PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL INJECTION PUMP AND POSSIBLY REPLACING THE ENGINE HEAD GASKET ON CERTAIN 318D2L EXCAVATORS
Usage:
TEBE3907-00
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| 17Nov2015 |
A-441
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| Before/After Parts stock action needed | PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL INJECTION PUMP AND POSSIBLY REPLACING THE ENGINE HEAD GASKET ON CERTAIN 318D2L EXCAVATORS |
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| 1124 7750 | PS44911 |
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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 "PS44911" 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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TERMINATION DATE |
| 30Nov2017 |
PROBLEM
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| The engine head gasket can fail on certain 318D2L Excavators. If the head gasket fails it can leak combustion gas into the coolant system, resulting in coolant over pressurization and overheating. Indication of failure includes engine overheating, coolant loss and gas in coolant. |
AFFECTED PRODUCT
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| Model | Identification Number |
| 318D 2L | DPJ00160-00161 JEB00120-00121 TZS00473-00474, 485-486 XAH00221-00286, 288-343 XGS00215-00218, 227-235, 237-249, 261-266, 268-270 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 4 | 1408718 | WASHER-SEATING (After Failure Only) |
| 1 | 1507732 | SEAL-O-RING (After Failure Only) |
| 1 | 1945390 | GASKET-MANIFOLD (After Failure Only) |
| 1 | 2256451 | GASKET-V COVER (After Failure Only) |
| 1 | 2257738 | SEAL-O-RING (After Failure Only) |
| 1 | 2257739 | SEAL-O-RING (After Failure Only) |
| 1 | 2258019 | GASKET-PUMP-HSG |
| 1 | 2258287 | GASKET-COVER |
| 4 | 2258526 | WASHER-COPPER (After Failure Only) |
| 1 | 2258536 | GASKET-MANIFOLD (After Failure Only) |
| 1 | 2584946 | GASKET-HEAD (After Failure Only - As Required) |
| 4 | 2751038 | SEAL-O-RING (After Failure Only) |
| 1 | 2863030 | RING-SEAL (After Failure Only) |
| 1 | 3533477 | GASKET-TURBO (After Failure Only) |
| 1 | 3533478 | GASKET-TURBO (After Failure Only) |
| 1 | 3693705 | GASKET-CYL HEAD (After Failure Only - As Required) |
| 1 | 4832326 | PUMP AS-FUEL |
| 20 | BULK_COOLANT | Coolant as per OMM-20 Liters (After Failure Only) |
| 16 | BULK_OIL | Oil as per OMM-16 Liters (After Failure Only) |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 19% 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. |
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ACTION REQUIRED
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Remove all 462-8111 Fuel Injection Pumps from dealer parts stock. |
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| Before completing the attached Rework Procedure, review the safety actions in the Operation and Maintenance Manual for safety information and safe working practices before starting the rework. If the head gasket has failed replace the head gasket and the fuel injection pump. If the head gasket has not failed replace the fuel injection pump only. The 483-2326 Fuel Injection Pump has revised injection timing to reduce the peak cylinder pressure in the engine. It is essential that the pump is installed as per the Disassembly and Assembly, "Fuel Injection Pump - Install - Delphi DP210" to achieve the desired fuel injection timing. |
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SERVICE CLAIM ALLOWANCES
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|
Submit one claim for all parts removed from dealer parts stock. |
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0-48 mo |
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| NOTE: This is a 5.5-hour job | ||||||
| For After failure, and additional 13.8 hours is allowed. A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure. |
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| If the head gasket has failed follow the rework procedure for both head gasket replacement and for fuel injection pump replacement If the head gasket has not failed follow the rework procedure for fuel injection pump replacement only. Head gasket replacement: Confirm the head gasket has failed through removal of the cylinder head and visual inspection of the gasket. Remove cylinder head ? refer to Disassembly and Assembly, "Cylinder Head - Remove". Confirm head gasket has failed through visual inspection, as per the images shown in Image 1.1.1. Clean the cylinder head face and the cylinder block face to remove any deposits on the gasket sealing surface using an appropriate cleaner. Do not use abrasive materials to remove the deposits during the cleaning process to ensure that the correct surface flatness is maintained. Inspect cylinder head for flatness and distortion. Refer to Image 1.1.2 for surface finish. Refer to System Operation Testing and Adjusting, "Cylinder Head ? Inspect" for more information. Resurface the cylinder head if required as per Testing and Adjusting, "Cylinder Head ? Inspect". Inspect cylinder block for surface finish on the top deck of the cylinder block. Refer to Image 1.1.2 for surface finish. If the cylinder block is within specifications, install a new 258-4946 Cylinder Head Gasket. If the block is not within specification, refer to Reuse And Salvage Guidelines, SEBF8076, "Specifications to Salvage Contact Surfaces of Cylinder Blocks" for more information. Note: A 369-3705 Cylinder Head Gasket may be required, depending on reuse and salvage guidelines. Follow Disassembly and Assembly, "Cylinder Head ? Install" with a new gasket as per above information. Fuel injection pump replacement: Follow Disassembly and Assembly, "Fuel Injection Pump - Remove - Delphi DP210". Do not reuse the fuel pump. Record removed fuel pump serial number in claim story. The fuel pump serial number is in the format "12345ABC". Install the new 483-2326 Fuel Pump as per Disassembly and Assembly, "Fuel Injection Pump - Install - Delphi DP210". Record the installed fuel pump serial number in claim story. It is essential to install the fuel injection pump with the correct engine position to achieve the correct fuel injection timing and the required reduction in peak cylinder pressure. Ensure that the new fuel priming procedure is followed. Refer to Service Magazine, SEPD1920, "New Fuel Priming Procedure for Certain 3054C and C7.1 (Mech) Machine Engines" for more information. |
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| Image1.1.1 |
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| Image1.1.2 |
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