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797F Off-Highway Truck Field Assembly Caterpillar


Fuel Tank - Install

Usage:

797F LAJ

Parts and Specification Information

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Illustration 1g03842228
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Illustration 2g03851374
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Illustration 3g06051785
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Illustration 4g06051759
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Illustration 5g03853520
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Illustration 6g03853887
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Illustration 7g03854167
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Illustration 8g03868371
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Illustration 9g03883419
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Illustration 10g03887439

Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

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Table 1
Item  Part Number  Part Description  Qty  Specification  Approximate Weight 
272-3454 Fuel Tank Ar, 362-6655 Fuel Tank Ar, 362-8380 Fuel Tank Ar, 362-8383 Fuel Tank Ar, 362-6670 Fuel Tank Ar, 272-3453 Fuel Tank Ar, 311-8657 Fuel Filter Lines Gp 
1  280-1060  Fuel Tank Gp  1  7571 L (2000 US gal)  2744 kg (6050 lb) 
362-6660 7571 L (2000 US gal)  2744 kg (6050 lb)
362-8375 5110 L (1350 US gal)  2100 kg (4630 lb)
362-8390 5110 L (1350 US gal)  2100 kg (4630 lb)
280-1058 3785 L (1000 US gal)  1569 kg (3460 lb)
362-6650 3785 L (1000 US gal)  1569 kg (3460 lb)
2  196-9873  Plate As(1)  1     
297-4213 Plate As(2)   
3  7X-2488  Bolt  3     
4  8T-5439  Hard Washer  8     
5  7N-5656  Sleeve  3     
6  8N-1214  Mount As  6     
7  6V-7688  Locknut  3     
8  7X-2564  Bolt  2     
9  446-2342  Hose As  1     
10  228-7094  O-Ring Seal  1     
11  152-9840  Elbow  1     
12    Fuel Filter As  1     
12A  198-4777  Hard Washer  6     
12B  225-6948  O-Ring Seal  2     
12C  457-5703  Fuel Pump Gp  1     
13  281-5933  Elbow As  1     
9T-3752 Check Valve   
14  238-5082  O-Ring Seal  1     
15  228-7092  O-Ring Seal  1     
16  152-9840  Elbow  2     
159-4724 Ball Valve   
17  5P-7701  O-Ring Seal  4     
18  178-2345  Liquid Level Sensor Gp  1     
19  130-5300  Clip  1     
20  8T-4121  Hard Washer  19     
21  8T-4196  Bolt  8     
22  7K-1181  Cable Strap  3     
23  8T-4136  Bolt  1     
24  5P-9085  Clip  1     
25  337-8235  Bracket As  1     
26  322-6562  Sensor Harness As  1     
27  8T-4186  Bolt  2     
28  381-2621  Cable Tie Mounting  1     
29  204-2281  Cable Strap  14     
30  344-5675  Nut  2     
31  204-8000  Cable Tie Mounting  7     
32  320-3061  Pressure Sensor Gp  1     
33  228-7101  O-Ring Seal  1     
34  8T-4136  Bolt  5     
35  345-3753  Cable Tie Mounting  1     
36  125-8534  Plate As  1     
36A  200-6345  Mount  1     
37  9X-7287  O-Ring Seal  1     
38  231-7582  Adapter  1     
39  6V-4590  O-Ring Seal  1     
40  1P-4582  Half Flange  2     
41  8T-4185  Bolt  6     
42  8T-4223  Hard Washer  4     
43  8T-4183  Bolt  4     
44  462-8880  Hose As  1     
45  462-8879  Hose As  1     
46  446-2358  Hose As  1     
47  329-5515  Tee As  1     
48  456-5054  Adapter As  1     
49  3E-6773  O-Ring Seal  1     
50  436-5657  Fuel Level Sensor Gp  1     
51  462-2855  Fuel Tank Harness As(3)  1     
454-6590 Fuel Tank Harness As(4)       
454-6594 Fuel Tank Harness As(5)  1     
52  227-6715  Stud  3  Tighten to 35 ± 5 N·m (26 ± 4 lb ft)   
53  454-6591  Bracket As  1     
54  462-2856  Plate(3)  1     
454-6588 Plate(4)  1     
454-6595 Plate(5)  1     
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(1) Use with 7571 L (2000 US gal) tanks
(2) Use with 5110 L (1350 US gal) and 3785 L (1000 US gal) tanks
(3) Use with 7571 L (2000 US gal) tanks
(4) Use with 5110 L (1350 US gal) tanks
(5) Use with 3785 L (1000 US gal) tanks

Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and material. Retain the bolts, washers, clamps, flanges, and O-ring seals.

Note: Clean all mounting and contact surfaces free of wax, dirt, debris, paint, and grease. Chase all threaded holes with an appropriately sized tap.

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

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

Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

Installation Procedure

Start By:

  1. Install the hoist cylinders

Note: Before tightening the harness hardware, remove the slack from the harness assemblies and provide adequate strain relief.

There are three sizes available for the fuel tank for the 797F.

  • 7570 L (2000 US gal)

  • 5110 L (1350 US gal)

  • 3785 L (1000 US gal)

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Table 2
Fuel Tank Options and Associated Part Numbers 
Tank Size  Tank Arrangement  Tank Group  Mounting Group 
7570 L (2000 US gal)  272-3454 Fuel Tank Ar  280-1060 Fuel Tank Gp  288-4733 Fuel Tank Mounting Gp 
362-6655 Fuel Tank Ar 362-6660 Fuel Tank Gp  362-6672 Fuel Tank Mounting Gp 
5110 L (1350 US gal)  362-8380 Fuel Tank Ar  362-8375 Fuel Tank Gp  362-8385 Fuel Tank Mounting Gp 
362-8383 Fuel Tank Ar 362-8390 Fuel Tank Gp  362-8385 Fuel Tank Mounting Gp 
3785 L (1000 US gal)  272-3453 Fuel Tank Ar  280-1058 Fuel Tank Gp  292-1197 Fuel Tank Mounting Gp 
362-6670 Fuel Tank Ar 362-6650 Fuel Tank Gp  362-6671 Fuel Tank Mounting Gp 
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    Illustration 11g03851567

  1. Clean the mounting support bores on the chassis free of wax, dirt, debris, paint, and grease.
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    Illustration 12g03887393
    (55) 7X-2489 Bolt
    (56) 8T-4167 Hard Washer
    (57) 8X-2575 Cap
    (58) 8X-2576 Shim Pack

  2. Remove four bolts (55), four hard washers (56), two caps (57), and four shim packs (58). Retain the hardware.
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    Illustration 13g03851559
    (1) 280-1060 Fuel Tank Gp

  3. Clean the contact surface of the mounting trunnions and the bracket mounting on fuel tank arrangement (1) free of wax, dirt, debris, paint, and grease
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    Illustration 14g03887397
    (55) 7X-2489 Bolt
    (56) 8T-4167 Hard Washer
    (57) 8X-2575 Cap

  4. Reinstall two caps (57), four hard washers (56), and four bolts (55). Do not install the shim packs.
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    Illustration 15g03852050
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    Illustration 16g03852027

  5. Measure and record Dimension (X). Measure and record Dimension (Y). Subtract Dimension (X) from Dimension (Y) to determine the required shim pack thickness. Repeat for the other side.
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    Illustration 17g03887398
    (55) 7X-2489 Bolt
    (56) 8T-4167 Hard Washer
    (57) 8X-2575 Cap

  6. Remove four bolts (55), four hard washers (56), and two caps (57). Retain the hardware.
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    Illustration 18g03854365

  7. Clean three mounting surfaces free of wax, dirt, debris, paint, and grease.
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    Illustration 19g03887400
    (60) 8T-4136 Bolt
    (61) 8T-4121 Hard Washer
    (62) 6H-1147 Strip
    (63) 295-1486 Channel, 362-8378 Channel, or 293-3061 Channel

  8. Remove two plug assemblies (59).

  9. Remove six bolts (60), six hard washers (61), three plates (62), and one channel (63). Retain the hardware.

    Note: The bolts (60), hard washers (61), plates (62), and channel (63) are not present on fuel tanks equipped with a top mounted fuel level sensor.

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    Illustration 20g03887440
    (13) 281-5933 Elbow As 9T-3752 Check Valve
    (14) 238-5082 O-Ring Seal
    (15) 228-7092 O-Ring Seal
    (15A) 228-7094 O-Ring Seal
    (16) 152-9840 Elbow 159-4724 Ball Valve
    (17) 5P-7701 O-Ring Seal

  10. Install one O-ring seal (14), one fitting assembly (13), and one O-ring seal (15).

  11. Install one O-ring seal (17), one fitting assembly (16), and one O-ring seal (15A).

    Note: Item (13) 281-5933 Elbow As 9T-3752 Check Valve and Item (16) 152-9840 Elbow 159-4724 Ball Valve should be shipped assembled with O-ring seals.

    Note: The elbow assembly on fitting assembly (16) is not installed on trucks equipped with the fuel heater arrangement. If equipped with the fuel heater arrangement, refer to step 1 to connect the fuel heater lines.

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    Illustration 21g06051796
    (12) Fuel Filter Assembly
    (12A) 198-4777 Hard Washer
    (21) 8T-4196 Bolt

  12. Position fuel filter assembly (12) onto the fuel tank and install six hard washers (12A) and six bolts (21).
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    Illustration 22g06051802

  13. Remove 1 bolt (64), 1 bolt (65), 1 bolt (66), 2 bolts (67), 2 bolts (68), 7 nuts (69), 9 hard washers (70), and 7 spacers (71). Retain the hardware. Discard 7 spacer (71).
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    Illustration 23g06051824

  14. Install pump group (12C) and 2 O-ring seals (12B). Install 2 bolts (67), 4 hard washers (70), and 2 nuts (69). Install 2 bolts (68), 4 hard washers (70), and 2 nuts (69).
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    Illustration 24g06051844

  15. Install 2 washers (70), 1 bolt (64), and 1 bolt (66). Install 1 bolt (65).
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    Illustration 25g06051921
    (10) 228-7094 O-Ring Seal
    (11) 152-9840 Elbow
    (17) 5P-7701 O-Ring Seal
    (32) 320-3061 Pressure Sensor Gp
    (33) 228-7101 O-Ring Seal

  16. Install 1 O-ring seal (17), 1 elbow (11), 1 O-ring seal (10), and 1 hose assembly (9). Install 1 O-ring seal (17) and 1 fitting assembly (16).
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    Illustration 26g03855582
    (18) 178-2345 Liquid Level Sensor Gp
    (19) 130-5300 Clip
    (20) 8T-4121 Hard Washer
    (21) 8T-4196 Bolt
    (22) 7K-1181 Cable Strap
    (23) 8T-4136 Bolt
    (24) 5P-9085 Clip
    (25) 337-8235 Bracket As

  17. Install one liquid level sensor group (18). Install one clip (19), one hard washer (20), and one bolt (21). Install one bracket assembly (25), one clip (24), one hard washer (20), and one bolt (23). Install one cable strap (22).

  18. Refer to "Fuel Level Sensor Connect"to connect the bottom mounted fuel level sensor.

  19. Refer to "Fuel Level Sensor Install (if equipped)"to install and connect the top mounted fuel level sensor.
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    Illustration 27g03851607
    Use with 7571 L (2000 US gal) fuel tanks
    (2) 196-9873 Plate As
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    Illustration 28g03884127
    Use with 5110 L (1350 US gal) and 3785 L (1000 US gal) fuel tanks
    (2) 297-4213 Plate As

  20. Clean the contact surfaces of plate assembly (2) free of wax, dirt, debris, paint, and grease.
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    Illustration 29g03852016
    Typical Example
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    Illustration 30g03852019
    (2) 196-9873 Plate As
    (3) 7X-2488 Bolt
    (4) 8T-5439 Hard Washer
    (5) 7N-5656 Sleeve
    (6) 8N-1214 Mount As
    (7) 6V-7688 Locknut

  21. Install one plate assembly (2), six mount assemblies (6), three sleeves (5), six hard washers (4), three bolts (3), and three locknuts (7).
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    Illustration 31g03851945

  22. Clean the contact surface of the lower mounting pad free of wax, dirt, debris, paint, and grease.
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    Illustration 32g03883600
    3785 L (1000 US gal)
    (1) 280-1058 Fuel Tank Gp or the 362-6650 Fuel Tank Gp

  23. If installing the 280-1058 Fuel Tank Gp or the 362-6650 Fuel Tank Gp, use a suitable lifting device to install fuel tank group (1). The weight of fuel tank group (1) is approximately 1569 kg (3460 lb).
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    Illustration 33g03883598
    5110 L (1350 US gal)
    (1) 362-8375 Fuel Tank Gp or the 362-8390 Fuel Tank Gp

  24. If installing the 362-8375 Fuel Tank Gp or the 362-8390 Fuel Tank Gp, use a suitable lifting device to install fuel tank group (1). The weight of fuel tank group (1) is approximately 2100 kg (4630 lb).
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    Illustration 34g03851389
    7571 L (2000 US gal)
    (1) 280-1060 Fuel Tank Gp or the 362-6660 Fuel Tank Gp

  25. If installing the 280-1060 Fuel Tank Gp or the 362-6660 Fuel Tank Gp, use a suitable lifting device to install fuel tank group (1). The weight of fuel tank group (1) is approximately 2744 kg (6050 lb).
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    Illustration 35g03887409
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    Illustration 36g03887410
    (55) 7X-2489 Bolt
    (56) 8T-4167 Hard Washer
    (57) 8X-2575 Cap
    (58) 8X-2576 Shim Pack

  26. Install the required number of shims from shim packs (58) that was determined in step 5. Install one cap (57), two hard washers (56), and two bolts (55). Repeat for the opposite side.
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    Illustration 37g03852382
    (4) 8T-5439 Hard Washer
    (8) 7X-2564 Bolt

  27. Install two hard washers (4) and two bolts (8).
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    Illustration 38g03887411
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    Illustration 39g03887414
    (73) 439-1101 Hose As, 443-1258 Hose As, or 297-4210 Hose As

  28. Remove one cap (71) and one cap (72). Connect hose assembly (73).
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    Illustration 40g06052238
    (9) 446-2342 Hose As

  29. Remove one plug (74). Install one hose assembly (9).

    Note: Hose assembly (9) is not installed on trucks equipped with the fuel heater arrangement. If equipped with the fuel heater arrangement, refer to step 1 to connect the fuel heater lines.

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    Illustration 41g06052204
    (76) 465-8092 Hose As
    (77) 338-0086 Hose As

  30. Remove two plugs (75) from hose assembly (76) and hose assembly (77).
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    Illustration 42g06052219
    (76) 465-8092 Hose As
    (77) 338-0086 Hose As

  31. Connect hose assembly (76) and hose assembly (77).
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    Illustration 43g03887419
    (79) 8T-4136 Bolt
    (80) 8T-4121 Hard Washer

  32. Remove one receptacle plug (78).

  33. Remove one bolt (79) and one hard washer (80). Retain the hardware.
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    Illustration 44g03887420
    (82) 465-9475 Chassis Harness As

  34. Remove two receptacle plugs (81) from harness assembly (82).
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    Illustration 45g03887426
    (82) 465-9475 Chassis Harness As

  35. Route harness assembly (82) onto the fuel filter assembly and connect harness assembly (82) to the pressure sensor (A) and the fuel pump (B). Install two cable straps (22) and one cable strap (29).
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    Illustration 46g03855859
    (20) 8T-4121 Hard Washer
    (21) 8T-4196 Bolt
    (27) 8T-4186 Bolt
    (28) 381-2621 Cable Tie Mounting
    (29) 204-2281 Cable Strap
    (30) 344-5675 Nut
    (31) 204-8000 Cable Tie Mounting

  36. Install two mounts (31), one mount (28), five hard washers (20), one bolt (21), two bolts (27), two nuts (30), and three cable straps (29).
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    Illustration 47g03887431

  37. Remove six bolts (83), six washers (84), one cover (85), and one O-ring seal (86).
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    Illustration 48g03887432
    (20) 8T-4121 Hard Washer
    (37) 9X-7287 O-Ring Seal
    (38) 231-7582 Adapter
    (39) 6V-4590 O-Ring Seal
    (40) 1P-4582 Half Flange
    (41) 8T-4185 Bolt
    (42) 8T-4223 Hard Washer
    (43) 8T-4183 Bolt
    (87) 334-5817 Hose As

  38. Install one O-ring seal (37) onto one adapter (38). Install one adapter (38), six hard washers (20), six bolts (41). Install one O-ring seal (39) onto hose assembly (87). Position hose assembly (87) from the service center onto adapter (38). Install two half flanges (40), four hard washers (42), and four bolts (43).

Fuel Heater Connect (if equipped)

  1. Use the following steps to connect the fuel heater lines to the fuel tank.
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      Illustration 49g03883376
      (47) 329-5515 Tee As 159-4724 Ball Valve
      (17) 5P-7701 O-Ring Seal

    1. Install one O-ring seal (17) and one tee and ball valve assembly (47).

      Note: Item (47) 329-5515 Tee As 159-4724 Ball Valve should be shipped assembled with O-ring seals.

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      Illustration 50g03883423

    2. Remove three cap assemblies (88) and one cap (89).
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      Illustration 51g03883426
      (90) 8T-4136 Bolt
      (91) 8T-4121 Hard Washer
      (92) 4D-7388 Clip

    3. Remove one bolt (90), one washer (91), and one clip (92). Retain the hardware.
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      Illustration 52g03883427
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      Illustration 53g03883777
      (44) 462-8880 Hose As
      (45) 462-8879 Hose As
      (46) 446-2358 Hose As

    4. Install one hose assembly (44), one hose assembly (45), and one hose assembly (46).
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      Illustration 54g03883431
      (90) 8T-4136 Bolt
      (91) 8T-4121 Hard Washer
      (92) 4D-7388 Clip

    5. Install one clip (92), one washer (91) and one bolt (90).

Fuel Level Sensor Connect

Note: The following procedure is identical for all three fuel tank sizes.

  1. Use the following steps to connect the bottom mounted fuel level sensor.
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      Illustration 55g03887427
      (26) 322-6562 Sensor Harness As
      (95) 124-9325 Fuel Level Sensor Gp

    1. Remove one receptacle plug (93) from the fuel level sensor harness (95). Remove one receptacle plug (94) from harness assembly (26).
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      Illustration 56g03887428
      (26) 322-6562 Sensor Harness As
      (95) 124-9325 Fuel Level Sensor Gp

    2. Connect harness assembly (26) to the fuel level sensor harness (95).
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      Illustration 57g03887429
      (60) 8T-4136 Bolt
      (61) 8T-4121 Hard Washer
      (62) 6H-1147 Strip
      (63) 295-1486 Channel, 362-8378 Channel, or 293-3061 Channel

    3. Install one channel (63), three plates (62), six hard washers (61), and six bolts (60).
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      Illustration 58g03855708
      (20) 8T-4121 Hard Washer
      (26) 322-6562 Sensor Harness As
      (29) 204-2281 Cable Strap
      (31) 204-8000 Cable Tie Mounting
      (34) 8T-4136 Bolt
      (35) 345-3753 Cable Tie Mounting
      (36) 125-8534 Plate As

    4. install four mounts (31), four hard washers (20), and four bolts (34).

    5. Route harness assembly (26) and install six cable straps (29).

    6. Install one plate assembly (36), one mount (35), two hard washers (20), and two bolts (34).
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      Illustration 59g03855717
      (18) 178-2345 Liquid Level Sensor Gp
      (26) 322-6562 Sensor Harness As

    7. Connect harness assembly (26) to liquid level sensor (18).
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    Illustration 60g03887430
    (26) 322-6562 Sensor Harness As
    (29) 204-2281 Cable Strap
    (31) 204-8000 Cable Tie Mounting
    (36A) 200-6345 Mount
    (79) 8T-4136 Bolt
    (80) 8T-4121 Hard Washer
    (82) 465-9475 Chassis Harness As

  2. After the fuel tank has been installed, connect harness assembly (26) to the rear chassis harness. Install one mount (31), one hard washer (80), and one bolt (79).

  3. Position one mount (36A) and install two cable straps (29) in order to secure harness assembly (82) to the hoist cylinder lubrication line. Route harness assembly (82). Install two cable straps (29). Connect fuel level sensor harness assembly (26) to the chassis harness.

Fuel Level Sensor Install (if equipped)

  1. The following procedure is identical for all three fuel tank sizes.

  2. Use the following steps to install and connect the top mounted fuel level sensor.
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      Illustration 61g03883849

    1. Remove six bolts (96), six washers (97), one cover (98), and one O-ring seal (99).
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      Illustration 62g03883850
      (19) 130-5300 Clip
      (20) 8T-4121 Hard Washer
      (29) 204-2281 Cable Strap
      (34) 8T-4136 Bolt
      (48) 456-5054 Adapter As
      (49) 3E-6773 O-Ring Seal
      (50) 436-5657 Fuel Level Sensor Gp

    2. Install one adapter assembly (48), one O-ring seal (49), six washers (20), and six bolts (34).

    3. Install one fuel level sensor group (50). Tighten one fuel level sensor group (50) until the seal seats to the port surface. Tighten an additional 1/4 turn.

    4. Install one cable strap (29), one clip (19), one washer (20), and one bolt (34).

      Note: Use the cable strap to secure the excess harness length and provide strain relief.

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      Illustration 63g03883851
      (51) 462-2855 Fuel Tank Harness As, 454-6590 Sensor Harness As, or 454-6594 Sensor Harness As

    5. Connect one fuel tank harness assembly (51) to the fuel level sensor group.
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      Illustration 64g03883901
      (12A) 198-4777 Hard Washer
      (20) 8T-4121 Hard Washer
      (29) 204-2281 Cable Strap
      (31) 204-8000 Cable Tie Mounting
      (52) 227-6715 Stud

      Note: The green tape feature on the harness is to be centered within the clipping components.

    6. Install three studs (52). Tighten three studs (52) to a torque of 35 ± 5 N·m (26 ± 4 lb ft). Install three mounts (31), three hard washers (20), and three cable straps (29).
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      Illustration 65g03884160
      (20) 8T-4121 Hard Washer
      (30) 344-5675 Nut
      (53) 454-6591 Bracket As
      (54) 462-2856 Plate, 454-6588 Plate, or 454-6595 Plate

    7. Install one bracket assembly (53), one plate (54), three hard washers (20), and three nuts (30).
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      Illustration 66g03883915
      (20) 8T-4121 Hard Washer
      (29) 204-2281 Cable Strap
      (31) 204-8000 Cable Tie Mounting
      (34) 8T-4136 Bolt

    8. Install seven mounts (31), seven hard washers (20), seven bolts (34), and seven cable straps (29).

    9. Install three hard washers (12A) and three cable straps (29).
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      Illustration 67g03884021
      (12A) 198-4777 Hard Washer
      (20) 8T-4121 Hard Washer
      (27) 8T-4186 Bolt
      (31) 204-8000 Cable Tie Mounting
      (36) 125-8534 Plate As

    10. Install one plate (36), two mounts (31), one hard washer (20), and one bolt (53).

    11. Install one hard washer (12A), one mount (31), one hard washer (20), and one bolt (27).
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      Illustration 68g03884024
      (18) 178-2345 Liquid Level Sensor Gp
      (29) 381-2621 Cable Strap
      (51) 462-2855 Fuel Tank Harness As, 454-6590 Sensor Harness As, or 454-6594 Sensor Harness As

    12. Route fuel level sensor harness assembly (51) and install two cable straps (29).

    13. Connect harness assembly (51) to liquid level sensor (18).
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    Illustration 69g03884287
    (29) 204-2281 Cable Strap
    (31) 204-8000 Cable Tie Mounting
    (36A) 200-6345 Mount
    (51) 462-2855 Fuel Tank Harness As, 454-6590 Sensor Harness As, or 454-6594 Sensor Harness As
    (79) 8T-4136 Bolt
    (80) 8T-4121 Hard Washer
    (82) 465-9475 Chassis Harness As

  3. After the fuel tank has been installed, connect harness assembly (51) to the rear chassis harness. Install one mount (31), one hard washer (80), and one bolt (79).

  4. Position one mount (36A) and install two cable straps (29) in order to secure harness assembly (73) to the hoist cylinder lubrication line. Route harness assembly (82). Install two cable straps (29). Connect fuel level sensor harness assembly (51) to the chassis harness.

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