View Full Version : Possible Fire Hazard

07-28-2006, 08:55 PM
Not sure if anyone has seen this. I hope I am not reposting, but has the potential to ruin a weekend.

No. 2005.APR05.SB-004SUBJECT: Fuel Fill Ground Wires

In a joint effort, the U.S. Coast Guard, ABYC, NMMAand MasterCraft have recently re-examined the standards re-guarding the bonding of plastic fuel fills with metallic caps and retaining chains. This review is a result of MasterCraft’s discovery that, under certain conditions, an electrostatic discharge can cause a spark during fueling, which could ignite fuel vapors. This finding was recently confirmed in a study performed by IMANNA Laboratories, which showed that if the boat is not in the water, and a land-based fuel pump nozzle comes into contact with or in close proximity to the metallic components of the fuel fill assembly, the connection of the metallic retaining chain and cap of the plastic fuel fill assembly to the boat’s bonding system may create an electrostatic discharge and a spark. This condition does not exist when the boat is in the water, due to the equalization of the ground potentials between the fuel pump nozzle and the boat’s bonding system.

While the chances of ignition of fuel or vapors is unlikely, because of the potential for serious injury if fire or explosion were to occur, MasterCraft, the U.S. Coast Guard, ABYC and NMMA all agree that new and existing installations of this type of fuel fill assembly SHOULD NOT INCLUDE any attachment to the boat’s bonding system. For boats with this type of fuel fill assembly, which are connected via a ground wire to the boat’s bonding sys-tem, such connections should be removed as described herein. However, please note that this directive applies only to PLAS-TIC fuel fill assemblies with metallic caps and retaining chains; the U.S. Coast Guard and ABYC standards still require that any ALL-METALLIC fuel fills continue to be bonded.

Please be advised that all MasterCraft boats (all mod-els) manufactured from the 1999 model year through the present contain plastic fuel fill assemblies with metallic caps and retaining chains manufactured by Perko, Inc., as shown here, and therefore require the corrective action described in this Service Bulletin. However, beginning with Serial Num-ber MBCNLHG3A505, MasterCraft has altered its manufacturing process in accordance with the change in standards by the U.S. Coast Guard and ABYC to no longer attach a grounding wire from the plastic Perko fuel fill assembly to the boat’s bonding system.

The purpose of this Service Bulletin is to direct you to disconnect the ground wire of the fuel fill assembly on all affected MasterCraft boats in accordance with the procedures outlined below. Please note that other than the ground wire itself, removal of the metallic components of the fuel fill assembly is not necessary. This action should be performed at the first available opportunity on all affected boats in your inventory and/or which are brought in for service by customers regardless of the type of service work performed or whether specifically requested by the customer. For further information regarding this issue, you are encouraged to visitwww.uscgboating.com.


Step 1: Locate the fuel fill assembly from inside the hull. Please note that some boat models have two fuel fills, and on those boats, this procedure must be performed on both fuel fills.

Step 2: Locate the green or green-and-yellow-striped ground wire, which is attached to the fuel fill assembly by a small bolt and nut. Use wire cutters to cut the ground wire as close as possible to the plastic fuel fill. Next, follow the ground wire away from the fuel fill and cut the ground wire again as far away as possible from the fuel fill. Remove and discard the piece of ground wire that was cut away to ensure that the consumer will not be able to reattach the ground wire (under the mistaken belief that it should be attached).

Step 3: Repeat this procedure on the second fuel fill, where applicable.

east tx skier
07-28-2006, 09:28 PM
It has been posted a while back, but thank you for brining it back up. Important stuff for those who may not have seen it before, but whose boats are affected. Thanks again.