PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW VENT AND FUEL TANK FOR FAST FUEL APPLICATIONS ON CERTAIN 16M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW VENT AND FUEL TANK FOR FAST FUEL APPLICATIONS ON CERTAIN 16M MOTOR GRADERS

Usage:

TEBE5531-00

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05Dec2016

K02C

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW VENT AND FUEL TANK FOR FAST FUEL APPLICATIONS ON CERTAIN 16M MOTOR GRADERS
1273		PS90659

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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 Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90659" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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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TERMINATION DATE

31Dec2018

PROBLEM

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The existing fuel tank on certain 16M Motor Graders is rated for 100 gpm (380 lpm). The tank can expand during the fast-fill operation if the design flow rate is exceeded. The tank may expand enough to contact and wear against adjacent components and develop leaks.

AFFECTED PRODUCT

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Model	Identification Number
16M	B9H00728-00730 R9H00229, 235

PARTS NEEDED

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Qty	Part Number	Description
2	1J9671	SEAL-O-RING
1	2T2396	ADAPTER-ELBOW (After Failure Only)
1	4J0527	SEAL-O-RING (After Failure Only)
2	4J5477	SEAL-O-RING-ORFS
1	6V8397	SEAL-O-RING-ORFS (After Failure Only)
1	6V8398	SEAL-O-RING-ORFS (After Failure Only)
1	6V8400	SEAL-O-RING-ORFS (After Failure Only)
2	7X7729	WASHER-HARD (After Failure Only)
4	8T4184	BOLT-HEX HEAD (After Failure Only)
2	8T4196	BOLT-HEX HEAD (After Failure Only)
4	8T4223	WASHER-HARD (After Failure Only)
1	9X2205	FILTER KIT-CAP (After Failure Only)
1	2763276	GASKET (After Failure Only)
1	2774844	GASKET
1	3303568	GASKET (After Failure Only)
1	3507735	KIT-FILTER (After Failure Only)
1	3532589	VALVE-FAST FILL (After Failure Only)
1	3577400	VENT-FAST FILL
1	3639085	CHANNEL (After Failure Only)
1	3845374	TANK AS (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Remove the 299-8018 Vent As. and replace it with the new 357-7400 Vent As. Inspect and clean the fuel cap and breather. Inspect the fuel tank for signs of bulging. If the fuel tank has rubbed other components or developed a leak, replace the tank with the new 384-5374 Tank As. Also, in the event of a bulged tank, replace the 363-9085 Channel as required. Inspect the signal line and fast fill valve for proper
function. Refer to 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%
0-25000 hrs, 0-96 mo	100.0%	50.0%	0.0%	50.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job

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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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1. Inspect the fuel cap, vent assembly, and fuel level sensor for any signs of fuel leakage. Pay particular attention to gasket joints as well as the hose on the vent assembly for any dampness, fuel residue, or material build-up; such signs could indicate a pressure build up in the tank and possible tank deformation. Note any gaskets or seals that may need replaced.

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2. Looking inside the left front enclosure door, inspect the rear of the fuel tank for any signs of bulging or contact with the engine. Inspect the tank for any signs of wear or gouging adjacent to the front timing cover of the engine. Look at the rear tank crossmember for any significant bowing or warpage. Replace the crossmember with new 363-9085 Channel as required utilizing new 8T-4196 Bolts and 7X-7729 Washers. Working on the right side of the fuel tank support assembly, remove the inspection cover (part number 273-3010). Inspect the tank for any signs of contact with the alternator or AC compressor (gouging, wear marks, etc.). If the fuel tank exhibits bulging, replace the fuel tank with new 384-5374 Tank Assembly. If replacing fuel tank, replace all O-rings and gaskets on the fuel tank. Replace 8T-4184 Bolts and 8T-4223 Washers on the fast fill valve flange when replacing tank. Follow the instructions in the following steps for inspection of the fast fill valve and replacement of the vent assembly.

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3. The fast fill vent assembly will be replaced on all units. Remove the vent tube and six mounting bolts that attach the vent assembly to the top of the fuel tank. Pull the old vent assembly upwards out of the tank. Disconnect the signal line from the 8T-6988 Adapter at the bottom of the vent assembly. Remove the 8T-6988 Adapter from the bottom of the vent assembly and set it aside; this will be reused. The O-rings and the gasket on the top of the tank will not be reused.

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4. The signal line and and fast fill valve will be inspected for proper function. Using a regulated air source with a gage and shutoff valve, connect the signal line (9/16-18 female) to the air source. Apply air pressure to the signal line until the 10 PSI of pressure is attained. Once this pressure is reached, isolate the signal line from the air source. Observe the pressure for 5 minutes; the pressure should remain constant.

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5. If the pressure does not drop, proceed to the next step. If the pressure has dropped, remove the fast fill valve from the rear of the tank. Remove the four screws on the foam suppressor and slide it off of the back of the fast fill valve. Inspect the signal line and adapter connections at the back of fast fill valve. If these fittings are tight, replace the fast fill valve. If the fittings were loose, tighten them and repeat the air pressure test described in the previous step. If the system does not maintain air pressure after running the test a second time, replace the fast fill valve. Replace the tank gasket and O-rings on the rear of the fast fill valve. Reposition the foam suppressor onto the fast fill valve and secure it with the four screws that were previously removed; apply loctite to the threads of the screws to ensure they do not loosen. Reassemble the fast fill valve to the back of the fuel tank.

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6. Place replacement 277-4844 Gasket for the new 357-7400 Vent Assembly on top of the fuel tank. Pull the signal line through the center of the gasket and using new 4J-5477 and 1J-9671 O-rings, attach the signal line, adapter, and vent assembly. Take care not to kink or induce a twist in the signal line. Reusing the existing hardware, secure the vent assembly to the top of the fuel tank. Orient the vent assembly exhaust port to the right side of the machine. Re-attach the vent hose and clamp.

7. Inspect the fuel cap breather for signs of leakage or damage. Clean/replace the breather as required.