PRODUCT SUPPORT PROGRAM FOR REPAIRING CRACKED FUEL TANKS ON CERTAIN D11T TRACK-TYPE TRACTORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING CRACKED FUEL TANKS ON CERTAIN D11T TRACK-TYPE TRACTORS

Usage:

REBE6793-01

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27Jan2011

(Revised 04Feb2011)

U-33

A-24

D-31

O-31

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING CRACKED FUEL TANKS ON CERTAIN D11T TRACK-TYPE TRACTORS
1273		PS51976

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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 "PS51976" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 27Jan2011 Service Letter. A change was made to the Problem.

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TERMINATION DATE

31Jan2013

PROBLEM

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The 225-5485 Standard Capacity Fuel Tank or the 247-7131 Extra Capacity Fuel Tank may crack and leak at multiple locations on certain D11T Track-Type Tractors.
See Image 1.1.1 in the rework procedure for potential crack locations on 225-5485 Standard Fuel Tanks.
See Image 1.7.1 in the rework procedure for potential crack locations on 247-7131 Extra Capacity Fuel Tanks.

AFFECTED PRODUCT

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Model	Identification Number
D11T	GEB00161-00816
D11T CD	TPB00160-00198

PARTS NEEDED

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Qty	Part Number	Description
2	PLATE	Dealer Fabricated (ONLY NEEDED FOR 247-7131 TANK)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Repair cracked areas of fuel tanks per the applicable steps in the attached Rework Procedure.

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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%
0-18000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 15.0-hour job
NOTE: This is a 15.0-hour job to remove, weld repair, and install the fuel tank on machines equipped with 225-5485 Standard Capacity Fuel Tank. An additional 10.0 hours will be allowed on machines equipped with a 247-7131 Extra Capacity Fuel Tank and Platform Arrangement. Note: A maximum of $150 U.S. will be allowed for labor and materials to fabricate the plates shown in Image 1.8.1. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the machine history folder for audit purposes. NOTE: In some cases the dealer may choose to have the tank repaired by a supplier. If the weld repair of the tank is done by a supplier, include the outside welding expenses at cost and claim the actual time required to remove and install the tank. Retain a copy of all invoices for outside expenses in the machine folder for audit purposes.

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PARTS DISPOSITION

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

Rework Procedure

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*****225-5485 Standard Capacity Fuel Tank Group******

Image1.1.1

1. Remove fuel tank per applicable steps in Disassembly / Assembly Manual RENR8178.

2. If there is a crack in Area 1, grind out the weld in the area of the crack and reweld. Use the procedures that are outlined in Special Instruction, REHS1841, "General Welding Procedures" specifically the section titled Welding on Fuel Tanks.

NOTE: Weld the vertical joints between Plates 1, 2, 3 before welding the horizontal joint between Plate 4 and Plates 1,2,3 and / or Plate 5 and Plates 1,2,3 as shown in Image 1.3.1.

Image1.3.1

3. If there is a crack in Area 2, grind out the weld in the area of the crack and reweld. Use the procedures that are outlined in Special Instruction, REHS1841, "General Welding Procedures" specifically the section titled Welding on Fuel Tanks.

4. Check the tank for leaks. NOTE: The tank should not be pressurized over 1.5 PSI to check for leaks. Clean interior of tank as required.

5. Reinstall the fuel tank per applicable steps in Disassembly / Assembly Manual RENR8178

*****247-7131 Extra Capacity Fuel Tank Group*****

Image1.7.1

1. Remove fuel tank per applicable steps in Disassembly / Assembly Manual RENR8178.

2. If there is a crack in Area 3, grind out the weld in the area of the crack and reweld. Use the procedures that are outlined in Special Instruction, REHS1841, "General Welding Procedures" specifically the section titled Welding on Fuel Tanks.

3. Fabricate a reinforcement plate for both the left and right side of the tank per Image 1.8.1.

Image1.8.1

4. Install the reinforcement plates on the left side and right side of fuel tank at Area 3 per Image 1.9.1. Do not start or stop welds in Area A, B, or C per Image 1.9.1.

Image1.9.1

NOTE: If the tractor is equipped with a cross fender lattice plate, grinding on the lattice plate may be required to provide adequate clearance between the cross fender lattice plate and the reinforcement plates added in Step 5.

5. If there is a crack in Area 4, grind out the weld in the area of the crack and reweld. Use the procedures that are outlined in Special Instruction, REHS1841, "General Welding Procedures" specifically the section titled Welding on Fuel Tanks.

6. If there is a crack in Area 5, grind out the weld in the area of the crack and reweld. Use the procedures that are outlined in Special Instruction, REHS1841, "General Welding Procedures" specifically the section titled Welding on Fuel Tanks.

7. Check the tank for leaks. NOTE: The tank should not be pressurized over 1.5 PSI to check for leaks. Clean interior of tank as required.

8. Reinstall the fuel tank per applicable steps in Disassembly / Assembly Manual RENR8178