Product Support Program For Replacing The Fuel Tank Mount On Certain D250E And D300E Articulated Trucks Caterpillar

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 Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4009" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the August 7, 1997 (Revised September 1997) Service Letter. Changes have been made to the TERMINATION DATE.

Termination Date

Problem

The front fuel tank mount in the 1166477 Tank Group may crack on certain D250E and D300E Articulated Trucks. The mounting can be replaced with an improved design.

Affected Product
Model & Identification Number

D250E (5TN1-1144)

D300E (7FN1-544)

Parts Needed

1 - 8G0841 Mounting

2 - 8T4122 Washer-Plate

1 - 7X0354 Bolt

1 - 7X0447 Nut-Full

1 - 1238643 Washer

1 - 1450208 Collar

2 - 1450209 Washer

1 - 1450211 Shim

1 - 1450212 Shim

1 - 1450213 Washer

1 - 1450214 Bracket As

1 - Fabricated Plate - See Illustration 1

Action Required

See the attached procedure.

Service Claim Allowances

NOTE: This is a 5-hour job.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach.

(1-Rework Procedure)

Rework Procedure

1. Park the machine on a hard level surface in a stable position.

2. Drain the contents of the fuel tank into a suitable container.

3. Purge the tank with carbon dioxide gas (CO2).

Applying heat to a tank which has held flammable liquids, even when "empty", can result in residual flammable liquid or vapor igniting with explosive force. This can result in injury or death. DO NOT weld or flame cut on any tank that has held flammable liquid without taking the proper safety precautions. Read the article entitled "Welding On Fuel And Hydraulic Tanks" in the July 2, 1990 Service Magazine.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill.

Read and understand the manufacturer's instructions and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and general area. Wear correct eye, ear, and body protection. Do not touch live electrical parts.

See American National Standard Z49.1 "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CRF 1910, available from U.S. Dept. of Labor, Washington, D.C. 20408.

NOTE: Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OSHA limits.

All repair welding operators must be qualified for fillet welding as outlined in the current ANSI/AWS 14.3 or Caterpillar Manufacturing Practice MC1000-105. The welding operator must also have used the welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained for welding operator's qualifications.

The SMAW process shall be used with E7018 (ANSI/AWS A5.5) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:

500 MPa (72 KSI) Tensile Strength

420 MPa (60 KSI) Yield Strength

22% Elongation in 50.0 mm (2.00 in)

27 J (20 ft lbs) Notch Toughness at -29° C (-20° F)

These are low hydrogen electrodes and must be stored in an electrode oven at 120° C (250° F) when not in use. If the electrodes get damp, scrap or recondition them to manufacturer's specifications.

The following recommendatons relate to electrode diameter and approximate current settings:

Diameter - 3.2 mm (.12 in)

Amperage - 70-140

4. Remove the front mounting bolt and loosen the rear mounts to allow the tank to swing out to provide room for repair.

NOTE: Tank will need support during this repair.

5. Remove old mount from the front of tank.

6. Repair all cracks in the main skin of the tank at the mount location.

7. Grind all repair welds flat to accept new mount.

8. Fabricate plate from Illustration 1 using ASTM A572 Grades 42, 50, or BS 4360 Grade 50B.

9. Locate and weld the fabricated Plate (1) to the front of the tank. (See Illustration 2) Note: The plug welds must have smooth transition and not to be over size.

10. Locate and weld the 145-0214 Front Mounting Bracket Assembly (2) to the 138-0160 Plate (1). (See Illustration 3)

11. Reinstall the tank using the new 8G0841 Mounting Bushing (See Illustration 4 for correct parts location). Shim as required to align tank vertically to frame.

Illustraiton 1 - Fabricate Plate

Illustration 2

Illustration3

Illustration 4