TANK ASSEM. 3L5849 - Caterpillar

Introduction
This Special Instruction, REHS1633 provides information in order to inspect the fuel tank for leaks. This Special Instruction also provides information in order to shim the fuel tanks.Inspection Procedure
The inspection procedure will determine if the fuel tank has been mounted correctly. If the fuel tank is leaking, proceed to the repair procedure.
Illustration 1 g00988531
(1) Rear mounting bolt (2) Rear mounting pad (3) FrameNote: The fuel tank should not contain more than 15 percent fuel before you start the inspection.
Loosen rear mounting bolts (1) for the two fuel tanks. Watch closely in order to determine if mounting pad (2) raises off frame (3) of the machine. If there is a gap between the mounting pad and the frame, proceed to the shimming procedure.Note: There are four mounting bolts that are located in the front of each fuel tank and in the rear of each fuel tank. Refer to Illustration 6.
If there is not a gap between the mounting pad and the frame, apply a torque of 56 9 N m (41 7 lb ft) to rear mounting bolts (1) of the two tanks.
Illustration 2 g00988532
Loosen front mounting bolts (4) for the two fuel tanks. Watch closely in order to determine if the mounting pad (2) raises off the frame (3) of the machine. If there is a gap between the mounting pad and the frame, proceed to the shimming procedure.
If there is not a gap between the mounting pad and the frame, apply a torque of 56 9 N m (41 7 lb ft) to front mounting bolts (2) of the two tanks.Shimming Procedure
The shimming procedure will eliminate the gap between the mounting pad and the frame that may occur after you apply the correct torque to the mounting bolts.
Illustration 3 g00988551
(5) Shim
Table 1
Required Parts    
Part Number     Description    
224-2420     Shim    
224-2421     Shim    
Use the 224-2420 Shim and the 224-2421 Shim in order to eliminate the gap between the mounting pad and the frame.
Torque the mounting bolts to 56 9 N m (41 7 lb ft).Repair Procedure
Use the following procedure in order to repair any leaks in the fuel tanks.
Drain the fuel into a suitable container.
Illustration 4 g00987872
(6) Hood assembly (7) Rear door assembly
Remove hood assembly (6) .
Remove rear door assembly (7) .
Illustration 5 g00988179
(8) Rear grill assembly (9) Shrouds
Remove rear grill assembly (8) and shrouds (9) .
Illustration 6 g00987870
(5) Shims (10) Fuel crossover pipe (11) Fuel nozzle assembly (12) Fuel level indicator (13) Mounting hardware
Remove fuel crossover pipe (10) and remove the fuel lines.
Remove the fuel nozzle assembly (11) .
Remove the electrical harness from the fuel level indicator (12) .
Connect a suitable lifting device to the fuel tank.
Remove the mounting hardware (13) from the fuel tank.
Remove the fuel tank and repair the leak.
Install the fuel tank. Refer to the inspection procedure in order to determine the correct amount of shims that are required for the installation of the fuel tank .
Reverse Step 2 through Step 9 in order