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Service LetterPRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL TRANSFER PUMP ON CERTAIN 924K, 930K, AND 938K WHEEL LOADERS, 312E, 314E, 316E L, AND 318E EXCAVATORS, 416F, 420F, 428F, 430F, 432F, 434F, 444F, AND 450F BACKHOE LOADERS, D3K 2, D4K 2, AND D5K 2 TRACK-TYPE TRACTORS, TH407C, TL1055C, AND TL1255C TELEHANDLERSMedia Number -TEBE1133-00 Publication Date -11/07/2014 Date Updated -11/07/2014

Caterpillar: Confidential Yellow

TEBE1133-00

11Jul2014

U-414A-301D-373O-351

After Failure Only

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL TRANSFER PUMP ON CERTAIN 924K, 930K, AND 938K WHEEL LOADERS, 312E, 314E, 316E L, AND 318E EXCAVATORS, 416F, 420F, 428F, 430F, 432F, 434F, 444F, AND 450F BACKHOE LOADERS, D3K 2, D4K 2, AND D5K 2 TRACK-TYPE TRACTORS, TH407C, TL1055C, AND TL1255C TELEHANDLERS

1256 1261 1274 PS52713

NOTE:Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, m512ersa


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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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52713" as the Part Number and "7755" as the Group Number. Use "96" as the 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.

TERMINATION DATE

31Jul2016

PROBLEM

The existing Electric Lift Pump (ELP or Fuel Transfer Pump) can fail due to either over voltage spikes or from compromised fuel supply on certain 924K, 930K, and 938K Wheel Loaders, 312E, 314E, 316E L, and 318E Excavators, 416F, 420F, 428F, 430F, 432F, 434F, 444F, and 450F Backhoe Loaders, D3K 2, D4K 2, and D5K 2 Track-Type Tractors, TH407C, TL1055C, and TL1255C Telehandlers. If the existing Electric Lift Pump (ELP or Fuel Transfer Pump) fails it may result in the engine not stalling due to using fuel from the fuel return line into the secondary filter. This failure mode may also result in blown fuses / tripped circuit breakers and high fuel temperatures.In some instances the engine may stall or derate.The replacement ELP will prevent the damage caused by over voltage spikes. The replacement of the air vent connector will prevent fuel from being pulled along the fuel return line into the secondary filter.

AFFECTED PRODUCT

Model Identification Number*******Group 1*******924K PWR00150-00158, 350-2925, 2927-2928, 2931930K RHN00155-00165, 167-168, 450-3007, 3009-3013938K SWL00001, 160-171, 250-2654, 10605

*******Group 2*******312E m512ersa




GAC00127-00362

PZL00136-00487, 489-496312E L MJD00143-00920, 922-984, 986-992

WEY00161-00457314E CR ECN00117-00233314E LCR DKD00180-00316

YCW00187-00260

ZJT00107-00769316E L DZW00131-00133, 135-1442

WZY00107-00129

YZZ00114-00366318E L DZF00123-00255

WZS00139-00265

*******Group 3*******416F ST KSF00150-01458420F IT JWJ00150-02103420F ST SKR00150-03358428F RAK00150-00285430F IT RGS00150-00376, 378-517430F ST RDF00150-00332, 334-608432F PXR00150-00361434F MTR00150-00175444F JXR00150-00202450F HJR00150-00202, 204-277

*******Group 4*******D3K 2 LGP GAE00160-00175

KLL00110-00466D3K 2 XL KFF00100-00328D4K 2 LGP KRR00130-00425D4K 2 XL KMM00120-00437D5K 2 LGP KYY00150-01156D5K 2 XL KWW00140-00774, 776-798

*******Group 5*******TH407C MLH00151-00152, 154, 156, 159-553, 555-583, 585-597,

599-617, 619-625, 627-636, 638-641, 643-644, 646-649, 651-654, 656-663, 665-666, 668-671, 676, 680-681, 685, 687-688, 690, 692, 697-709, 711, 714-715, 718, 720

TL1055C KDE00150-00644, 646-1092, 1094, 1096-1099, 1101, 1103-1179, 1183-1187, 1190

TL1255C DHW00152-00849, 851, 853-938, 940-941, 943, 945-948, 950-1011, 1013-1018, 1020-1021, 1023, 1025

m512ersaCaterpillar: Confidential Yellow



PARTS NEEDED

QtyPart Number Description

*******Group 1*******

1 3708376 KIT-CLEANLINESS

1 3848512 SCREEN-FUEL

1 4465409 PUMP AS-FUEL XFR

1 4556332 KIT-F CONNECTION

In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.

*******Group 2*******



1 4465409 PUMP AS-FUEL XFR



*******Group 3*******

1 3169351 MOUNT-FIR TREE


1 3848512 SCREEN-FUEL m512ersaCaterpillar: Confidential Yellow



1 4465393 PUMP GP-F XFR



*******Group 4*******







*******Group 5*******






In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for m512ersa




ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age

whichever comes first

Caterpillar Dealer Suggested Customer Suggested

Parts %Labor

Hrs%Parts %

Labor

Hrs%Parts %

Labor

Hrs%

*******Group 1*******

0-3000 hrs,0-24 mo

100.0% 100.0% 0.0% 0.0% 0.0% 0.0%

NOTE: This is a 3.0-hour job for Group 1

Product smu/age



Parts %Labor

Hrs%Parts %

Labor

Hrs%Parts %

Labor

Hrs%

*******Group 2*******

0-3000 hrs,0-24 mo

100.0% 100.0% 0.0% 0.0% 0.0% 0.0%


Product smu/age



Parts %Labor

Hrs%Parts %

Labor

Hrs%Parts %

Labor

Hrs%

*******Group 3*******

0-3000 hrs,0-24 mo

100.0% 100.0% 0.0% 0.0% 0.0% 0.0%





Product smu/age



Parts %Labor

Hrs%Parts %

Labor

Hrs%Parts %

Labor

Hrs%

*******Group 4*******

0-3000 hrs,0-24 mo

100.0% 100.0% 0.0% 0.0% 0.0% 0.0%


Product smu/age



Parts %Labor

Hrs%Parts %

Labor

Hrs%Parts %

Labor

Hrs%

*******Group 5*******

0-3000 hrs,0-24 mo

100.0% 100.0% 0.0% 0.0% 0.0% 0.0%


PARTS DISPOSITION

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

Rework Procedure

Group Number 1 Group Number 2

Refer to the relevant Machine model Disassembly and Assembly Manual for removal and installation instructions of the Electric Lift Pump (Transfer Pump) and Screen-Fuel.1)Isolate the fuel and electrical supply.2)Remove and replace the Screen- Fuel. Ensure all open fuel line orifices are capped during the procedure.3)Remove and replace the Electric Lift Pump (Transfer Pump). Ensure all open fuel line orifices are capped during the procedure.

4) Remove the secondary filter air vent fuel return line. Ensure all fuel pipe orifices are capped off (using capping kit) prior to carrying m512ersa




out the next steps.5) Remove the secondary filter air vent fuel line connector (this may be a banjo or spigot dependant on machine model). See Image 1.2.16) Assemble the replacement secondary filter air vent fuel line connector (banjo or spigot. See Image 1.2.27) Tighten the spigot connection to 17+/-2Nm.8) Tighten the banjo bolt connection to 17+/-2Nm. Ensure the banjo orientation is maintained within the dimension shown in Image 1.2.3 during the tightening operation.9) Reinstate the fuel and electrical supply.

Image1.2.2

Group Number 3 Group Number 4 Group Number 5

Refer to the relevant Machine model Disassembly and Assembly Manual for removal and installation instructions of the Screen-Fuel.1) Isolate the fuel and electrical supply.2) Remove and replace the Screen-Fuel. Ensure all open fuel line orifices are capped during the procedure.3) Release any clamps securing fuel hose to the spigots of the Electric Lift Pump. Ensure all open fuel line orifices are capped during the procedure.4) Remove the electrical connector from the Electric Lift Pump.5) If the starter motor if fitted in front of the Electric Lift Pump then refer to the engine Disassembly and Assembly manual for instructions on removing the Electric Starting Motor. Refer to Image 2.1.16) Cut and remove the cable tie that secures the speed sensor wiring harness to the rear of the Electric Lift Pump mounting bracket Refer to Image 2.1.27) Undo and remove the Electric Lift Pump mounting bracket bolts (3 off) affixed to the engine. NOTE: Do NOT remove the Electric Lift Pump m512ersa




from the mounting bracket. Refer to Image 2.1.38) Remove and replace the Electric Lift Pump.9) Re-assembly of the replacement Electric Lift Pump is the reverse of the disassembly.10) Tighten the Electric Lift Pump bracket mounting bolts (3 off M8) to 22+/-5.5 Nm.11) Re-assembly of the Electric Starting Motor is the reverse of the disassembly. Refer to the engine Disassembly and Assembly manual for assembly instructions.12) Install the electrical connector to the Electric Fuel Pump ensuring the electrical connector is fully located by carrying out a pullback test.13) Care must be taken when assembling the cable tie to ensure harness covering is not damaged.

Image2.1.1

Image2.1.2




Image2.1.3

14) Remove the secondary filter air vent fuel return line. Ensure all fuel pipe orifices are capped off (using capping kit) prior to carrying out the next steps.15) Remove the secondary filter air vent fuel line connector (this may be a banjo or spigot dependant on machine model). See Image 2.2.116) Assemble the replacement secondary filter air vent fuel line connector (banjo or spigot). See Image 2.2.217) Tighten the spigot connection to 17+/-2Nm if fitted18) Tighten the banjo bolt connection to 17+/-2Nm if fitted. Ensure the banjo orientation is maintained within the dimension shown in Image 2.2.3 during the tightening operation.19) Reinstate the fuel and electrical supply.

Image2.2.2 m512ersaCaterpillar: Confidential Yellow

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techdoc print page - Cgt Ediliziaweb.cgtedilizia.it/SISCO/Documenti/1/PS52713.pdf · 2014-07-25 · regulations, directives, ordinances, orders, or statutes of the United States,