PRODUCT SUPPORT PROGRAM FOR INSTALLING A CLEAN FUEL MODULE ON CERTAIN 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A CLEAN FUEL MODULE ON CERTAIN 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE2072-02

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17Dec2014

(Revised 18Nov2015)

U-768

A-568

D-675

O-667

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSTALLING A CLEAN FUEL MODULE ON CERTAIN 797F OFF-HIGHWAY TRUCKS
1261 1296 1256 1405 1154		PS44611

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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 "PS44611" 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:

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 17Dec2014 (Revised 28Jul2015) Service Letter. Changes have been made to the Title, Problem, Affected Product, Parts Needed, Action Required, and Service Claim Allowances. The hoses are no longer part of the kits.

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TERMINATION DATE

31Dec2016

PROBLEM

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The existing low pressure fuel system can cause engine shutdowns due to inability to prime or maintain prime on certain 797F and Off-Highway Trucks. If the existing low pressure fuel system loses prime it can cause machine startability issues and unplanned down time.

Customers using fuel at or above the specification for fuel cleanliness may also see improved life of fuel system components including injectors and high pressure fuel pumps and allow more customers to meet 500 hours fuel filter changes and allow customers to refill machines at lower tank levels.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
797F	LAJ00141, 145-147, 151-157, 189-194, 197-199, 204-215, 222-223, 229, 232, 237-246, 270-272, 275, 277, 280, 282, 286, 288, 290-291, 297-300, 305, 309-310, 314, 316, 318-319, 325-326, 329-340, 343-344, 349-351, 353, 355, 357-366, 368, 370, 372-373, 375-379, 383-392, 395-396, 399-400, 412-413, 416-417, 421-422, 424, 432, 434, 439-440, 442-444, 468, 478-482, 484-485, 502-506

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*****Group 2*****
797F	LAJ00537, 539-541

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	4462342	HOSE AS (if NOT equipped with fuel heater)
1	4517288	HOSE AS (if equipped with fuel heater)
1	4591585	KIT-CFM (if equipped with fuel heater)
1	4591586	KIT-CFM (if NOT equipped with fuel heater)
1	4628879	HOSE AS (if equipped with fuel heater)
1	4628880	HOSE AS (if equipped with fuel heater)
1	4628881	HOSE AS (if equipped with fuel heater)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 11% 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	4462342	HOSE AS (if NOT equipped with fuel heater)
1	4517288	HOSE AS (if equipped with fuel heater)
1	4591585	KIT-CFM (if equipped with fuel heater)
1	4591586	KIT-CFM (if NOT equipped with fuel heater)
1	4628879	HOSE AS (if equipped with fuel heater)
1	4628880	HOSE AS (if equipped with fuel heater)
1	4628881	HOSE AS (if equipped with fuel heater)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 11% 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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For Group 1, an improved alternator is required to operate the CFM and requires the completion of PS44608/REHS9653. Failure to update the alternator may lead to situations where, during extended periods of engine idling, the alternator may not be able to source a sufficient level of current to maintain the truck's electrical system needs. This may lead to battery discharge, low system voltage events, and the potential for erratic behavior from the truck's electronic systems. If PS44608 has already been completed no further upgrades to the alternator are required.

Update the machine to add the CFM to reduce the risk of loss of prime and/or startability issues. The CFM will also increase the cleanliness of the fuel system. Improved cleanliness will increase the service life of the high pressure fuel pump, injectors, and other fuel system components.

Refer to the Service Manual if/as necessary to install the clean fuel module (CFM).

Note that the latest engine software is required to run the CFM pump and the CFM must be activated within ET. Within ET, navigate to the "Engine Configuration Parameters" and change the status of the "Electric Fuel Transfer Pump Installation Status" to "Installed".

Note that the addition of the CFM drove a harness change to the engine. An update to the chassis harness may be required when replacing the engine. Reference SEPD1969-An Updated Left Side Engine Harness Connector is Now Used in Certain 793F, 793F CMD, 793F AC, 795F AC, and 797F Off-Highway Trucks

Refer to the following special instructions to update your machine:
REHS9653 - Special Instruction to update the alternator
REHS9559 - Special Instruction to install the CFM on a 797F

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-60000 hrs, 0-120 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 30.0-hour job for Group 1
Only one CFM kit allowed per claim. Dealer must verify machine configuration and order the correct CFM kit based upon if the machine is equipped with a fuel heater.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-60000 hrs, 0-120 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 30.0-hour job for Group 2
Only one CFM kit allowed per claim. Dealer must verify machine configuration and order the correct CFM kit based upon if the machine is equipped with a fuel heater.