. hand tightening the seven bolts will help prevent prestressing of the pump assembly.
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Illustration 49 g03749477 (3) 457-5703 Fuel Pump Gp - Remove and discard the two plugs from fuel pump group (3).
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Illustration 50 g03749743 (N) Ball valve
(3)457-5703 Fuel Pump Gp
(12)5P-7701 O-Ring Seal
(13)152-9840 Elbow
(14)228-7094 O-Ring Seal - Secure retained ball valve (N) with O-ring seal (12) onto fuel pump group (3).
Secure elbow (13) with O-ring seal (12) and O-ring seal (14) onto retained ball valve (N).
Secure elbow (13) with O-ring seal (12) and O-ring seal (14) onto the top of fuel pump group (3).
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Illustration 51 g06089166 (R) Hose assembly
(12)5P-7701 O-Ring Seal
(13)152-9840 Elbow
(14)228-7094 O-Ring Seal
(15)446-2342 Hose As - Secure retained hose assembly (R) to middle elbow (13).
Secure hose assembly (15) between upper elbow (13) and lower elbow (13).
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| Illustration 44 | g03749389 |
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(A) Adapter
(B) Elbow (C) Tube assembly (D) Bolt (E) Washer (F) Plate (G) Half flange (H) Half flange (J) Grommet (K) Elbow (L) Bolt (M) Washer | |
Installation With a Fuel Heater
| Required Parts - Pump Fuel Line Installation (With Heater) | |||
| Item | Qty | Part Number | Description |
| 1 | 1 | O-Ring Plug | |
| 2 | 1 | O-Ring Seal | |
| 3 | 1 | Fuel Pump Gp | |
| 4 | 2 | O-Ring Seal | |
| 5 | 2 | Bolt | |
| 6 | 13 | Hard Washer | |
| 7 | 4 | Nut | |
| 8 | 2 | Bolt | |
| 9 | 2 | Bolt | |
| 10 | 1 | Bolt | |
| 11 | 1 | Sleeve | |
| 12 | 1 | O-Ring Seal | |
| 13 | 1 | Elbow | |
| 14 | 1 | O-Ring Seal | |
| 15 | 1 | Elbow | |
| 16 | 5 | O-Ring Seal | |
| 17 | 1 | Bracket As | |
| 18 | 2 | Taperlock Stud | |
| 19 | 2 | Nut | |
| 20 | 2 | Hard Washer | |
| 21 | 2 | Bolt | |
| 22 | 2 | Elbow | |
| 23 | 4 | O-Ring Seal | |
| 24 | 2 | Connector | |
| 25 | 1 | Hose As(2) | |
| 26 | 1 | Hose As(2) | |
| 27 | 1 | Hose As(2) | |
| 28 | 1 | Bracket As | |
| 29 | 1 | Clip | |
| 30 | 1 | Bolt | |
| (1) | Part of the |
| (2) | Hose assembly is not serviceable, refer to Hydraulic Information System (HIS) |
- Disconnect hose assembly (N).
Remove and discard the following components:
- Hose assembly (A)
- Elbow (B)
- Hose assembly (C)
- Adapter (D)
- Adapter (E)
- Plate assembly (G)
- Elbow (H)
- Hose assembly (J)
- Plug (K)
- Adapter (M)
Remove and retain the following parts:
- Thermal compensator valve (F)
- Ball valve (L)
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Illustration 53 g03749394 ( P) Bolt
(R) Washer
(1)9S-4181 O-Ring Plug
(2)238-5084 O-Ring Seal - Remove and discard three bolts (P) and three washers (R) that secure the forward filter base to the bracket assembly.
- Install O-ring plug (1) with O-ring seal (2) into the available port on the rear filter base.
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Illustration 54 g03749404 (3) 457-5703 Fuel Pump Gp
(4)225-6948 O-Ring Seal
(5)6V-1819 Bolt
(6)8T-4121 Hard Washer
(7)8T-4133 Nut
(8)8T-5005 BoltShow/hide table
Illustration 55 g03749461 (3) 457-5703 Fuel Pump Gp
(6)8T-4121 Hard Washer
(9)8T-6685 Bolt
(10)5N-8427 Bolt
(11)450-0342 Sleeve - Secure fuel pump group (3) to the front filter base by using two O-ring seals (4), two bolts (5), eight hard washers (6), four nuts (7), and two bolts (8).
Secure fuel pump group (3) from the top by using two bolts (9), two hard washers (6), bolt (10), and sleeve (11).
Note: Tighten the two bolts (5), two bolts (8), two bolts (9), and one bolt (10) by hand before you start the torque sequence. hand tightening the seven bolts will help prevent prestressing of the pump assembly.
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Illustration 56 g03749477 (3) 457-5703 Fuel Pump Gp - Remove and discard the two plugs from fuel pump group (3).
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Illustration 57 g03749396 (L) Ball valve
(N) Hose assembly
(2)238-5084 O-Ring Seal
(3)457-5703 Fuel Pump Gp
(12)5P-7701 O-Ring Seal
(13)152-9840 Elbow
(14)228-7094 O-Ring Seal
(15)6V-9005 Elbow
(16)228-7093 O-Ring Seal - Secure retained ball valve (L) with O-ring seal (12) to the lower port on fuel pump group (3).
Secure elbow (13) with O-ring seal (12) and O-ring seal (14) to retained ball valve (L).
Connect existing hose assembly (N) to elbow (13).
- Secure elbow (15) with O-ring seal (16) and O-ring seal (2) to the upper port on fuel pump group (3).
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Illustration 58 g03749408 - Remove and discard the two bolts and washers that secure the bracket assembly for the brake filter to the frame.
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Illustration 59 g03749901 (F) Thermal compensator valve
(6)8T-4121 Hard Washer
(16)228-7093 O-Ring Seal
(17)462-8886 Bracket As
(18)310-1945 Taperlock Stud
(19)329-3356 Nut
(20)198-4778 Hard Washer
(21)8T-4172 Bolt
(22)8T-6684 Elbow
(23)238-5082 O-Ring Seal
(24)6V-8714 Connector - Secure bracket assembly (17) to the frame by using two studs (18), two nuts (19), and two hard washers (20).
Secure retained thermal compensator valve (F) to bracket assembly (17) by using two bolts (21) and two hard washers (6).
Secure two elbows (22) with two O-ring seals (16), and two O-ring seals (23) to thermal compensator valve (F).
Secure connector (24) with O-ring seal (16) and O-ring seal (23) to thermal compensator valve (F).
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Illustration 60 g03749928 (15) 6V-9005 Elbow
(16)228-7093 O-Ring Seal
(22)8T-6684 Elbow
(23)238-5082 O-Ring Seal
(24)6V-8714 Connector
(25)462-8880 Hose As
(26)462-8881 Hose As - Secure hose assembly (25) between connector (15) and connector (24).
Secure connector (24) with O-ring seal (16) and O-ring seal (23) to the core cooler assembly.
Secure hose assembly (26) between elbow (22) and connector (24).
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Illustration 61 g03749940 (S) Tee
(T) Bolt
(U) Washer
(6)8T-4121 Hard Washer
(22)8T-6684 Elbow
(27)462-8879 Hose As
(28)289-9754 Bracket As
(29)4D-7388 Clip
(30)8T-4136 Bolt - Secure hose assembly (27) between elbow (22) and tee (S).
- Secure bracket assembly (28) to the plate assembly for the core cooler assembly by using existing bolt (T) and washer (U).
Secure hose assembly (27) to bracket assembly (28) by using clip (29), bolt (30), and hard washer (6).
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| Illustration 52 | g03749784 |
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(A) Hose assembly
(B) Elbow (C) Hose assembly (D) Adapter (E) Adapter (F) Thermal compensator valve (G) Plate assembly (H) Elbow (J) Hose assembly (K) Plug (L) Ball valve (M) Adapter (N) Hose assembly | |
Engine Software
- 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 62 g03749242 Typical view - Navigate to the "Engine Configuration Parameters" and change the status of the "Electric Fuel Transfer Pump Installation Status" to "Installed".
