2007/06/04 Caterpillar

Off-Highway Truck:

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

Service Magazine SEPD0795, 1 August 2005, "A Redesigned Fuel Tank Eliminates the Filler Neck and Fuel Cap From Coming In Contact with Certain MSD Bodies". Disregard this article. See the replacement article that follows.

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceService Magazine, SEPD0025, 02 July 1990, "Welding On Fuel And Hydraulic Tanks"

Description of Change: The filler neck and fuel cap may come in contact with certain MSD bodies. On some 789C Off-Highway Trucks, the filler neck and fuel cap are located top of the fuel tank. The ribs on the MSD II bodies for the 789C Off-Highway Truck may contact the filler neck and the fuel cap. This contact does not allow the body to be fully lowered. A redesigned fuel tank eliminates the filler neck and fuel cap from coming in contact with the ribs on certain MSD bodies. The interference with the body is eliminated by removing the filler neck and the fuel cap. The filling of the fuel tank is accomplished with the fast fill fuel arrangement.

Adaptable To: The redesigned 150-9548 Fuel Tank As is effective with the following machines:

• 789C (S/N: 2BW598-UP)

The previous 150-9548 Fuel Tank As may be reworked to the latest design of the fuel tank. The following machines may be reworked:

• 789C (S/N: 2BW1-597)

Refer to the instructions that follow in order to rework the 150-9548 Fuel Tank As .

Note: This procedure requires the use of the fast fill fuel arrangement in order to refuel the tank.

Rework Procedure

ReferenceRefer to the guidelines that are listed in Service Magazine, SEPD0025, 02 July 1990, "Welding On Fuel And Hydraulic Tanks".

ReferenceRefer to the guidelines that are listed in Special Instruction, REHS1841, "General Welding Procedures".

1. Remove the fuel cap.

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Illustration 1	g01186421

2. Use a suitable cutting device in order to remove filler neck (1) from the fuel tank.

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Illustration 2	g01186434
(A) 152.0 mm (6.00 inch) (B) 6.0 mm (0.24 inch)

3. Fabricate plate (2), as shown.

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Illustration 3	g01384790
(W1) 6.0 mm (0.24 inch) Fillet Weld

4. Install plate (2) at the location for filler neck (1). Weld (W1) is a continuous fillet weld.

5. Check the tank for leaks.