PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL SENDER AND RECEIVER PLATE GASKETS ON CERTAIN 216B 3 AND 226B 3 SKID STEER LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL SENDER AND RECEIVER PLATE GASKETS ON CERTAIN 216B 3 AND 226B 3 SKID STEER LOADERS

Usage:

TEBE3195-01

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17Jun2015

(Revised 18Feb2016)

A-220

D-260

O-268

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Before/After Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL SENDER AND RECEIVER PLATE GASKETS ON CERTAIN 216B 3 AND 226B 3 SKID STEER LOADERS
1258 1263 1274		PS44776

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS44776" 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:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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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 17Jun2015 service Letter. Changes have been made to the Termination Date, Affected Product, Action Required to add Parts Stock Action, Service Claim Allowances, and Parts Disposition.

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TERMINATION DATE

30Jun2017

PROBLEM

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The existing gasket used to seal the receiver and sender plates to the diesel fuel tank does not meet the required material specifications on certain 216B 3 and 226B 3 Skid Steer Loaders. Extended exposure of this gasket to diesel fuel may cause gasket to degrade, resulting in poor sealing and gasket debris accumulation in the fuel filter leading to engine performance loss. The gasket needs to be replaced in order to ensure proper engine performance.

AFFECTED PRODUCT

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Model	Identification Number
216B 3	HR200115-00150 PWK00100-00102, 105-112, 114-245, 270-309, 315-430, 496-670
226B 3	DXZ00110-00112, 115-182, 191-240, 249-262, 276-277, 315-347, 353-399, 402-405, 413-419, 430, 461-631

PARTS NEEDED

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Qty	Part Number	Description
1	1G7206	FILTER-FUEL (After Failure Only)
4	7K1181	STRAP-CABLE
2	1428823	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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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****Parts Stock ****

Remove all 142-8823 Gaskets from dealer parts stock. There is not a clear way to tell the difference between good and bad 142-8823 Gaskets. It is recommended to remove all and order new gaskets.

****Affected Product****

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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%
0-1200 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job
Note: $50 US dollars will be allowed to cover travel time if required to perform the Before Failure repair. Note: $50 US dollars will be allowed for After Failure to cover diesel tank flushing and refill per the Rework Procedure

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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Rework Procedure

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1. Open the engine compartment door and secure the door in the open position using a 142-8832 Pin Assembly. The 231-2105 Fuel Sender Plate is located on the machine left hand side, while the 142-8810 Fuel Receiver Plate is located on the machine right hand side. Refer to Image1.1.1.

Image1.1.1

2. Remove the engine air filter housing from the machine. Refer to Image1.2.1.

Image1.2.1

3. Disconnect the hydraulic oil filter mounting bracket from machine. Refer to Image1.3.1. Carefully place the assembly on the engine compartment floor. Refer to Image1.3.2. Cut the 7K-1181 Tie Straps, if necessary, to allow better access to the fuel sender plate. Refer to Image1.3.3.

Image1.3.1

Image1.3.2

Image1.3.3

4. Loosen the clamps that connect the fuel fill overflow and fuel tank inlet/outlet hoses to the sender plate and remove hoses. Disconnect the fuel level sensor connector from the engine compartment harness. Refer to Image 1.4.1

Image1.4.1

5. Loosen the bolts that secure the 231-2105 Fuel Sender Plate to the fuel tank. Raise the fuel sender assembly and remove the existing gasket. Be careful to not damage the fuel level float during this step.

6. Install a new 142-8823 Gasket and re-assemble the 231-2105 Fuel Sender Assembly using the existing 8T-4970 Bolts and 8T-4205 Washers. Tighten bolts to a specified torque of 6 +/- 1 N.m (4.42 +/-0.737 ft lb).

7. Re-assemble the fuel tank inlet and outlet hoses to the top of fuel sender plate. Tighten the 1P-4278 Clamps to a specified torque of 1.4 +/- 0.3 N.m (1.032 +/- 0.22 ft lb). Re-assemble the fuel fill overflow hose to the fuel sender plate and tighten the 5P-4961 Clamp to a specified torque of 4.5 +/- 0.7 N.m (3.32 +/- 0.51 ft lb).

8. Reconnect the fuel level sensor connector to the engine compartment harness.

9. Re-assemble the hydraulic filter assembly to the machine using the existing 8T-4133 Nuts and 8T-4121 Washers. Tighten the nuts to a specified torque of 55 +/- 10 N.m (40.56 +/- 7.37 ft lb).

10. Re-assemble the engine air filter housing to the machine using the existing 5C-7261 Nuts and 5P-4116 Washers. Tighten the nuts to a specified torque of 15 +/- 3 N.m (11.06 +/- 2.2 ft lb).

11. Constrain the engine compartment harness using 7K-1181 Tie-Straps, if previously removed.

12. Loosen the 180-3007 Clamp and disconnect the 218-6661 Fuel Filler Hose from the fuel receiver plate. Refer to Image1.5.1.

Image1.5.1

13. Loosen the bolts that secure the 142-8810 Fuel Receiver Plate to the fuel tank. Remove the plate. The existing gasket will not be reused.

14. Install a new 142-8823 Gasket and re-assemble the 142-8810 Fuel Receiver Assembly using the existing 5C-9553 Bolts and 8T-4205 Washers. Tighten the bolts to a specified torque of 6 +/- 1 N.m (4.42 +/-0.737 ft lb).

15. Re-assemble fuel filler hose to the top of fuel receiver plate. Tighten the 180-3007 Clamp to a specified torque of 7.5 +/- 1 N.m (5.53 +/- 0.74 ft lb).

16. If the gaskets have failed and contaminated the fuel tank, flush and refill tank and change the 1G-7206 Fuel Filter.