PRODUCT SUPPORT PROGRAM FOR INSPECTING THE HIGH PRESSURE FUEL PUMP ON CERTAIN 3512E PETROLEUM ENGINES, AND SPF743 TRAILER MOUNTED PUMPERS Caterpillar
PRODUCT SUPPORT PROGRAM FOR INSPECTING THE HIGH PRESSURE FUEL PUMP ON CERTAIN 3512E PETROLEUM ENGINES, AND SPF743 TRAILER MOUNTED PUMPERS
Usage:
TEBE8909-01
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10Apr2019
(Revised 10May2019)
U-222
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Before/After
Parts stock action needed
PRODUCT SUPPORT PROGRAM FOR INSPECTING THE HIGH PRESSURE FUEL PUMP ON CERTAIN 3512E PETROLEUM ENGINES, AND SPF743 TRAILER MOUNTED PUMPERS
125H
PS46223
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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 Program must be administered either before or after failure.
In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46223" as the Part Number
and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.
If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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NOTE:
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field,
"7755" as the Group Number, "56" as the Description Code.
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NOTE:
Although this Program is to be administered as described above on the Affected Product,
parts should be removed from parts stock as soon as possible.
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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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NOTE:
This Revised Service Letter replaces the 10April2019 Service Letter. Changes have been made to the Affected Product, Parts Needed, Action Required, Service Claim Allowances, Parts Disposition, and Rework Procedure.
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TERMINATION DATE
30Apr2021
PROBLEM
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The existing high pressure fuel pump can experience a failure which may generate debris in the lube oil system certain 3512E Petroleum Engines, and SPF743 Trailer Mounted Pumpers.
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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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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****Parts Stock ****
Remove all 521-5433 high pressure fuel pumps from dealer parts stock.
****Affected Product****
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If the existing high pressure fuel pump has at least 750 hours and at next scheduled oil and oil filter change, perform the attached Rework Procedure.
When an inspection is performed, document the condition of the camshaft lobes by taking a photograph and attaching it to the claim. The photograph will be required when submitting the claim.
If a high pressure fuel pump fails inspection, record the new and the replaced (failed) high pressure fuel pump serial in the claim. This documentation will be required when submitting the claim.
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SERVICE CLAIM ALLOWANCES
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****Parts Stock****
Submit one claim for all parts removed from dealer parts stock.
****Affected Product****
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-15000 hrs, 0-48 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 1
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
1 hour allowed for pump inspection.
An additional 5 hours are allowed for pump replacement.
Reasonable Travel and Mileage is allowed.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-14000 hrs, 0-60 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 2
1 hour allowed for pump inspection.
An additional 10 hours are allowed for pump replacement.
Reasonable Travel and Mileage is allowed.
PARTS DISPOSITION
****Parts Stock****
NACD:
Hold all 521-5433 high pressure fuel pumps for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
****Affected Product****
NACD:
Hold all 521-5433 high pressure fuel pumps for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
Rework Procedure
1. With engine off, remove the HPFP side port plugs (1) in Image 1.1.1. Inspection procedure is most effective if the engine has been off for at least one hour. A small amount of additional oil may drain from the HPFP. Retain the plugs for reinstallation later. Note: o-rings may stick to pump housing, if so remove the o-ring and re-install on the plug.
2. Using a flashlight to illuminate the camshaft, visually inspect the surface of the cam lobe in the first port (closest to front of engine). Evaluate the cam lobe surface for surface texture/appearance.
Example pictures of Acceptable/Monitor/Failed cam lobes are shown below.
If the condition of the cam lobe is questionable, use of a borescope may be required to further evaluate the condition of the pump cam. If the condition does not clearly match one of the three conditions(Acceptable/Monitor/Failed), use a borescope to photograph the cam lobe in question and share the photos with your Dealer TC. The TC can create a GDSN Product Health Service Request and attach the photos and reference this publication in the description prior to submitting the SR to Caterpillar for assistance.
3. Repeat the inspection for the remaining three cam ports.
If ANY lobes have a condition like ?Failure? (shown below), the HPFP should be replaced. Refer to ?Fuel Pump (High Pressure) - Remove and Install? Disassembly and Assembly guide.
4. If all four lobes are in acceptable condition, an additional inspection can be completed to increase confidence in the health of the HPFP. Bar the engine one-third of a revolution and reinspect all four cam ports. It is possible for the HPFP cam to show damage on only one lobe and only part way around the cam lobe ? this process will confirm the cam is acceptable on all sides of all lobes.
If all four lobes are still acceptable, no additional action is needed.
If any lobe shows signs of damage (Failure) after rotation, the HPFP should be replaced. Refer to Disassembly and Assembly, ?Fuel Pump (High Pressure) - Remove and Install?.
5. Reinstall the four side port plugs and torque to 27 Nm (20 Ft Lb).
6. Do NOT attempt to refill HPFP with oil. The HPFP will refill with oil on the next engine crank/start.
Image1.1.1
Cam condition: Acceptable Clearly visible cross-hatch polishing pattern Even surface texture across the cam lobe Minimal (1-2) lines or marks around cam lobes ? camshafts will occasionally have tracking marks around the lobes, which is typical and does not necessarily
Action: Continue visual camshaft inspections
Image1.2.1
Cam condition: Monitor Several minor lines or marks around cam face Cross-hatch polish still visible across cam face Lines may have some width and may not reflect light
Action: Continue visual camshaft inspections, If the condition does not clearly match one of the three conditions(Acceptable/Monitor/Failed), use a borescope to photograph the cam lobe in question and share the photos with your Dealer TC. The TC can create a GDSN Product Health Service Request and attach the photos and reference this publication in the description prior to submitting the SR to Caterpillar for assistance.
Image1.3.1
Cam condition: Failure (of HPPF) Surface of cam appears ?ground? or ?dimpled? Brass colored material visible Significant marks or grooving of cam face Clear depth to lines/marks around camshaft
Action: Replace HPFP
Image1.4.1
Use KENR8163 for instructions on replacing a 521-5433 high pressure fuel pump.
