PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL TANK ON CERTAIN 777D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL TANK ON CERTAIN 777D OFF-HIGHWAY TRUCKS

Usage:

REBE9336-02

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14Feb2013

(Revised 05Jul2013)

D-49

O-54

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL TANK ON CERTAIN 777D OFF-HIGHWAY TRUCKS
1273		PS43839

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43839" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 14Feb2013 (Revised 26Feb2013) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

28Feb2015

PROBLEM

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The existing 302-2804 Fuel Tank, on certain 777D Off-Highway Trucks, can exhibit internal and external weld cracks on the front of the fuel tank. These cracks can result in a fuel leak. If the existing 302-2804 Tank As. leaks fuel from an external weld on the front of fuel tank, it will likely have additional weld failures on the interior of the tank. The internal structure failures must be repaired. Repairing only the external weld failures in this area of the tank will result in repeat failures in less time than the initial failure.

AFFECTED PRODUCT

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Model

Identification Number

777D

FKR00506-00507, 745-756, 803-808, 811-815, 830-836, 839-845, 851-866, 869-873, 886-900, 916-938, 947-949, 966-967, 977-989, 1001-1014, 1040-1052, 1081-1092, 1125-1134, 1169-1174, 1178-1182, 1217-1228, 1230-1231, 1265-1268, 1344-1349, 1364-1368, 1371-1378, 1412-1417, 1422-1424, 1427-1430, 1455-1459, 1465-1469, 1534-1540, 1593-1602, 1612-1614, 1635-1648, 1685-1687, 1709-1722, 1820-1836, 1841-1842, 1852, 1858-1867, 1913-1928

PARTS NEEDED

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Qty	Part Number	Description
1	5H6734	SEAL-O RING (Item #11 )
1	5P6459	GROMMET (Item #12 )
1	ADAPTER1	Part retained during removal procedure.
1	ADAPTER2	Part retained during removal procedure.
2	BAFFLE	Dealer Fabricated Part (Item #2 )
1	FRONTPLATE	Dealer Fabricated Part (Item #1 )
2	PLATE1	Dealer Fabricated Part (Item #3 )
1	PLATE2	Dealer Fabricated Part (Item #6 )
4	PLATE3	Dealer Fabricated Part (Item #8 )
1	PLATE4	Dealer Fabricated Part (Item #9 )
2	PLATE5	Dealer Fabricated Part (Item #10 )
1	PLATEFF	Dealer Fabricated Part (Item #5 )
1	SENDERAS	Part retained during removal procedure.
1	TUBE1	Dealer Fabricated Part (Item #4 )
1	TUBE2	Dealer Fabricated Part (Item #7 )
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Please refer to Special Instructions REHS6119, "Procedure to Rework the 302-2804 Fuel Tank Gp on the 777D Off-Highway Trucks", for rework of the tank.

Record the serial number and supplier code in SIMSi.

The 163-8495 Plate listed in the special instructions is to be fabricated by the dealer. It is PLATEFF (Item #5) in the Parts Needed and shown in Image1 below. The plate should be made out of ASTM A36 carbon steel.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-24000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 25.0-hour job
This is a 25 - hour job including the time required to fabricate the internal and reinforcement plates. A maximum of $120.00 U.S. will be allowed for materials to fabricate the plates shown in the special instruction. The 163-8495 Plate in the special instruction is not to be claimed against this program. It is to be fabricated by the dealer.

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