Usage:
July 26, 1999
(Revised September 2003)
U-210
A-170
AU-142
S-117
H-86
O-183
| After failure only |
PRODUCT SUPPORT PROGRAM FOR INSTALLING AN IMPROVED FUEL TANK ON CERTAIN CH35, CH45, AND CH55 CHALLENGER TRACTORS |
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| 1273 |
PS5687
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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.
NOTE: THIS SERVICE LETTER DOES NOT APPLY TO THOSE TRACTORS PREVIOUSLY REWORKED WITH THE IMPROVED 1700000/">170-0000 FUEL TANK GP. UNDER A PREVIOUS SERVICE LETTER.
NOTE: This Revised Service Letter replaces the July 26, 1999 (Revised August 2002) Service Letter. Changes have been made to the Termination Date.
TERMINATION DATE
July 31, 2005PROBLEM
The main fuel tank may leak in service. Failed tanks should be replaced with an improved design. The tank plate thickness is increased, the plates have more gradual bends, the auxiliary tank transfer hose connection has been relocated to the center, and the front support is a separate strap-on design, rather than welded construction. The improvements increase the fuel tank life.AFFECTED PRODUCT
Model |
Identification Number |
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| CH35 | 8RD1-71 |
| ADK1-329 | |
| CH45 | ABF1-112 |
| 3BK1-367 | |
| CH55 | 6NN1-149 |
| AEN1-422, 424-435 | |
| CH35 | 8DN547, 552-553, 556-566, 568-570, 572-604, 606-619, 621-622, 624-625, 627-651, 850-881, 897-899, 903-904, 906-920, 937, 940-949, 952-958, 973-975, 981-983, 988-992, 1001 |
| CH45 | 1DR1-1767, 1793-1901, 1935-Up |
| CH55 | 7DM1-954, 975-Up |
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| CH35 | 8DN1-546, 548-551, 554-555, 567, 571, 605, 620, 623, 626, 652-849, 900-902, 905, 935-936, 938-939, 950-951, 959-972, 976-980, 984-987, 993-1000, 1002-Up |
PARTS NEEDED
| Qty | Part Number | Description | ||
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8T4121 | Washer - Hard (As required) | ||
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8T4185 | Bolt (As required) | ||
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7X0578 | Washer - Hard (As required) | ||
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1549731 | Thread Lock | ||
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1685083 | Hose - Fuel Transfer | ||
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1685084 | Guard | ||
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1700000 | Tank Gp. - Fuel | ||
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1712563 | Shield | ||
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1792021 | Spring (As required) | ||
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8T4121 | Washer - Hard (As required) | ||
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8T4185 | Bolt (As required) | ||
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7X0578 | Washer - Hard (As required) | ||
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1549731 | Thread Lock | ||
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1685084 | Guard | ||
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1700000 | Tank Gp. - Fuel | ||
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1712563 | Shield | ||
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1792021 | Spring (As required) | ||
ACTION REQUIRED
***** Affected Product *****
See the attached rework procedures for the respective Affected Product groups.
***** Parts Stock *****
Remove all 109-3224 Fuel Tank As. from parts stock.
SERVICE CLAIM ALLOWANCES
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3001-5000 hrs |
33.3% |
3 |
0 |
0 |
50 % |
3 |
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PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.a) The front fuel tank retaining band should be retained with two (2) each of the following fastener hardware:
8T4121 Hard Washer 11.0 mm ID; 21.0 mm OD; 2.5 mm Thick
1792021 Spring (Belleville Washer)
7X0578 Hard Washer 10.2 mm ID; 32.0 mm OD; 2.5 mm Thick
b) For a proper fit, check the location of two chain links (A). If installed as shown in Illustration 1, remove the links (A) from the bottom, rear of the fuel tank before installing the tank on the tractor. If installed as shown in Illustration 2, then proceed with the tank installation.
2) Remove the hood and existing main fuel tank from the tractor. Refer to the Service Manual module, "Disassembly and Assembly (3116 Engine for Challenger 35, and Challenger 45 Agricultural Tractors and 3126 Engine for Challenger 55 Agricultural Tractor Engine Supplement)", Form No: RENR1788, p. 61.
Steps 3 & 4 Apply to Group 1 Only (With Auxiliary Fuel Tank).
3) Remove the components shown in Illustration 3. Retain the removed hose clamps for Step 4.
4) Modify (cut) the new 1685083 Fuel Transfer
Hose to allow attachment to the new tank and existing 1095751 Tube (elbow).
Refer to Illustration 4. Assemble the hose to the auxiliary fuel tank by
using the previously removed hose clamps. (Don't tighten until both ends
of the hose are installed.) Using a hoist, lower the 1700000 Fuel Tank
Gp. into position. Before removing the hoist and securing the tank, make
the remaining connection of the fuel transfer hose to the new tank. Care
should be taken to minimize contact of the Fuel Transfer Hose with existing
tractor electrical harnesses and hydraulic lines. Tighten the clamps.
Step 5 Applies to Group 2 Only (Without Auxiliary Fuel Tank).
5) For tractors not equipped with an auxiliary fuel tank, make sure that plug (7) and O-ring (8) are installed. (Refer to Illustration 5.) Using a hoist, lower the 1700000 Fuel Tank Gp. into position.
6) Loosen bolts (B) for the tank retaining band. Tighten bolts (9) and (10). Reuse the existing hardware. (Refer to Illustration 6.) Remove bolts (B). Clean threads. Install the required hardware as follows:
a) 8T4185 Bolt
b) 8T4121 Hard Washer (21.0 mm OD) - Next to bolt head
c) 1792021 Spring (Belleville Washer) - Smaller diameter next to 8T4121 Hard Washer
d) 7X0578 Hard Washer (32.0 mm OD) - Next to larger Spring diameter
e) Apply 1549731 Thread Lock to the bolt threads as directed.
f) Install bolt through support bracket clearance hole threading into tank retainer band boss.
g) Tighten to 32 +/- 7 N-m (24 +/- 5 lb-ft). (Refer to Illustration 7.)
7) Reinstall all of the lines and covers on the left side of the tractor. The removed 1344142 Cover is replaced with the new 1685084 Guard (11). (Refer to Illustration 6.)
8) Install the 1712563 Shield (12) as shown in Illustration 8.
9) Reinstall the hood. The hood position may need to be adjusted slightly from the original position.
Illustration 1
Illustration 2
6) Modified 1685083 Fuel Transfer Hose
Illustration 4
Illustration 5
Illustration 6
Detail sketch of fuel tank retaining band fastener hardware showing relative location of components.
8T4185 Bolt
8T4121 Hard Washer
Illustration 7
13) Washer
14)Bolt