784C and 785C Off-Highway Trucks Machine Systems Caterpillar

Installation Procedure

1. Verify that all of the components of the fuel tank are clean and free of foreign material prior to installation.

2. Inspect all of the components for wear and replace the components, if necessary.

3. Determine the thickness of the shim packs for the mounts for fuel tank (1) in the following manner:
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   Illustration 1	g00508625

   1. Use two bolts (18) and the washers in order to install cap (19) onto the frame. Tighten two bolts (18) to a torque of 370 ± 50 N·m (273 ± 37 lb ft).

   2. Measure the vertical inside diameter between cap (19) and the frame. Record this measurement as Dimension (A).
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      Illustration 2	g00508646

   3. Measure the outside diameter of bar (21) on the side of fuel tank (1). Record this measurement as Dimension (B).

   4. In order to determine the desired thickness of shim pack (20), subtract Dimension (B) from Dimension (A). Assemble the shim pack in order to achieve a tolerance of 0.00 to −0.12 mm (0.00 to −0.005 inch). Record the required thickness of shim pack (20) after the fuel tank is positioned on the truck frame.

      Note: Do not install any shims at this time.

   5. Remove two bolts (18), the washers and cap (19).

   6. Repeat Step 3.a through Step 3.e for the other side of fuel tank (1).
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   Illustration 3	g00508610

4. Use a suitable lifting device and a hoist in order to position fuel tank (1). The weight of fuel tank (1) is 680 kg (1500 lb).
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   Illustration 4	g00508614

5. Use two bolts (18) and the washers in order to install shim pack (20) and cap (19). Tighten two bolts (18) to a torque of 370 ± 50 N·m (273 ± 37 lb ft).

6. Repeat Step 5 for the other side of fuel tank (1).
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   Illustration 5	g00508611

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   Illustration 6	g00508612

7. Install two mountings (16) and two mountings (17). Install two bolts (14), two washers (15) and the two washers. Remove the hoist and the lifting device.
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   Illustration 7	g00508609

8. Install hose assembly (13) and tighten hose clamp (12).
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   Illustration 8	g00508606

   Note: Apply 5P-3413 Pipe Sealant to the tapered external threads of elbow (11) and fuel shutoff valve (10) prior to installation.

9. Install fuel shutoff valve (10). Connect hose assembly (8) to fuel shutoff valve (10).

10. Install elbow (11). Connect hose assembly (9) to elbow (11).
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    Illustration 9	g00508600

11. Insert wire harness (6) into guard (5). Connect wire harness (7) to wire harness (6) at the electrical connection.
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    Illustration 10	g00508599

12. Install six bolts (3) and the washers in order to install guard (4).

13. Fill the fuel tank with fuel to the correct level. Prime the fuel system. Refer to Operation and Maintenance Manual, SEBU7173, "Fuel System - Prime" for the correct procedure.

End By:

1. Disconnect the retaining cable. Refer to Disassembly and Assembly, "Truck Body Retaining Cable - Remove and Install".