69D and 769D Off-Highway Trucks and 771D Quarry Truck Machine Systems Caterpillar

Fuel Tank - Remove

Usage:

769D 5SS

Removal Procedure

Start By:

Install the retaining ring and pin (body). Refer to Disassembly and Assembly, "Retaining Ring and Pin (Body) - Remove and Install".

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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, PERJ1017, "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.

Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will prevent dirt from entering the internal components.

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Illustration 1	g00484500

Slowly open the fuel tank cap assembly in order to release the pressure in the fuel tank. Position a suitable container below the fuel tank in order to contain the fuel for storage or disposal. Remove pipe plug (1) from the bottom of the fuel tank. Drain the fuel from the fuel tank. The capacity of the fuel tank is 530 L (140 US gal).
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Illustration 2 g00485059
Remove tie strap (2) that is located behind fuel tank (3) on the inside of the frame assembly.
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Illustration 3 g00485080
Remove two bolts (4), the hard washers and two clips (5).
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Illustration 4 g00485081
Turn ball valve (8) to the OFF position.
Put identification on all hose assemblies for installation purposes. Disconnect two hose assemblies (6) and (7) from the fuel tank.
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Illustration 5 g00485082
Remove locknut (10), the hard washer and the bolt from the bottom of the fuel tank. Check the condition of two mountings (9) for wear or damage. If necessary, replace the mountings after the fuel tank has been removed.
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Illustration 6 g00485084
Pull float sender wiring harness (11) outward until the electrical connector exits the fuel tank.
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Illustration 7 g00485085
Disconnect float sender wiring harness (11) from chassis wire harness (12) at the electrical connection.
Pull chassis wire harness (12) from the rear of the fuel tank.
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Illustration 8 g00485122
Attach a suitable lifting device to the fuel tank, as shown. Secure the lifting device to a hoist. Apply a slight amount of tension on the lifting device, but do not lift the fuel tank.
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Illustration 9 g00485123
Remove two nuts (14), the hard washers and U-bolt (13). Repeat this procedure for the remaining U-bolt.
Lift the fuel tank slightly in order to clear the frame assembly. Carefully move the fuel tank away from the frame assembly until the ball valve has cleared the frame assembly. The weight of the fuel tank is 236 kg (520 lb).