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TICO Document #: SFN-20231230A (formerly TES 259)
Description of Procedure: In some applications, the t-bolt securing the fuel tank straps and fuel tank to the chassis is shearing. Replace broken fuel tank straps with new yoke-style fuel tank straps
Units Affected: All diesel units
Parts Required: KIT – FUEL TANK STRAPS, YOKE STYLE, DIESEL (QTY 1) 970088
Planned Labor: 90 minutes
Instructions:
Park the vehicle on a flat surface, apply a parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.
Locate the fuel tank on the driver's side of the chassis. Determine if the fuel tank straps are broken or if the fuel tank is loose when boarding the vehicle.
2A If the straps are broken and/or the fuel tank is loose, remove the straps and continue with this procedure.
Begin removing the 3/8” hardware, attaching the transmission cover grating and boom cover grating to the chassis (Figures #2 & #3). Set hardware aside.
Remove and set aside the transmission and boom cover gratings (Figure #4).
To gain access to the rearward Jbracket mounting bolts (circled in Figure #6), raise the boom to the upward position.
Use a steel bar to prevent the boom from lowering during the installation process. Ensure that the bar is placed behind the risers so that the boom is fully secured (see Figure #5).
Begin removing the 3/8” screws mounting the fuel tank grating to the top of the fuel tank. Set hardware aside.
Remove and set aside the fuel tank grating (Figure #7).
If the top t-bolt (Figure #8) and the bottom t-bolt (Figure #9) are still intact, begin removing the ½” locknuts on the t-bolts. Discard this hardware.
Remove and discard the old-style fuel tank straps from the tank.
Find the fuel line connections on the top of the diesel fuel tank (shown in Figure #10).
Remove the hose clamps on all three fuel lines. Set aside these clamps.
• CAUTION: Restrict the fuel lines so that diesel fuel cannot escape. Do not damage the fuel lines during this process. Be sure to properly dispose of any diesel fluid that may have spilled.
Find and remove the #10 hardware for the fuel level sender connections (see Figure #11). Set aside #10 hardware.
Using an appropriate lifting device, remove the fuel tank from the chassis.
This will expose the J-brackets and “wet” air tank assembly shown in Figure #12.
Remove the ½” hardware circled in Figure #12 and set aside the air tank assembly for reinstallation. Be careful not to damage any airlines during this process.
Remove the 5/16” hardware mounting the diesel fuel filter to the cab protection bar (Figure #13).
Use the supplied cable tie to secure the fuel filter assembly so that the forward J-bracket mounting hardware can be accessed (hardware circled in Figure #14).
Remove the current J-brackets and the stiffening channels behind them. Discard the old-style Jbrackets.
Install the new J-brackets (P/N 200471 found in kit). Be sure to reinstall the existing stiffening channel behind the new J-brackets.
At this point, use only the top two holes (circled in Figure #15) to install the new J-brackets and channels.
• Do not use any 5/8” washers on the outside face of the J-brackets.
• NOTE: New 5/8” hardware will be supplied in the service kit.
With the J-brackets in place, begin reinstalling the “wet” air tank assembly, as shown in Figure #16.
Next, new rubber isolators (supplied in kit, P/N 20171) can be applied to the Jbrackets (Figure #16).
Apply the isolators approximately 2.5 inches from the bottom edge of the J-brackets (Figure #17).
Next, install the “yoke” brackets, as shown in Figure #18, on both Jbrackets. (P/N’s 123457 & 123458).
The left-hand (see “L” laser etched in part) yoke bracket (P/N 123457) needs to be installed on the front side of the J-brackets.
Be sure to remove the 5/8” washers, as indicated in Figure #18. The top four holes should not have washers on the outside face of the J-brackets.
Next, reinstall the retained ½” hardware, attaching the lower half of the J-bracket to the stiffening channel.
Using an appropriate lifting device, reinstall the fuel tank.
Position the tank so that the front face of the tank is approximately 4.5 inches from the front stiffening channel (see Figure #19).
Next, install the top side of the new tank straps (P/N 200469).
Use the ½” clevis pin and cotter pin provided in the kit (see Figure #20).
Place the clevis pin through both yoke brackets and the tank strap eyelet to create the top-side connection (Figure #20).
Make sure the cotter pins are properly installed on the rear side of the J-brackets
Next, install the bottom connection of the fuel tank straps with the ½” t-bolts.
New ½” washers and locknuts are supplied in the service kit for this step.
Torque the ½” locknut to 36 ft-lbs.
Bolt the fuel filter back onto the driver's side of the cab protection bar (Figure #22).
Reconnect the fuel line by reusing the previously removed hose clamps (see Figure #23).
CAUTION: Be sure to dispose of any diesel fluid that may have spilled properly.
NOTE: Torque hose clamps to 35 in. – lbs. max. Do not over-tighten.
Reconnect the fuel level sender connections using the retained #10 hardware (see Figure #24).
NOTE: Torque #10 electrical connections to 20 in. – lbs. max. Do not over-tighten.
With all the fuel lines reconnected, prime the fuel filter using the handle shown in Figure #22. Continuously depress the handle until sufficient pressure has been created and the handle does not easily move anymore.
Reinstall the fuel tank grating (Figure #25) with previously removed 3/8” screws.
Remove the steel bar from underneath the boom and lower the boom (Figure #26).
Reinstall the transmission cover grating (Figure #27).
Reinstall the boom cover grating (Figure #28).
Remove the “Lock Out, Tag Out” plaque.
Return vehicle to service.