PSP FOR REPAIRING THE FUEL TANK ON CERTAIN 235C EXCAVATORS - PS0506 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, LIMITED BRA ZIL Caterpillar

PSP FOR REPAIRING THE FUEL TANK ON CERTAIN 235C EXCAVATORS - PS0506 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, LIMITED BRA ZIL

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Caterpillar: Confidential Yellow

PSP FOR REPAIRING THE FUEL TANK ON CERTAIN 235C EXCAVATORS - PS0506 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA, LIMITED BRA ZIL

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.


U-26
A-18
AU-15
B-3.1
E-22
O-24
1273   PS0506
NOTE: This Program can only be administered after a failure
occurs. The decision whether to apply the Program is made
by the dealer. When reporting the repair, use "PS0506" as
Part Number, "7755" as Group Number, and "96" as
Description Code.

Termination Date

February 29, 1992

Problem

The fuel tank may crack at one or more locations on certain 235C Excavators.
If a fuel tank cracks in one area, all areas covered in the rework procedure
should be repaired or reworked to increase the service life of the fuel tank.

Affected Product

Model Identification Number
***** Group 1 *****
235C 5AF1005-1157
3WG219-231
2PG626-652
4DG489-525
***** Group 2 *****
235C 5AF1-1004
3WG1-218
2PG1-616
4DG1-471, 474

Parts Needed

1 - 1F0748 Nut
2 - 9F2978 Nut
1 - 8T4223 Washer
1 - 6V8188 Nut
1 - 7X0326 Bolt

Action Required

See the attached procedure.

Service Claim Allowances

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost)  (C/L) (Sell)
comes
first
***** Group 1 *****
0-2000 100% 6 0 0 0 0
0-18 mo
2001-4000 100% 2 0 2 0 2
19-36 mo
NOTE: This is a 6-hour job.
***** Group 2 *****
0-2000 100% 10 0 0 0 00-18 mo
2001-4000 100% 4 0 3 0 3
19-36 mo
NOTE: This is a 10-hour job.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts
handling.
Attach. (1-Rework Procedure)
Rework Procedure
Remove the fuel tank from the excavator and prepare it for welding. Refer to
the Service Manual and the Service Magazine dated July 2, 1990, "Welding on
Fuel and Hydraulic Tanks."
***** Group 1 *****
1. Remove the lug and two weld nuts at the top of the post assembly. See
Location A in Illustration 1. Grind the area smooth and remove all
paint and rust from the area to be welded.
2. Cut a sheet metal angle as shown in Illustration 2. (See note)
3. Weld the angle to the fuel tank post assembly. See Location A in
Illustration 3. (See note)
4. Drill holes through the angle using existing holes as locators. Weld a
1F0748 Weld Nut in place of the lug that was removed. Weld two new
9F2978 Weld Nuts in place of the weld nuts that were removed. See
Illustration 4.
5. Remove the 8T8919 Bolt and 8T4223 Washer. See Illustration 9.
Install a 7X0326 Bolt, 8T4223 Washer and 6V8188 Nut. See Illustration
10.
NOTE: Mild steel material using E7018, L-50, .035-.045 or equivalent.
***** Group 2 *****
1. Remove the lug and two weld nuts at the top of the post assembly. See
Location A in Illustration 1. Grind the area smooth and remove all
paint and rust from the area to be welded.
2. Cut a sheet metal angle as shown in Illustration 2. (See note)
3. Weld the angle to the fuel tank post assembly. (See note) See Location
A in Illustration 3.
4. Drill holes through the angle using existing holes as locators. Weld a
1F0748 Weld Nut in place of the lug that was removed. Weld two new
9F2978 Weld Nuts in place of the weld nuts that were removed. (See
note) See Illustration 4.
5. Cut a doubler plate for each of Illustrations 5 and 6.
6. Grind smooth and remove all paint and rust from the areas to be welded
in Locations B and C. See Illustration 1.
7. Weld the backside of the upper bracket (Location B). (See note) Then
weld the doubler plate to the upper bracket. See Illustration 7.
8. Weld the backside of the lower bracket (Location C). Then weld the
doubler plate to the lower bracket and fuel tank. (See note) See
Illustration 8.
9. Check for leaks in the tank by pressurizing the tank with air and
spraying the welded areas with soapy water. Bubbles will appear where
leaks exist.
10. Repair any leaks that are found.
11. Clean and paint the welded areas and install the tank in the excavator.
12. Remove the 8T8919 Bolt and 8T4223 Washer. See Illustration 9.
Install a 7X0326 Bolt, 8T4223 Washer and 6V8188 Nut. See Illustration
10.
NOTE: Mild steel material using E7018, L-50, .035-.045 or equivalent.
****** IMAGE: SEBE4512.00001.001
CAPTION: Illustration 1 - Failure Locations
****** IMAGE: SEBE4512.00001.002
CAPTION: Illustration 2 - Location A
****** IMAGE: SEBE4512.00001.003
CAPTION: Illustration 3 - Location A
****** IMAGE: SEBE4512.00001.004
CAPTION: Illustration 4 - Location A
****** IMAGE: SEBE4512.00001.005
CAPTION: Illustration 5 - Location B
****** IMAGE: SEBE4512.00001.006
CAPTION: Illustration 6 - Location C
****** IMAGE: SEBE4512.00001.007
CAPTION: Illustration 7 - Location B
****** IMAGE: SEBE4512.00001.008
CAPTION: Illustration 8 - Location C
****** IMAGE: SEBE4512.00001.009
CAPTION: Illustration 9 - Location A - Existing Right Side View
****** IMAGE: SEBE4512.00001.010
CAPTION: Illustration 10 - Location A - Reworked Right Side View