Fuel Sender Leaks on C-Series Multi Terrain Loaders and Skid Steer Loaders{1273} Caterpillar

Multi Terrain Loader:

277C (S/N: JWF1-216)

287C (S/N: MAS1-255)

297C (S/N: GCP1-304)

Skid Steer Loader:

246C (S/N: JAY1-365)

256C (S/N: DWS1-351)

262C (S/N: MST1-373)

272C (S/N: RED1-374)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

Leaks at the fuel sender have been reported on some C-Series Multi Terrain Loaders and Skid Steer Loaders. The leaking has been observed at the mounts for the fuel level sender on the fuel tank. These leaks occur when the fuel tank is full.

Solution

If a fuel leak in the area of the fuel sender is observed, follow the procedure below. No action is required if there are no signs of leakage from the area of the fuel sender.

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Illustration 1	g01407659

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Illustration 2	g01407819

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Illustration 3	g01407715

1. Remove the intake duct on the engine air cleaner (if equipped) by loosening the clamp on the air cleaner housing. Remove the duct from the mounting flange and put aside for reinstallation. Reference Illustrations 1, 2, and 3.

2. Disconnect the wiring harness connection for the fuel sender.

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Illustration 4	g01407824

3. Remove 5C-9553 Bolts and 8T-4205 Hard Washers from the top of the flange on the fuel sender. Lift 271-2912 Fuel Level Sender from the tank, but do not remove 271-2912 Fuel Level Sender completely. Reference Illustration 4.

4. Remove 151-2110 Gasket from the fuel sender and discard the gasket.

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Illustration 5	g01407858

5. Install 9R-7240 Gasket by routing the gasket down the harness for the fuel sender. Stretch 9R-7240 Gasket over the flange on the fuel sender. Ensure that the surface of 9R-7240 Gasket and the surface of the mounting flange are clean and dry. Reference Illustration 5.

6. Align the holes of the gasket with the holes in the flange on the fuel sender. Install all 5C-9553 Bolts and 8T-4205 Hard Washers through the flange and the gasket.

7. Ensure that the surface of the gasket and the mating surface of the tank are clean and dry. Install 5C-9553 Bolts into the tank. Hand tighten the bolts in a star pattern.

8. Use a star pattern to the bolts to a torque of 4.5 ± 0.5 N·m (40 ± 4 lb in). Torque the bolts twice in order to ensure proper torque. Do not exceed the torque specification for the bolts in this joint.

9. Reconnect the harness to the sender.

10. Reinstall the intake duct (if equipped) onto the housing for the engine air cleaner. Reinstall the intake duct into the mounting flange. Reference Illustrations 2 and 3. Tighten the clamp at the air cleaner housing.