Usage:
| 17Dec2014 |
| (Revised 16Dec2016) |
| Before/After Parts stock action needed | PRODUCT SUPPORT PROGRAM FOR THE INSTALLING CLEAN FUEL MODULE ON CERTAIN 793F AND 795F OFF-HIGHWAY TRUCKS |
|
| 1261 1380 1274 1702 1405 1290 1251 1713 1408 | PS44610 |
|
| 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 "PS44610" 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. |
| 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. |
| 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. |
| 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. |
| NOTE: | This Revised Service Letter replaces the 17Dec2014 (Revised 07Sep2016) Service Letter. Changes have been made to the Termination Date and Parts Stock Action was added. |
TERMINATION DATE |
| 31Dec2017 |
PROBLEM
| The existing low pressure fuel system can cause engine shutdowns due to inability to prime or maintain prime on certain 793F and 795F Off-Highway Trucks. If the existing low pressure fuel system loses prime it can/will cause machine startability issues and unplanned down time. The addition of the clean fuel module, 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. Customers will more reliably meet 500 hours fuel filter changes and allow customers to operate machines at lower tank levels. The addition of the alternator with fully potted electronics will provide improved alternator life reducing failures due to vibration. The increased alternator output at low engine RPM will improve battery life in most applications by reducing deep cycling. |
AFFECTED PRODUCT
| Model | Identification Number |
| *******Group 1******* | |
| 793F | SSP00112-00287, 290-300, 302-438, 441-543, 545-626, 628-629, 633-733, 735-749, 751-758, 760-882, 884-888, 892-907, 909-912, 914-915, 917-918, 921, 923-950, 952-959, 961-999, 1002-1021 |
| 793F XQ | SND00100-00131 |
| *******Group 2******* | |
| 795F AC | ERM00151-00167, 170-198, 200-206, 209-210, 216-217, 219, 221-269, 277-293 |
| 795F XQ | SNT00100 |
| *******Group 3******* | |
| 793F | SSP01022-01071 |
| *******Group 4******* | |
| 795F AC | ERM00294-00296 |
| 795F XQ | SNT00101 |
| *******Group 5******* | |
| 793F CMD | RBT00111-00171 |
PARTS NEEDED
Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 1K4649 | SPACER |
| 3 | 1V6645 | SPACER |
| 2 | 5P8245 | WASHER-HARD |
| 17 | 6V1820 | BOLT |
| 1 | 6V4248 | BOLT |
| 1 | 6V4249 | BOLT-HEX HEAD |
| 13 | 6v5839/">6V5839 | WASHER-HARD |
| 8 | 6V5843 | BOLT-HEX HEAD (After Failure Only) |
| 1 | 6V6782 | CLIP-TOP |
| 1 | 6V6783 | CLIP-BOTTOM |
| 2 | 6V7673 | BOLT-HEX HEAD |
| 1 | 6V8149 | NUT-HEX |
| 2 | 6V8336 | BOLT |
| 2 | 6v9028/">6V9028 | SEAL-O-RING |
| 1 | 7S3916 | CLIP |
| 1 | 7S3919 | CLIP |
| 3 | 7V6571 | GROMMET |
| 1 | 8T0643 | BOLT |
| 2 | 8T1889 | CLIP-2 PIECE |
| 2 | 8T1890 | CLIP-2 PIECE |
| 2 | 8T5436 | BOLT-HEX HEAD |
| 2 | 8T6408 | BOLT-HEX HEAD |
| 2 | 8t6850/">8T6850 | SEAL-O-RING (After Failure Only) |
| 1 | 8T7876 | SEAL-O-RING |
| 1 | 1030892 | GROMMET |
| 2 | 1128186 | SEAL-O-RING (After Failure Only) |
| 1 | 1129069 | BRACKET |
| 2 | 1400174 | BOLT-HEX HEAD |
| 16 | 1984766 | WASHER-HARD |
| 2 | 2588738 | SEAL-O-RING |
| 1 | 2594597 | SEAL-O-RING |
| 1 | 3331207 | IDLER AS |
| 2 | 3449286 | RING |
| 1 | 3516636 | TENSIONER-BELT |
| 1 | 3826928 | ELBOW (After Failure Only) |
| 1 | 3900533 | BELT |
| 1 | 3924074 | HOSE AS |
| 1 | 4207737 | SUPPORT |
| 1 | 4304358 | HOSE AS |
| 1 | 4370125 | ALTERNATOR GP -B |
| 1 | 4478058 | SUPPORT |
| 1 | 4487924 | PULLEY |
| 1 | 4501429 | TUBE AS |
| 1 | 4510072 | GUARD-ALT |
| 1 | 4510073 | GUARD AS-ALT |
| 1 | 4510074 | GUARD AS-ALT |
| 1 | 4518540 | HOSE AS |
| 1 | 4518541 | HOSE AS |
| 2 | 4518542 | HOSE AS |
| 1 | 4565132 | CABLE AS |
| 1 | 4575212 | CABLE AS |
| 1 | 4591579 | KIT-CFM (Trucks equipped with fuel heater) |
| 1 | 4591582 | KIT-CFM (Trucks NOT 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 | 1K4649 | SPACER |
| 3 | 1V6645 | SPACER |
| 2 | 2Y5829 | NUT-HEX |
| 2 | 5P8245 | WASHER-HARD |
| 17 | 6V1820 | BOLT |
| 1 | 6V4248 | BOLT |
| 1 | 6V4249 | BOLT-HEX HEAD |
| 17 | 6v5839/">6V5839 | WASHER-HARD |
| 8 | 6V5843 | BOLT-HEX HEAD (After Failure Only) |
| 2 | 6V7673 | BOLT-HEX HEAD |
| 1 | 6V8149 | NUT-HEX |
| 2 | 6V8336 | BOLT |
| 2 | 6v9028/">6V9028 | SEAL-O-RING |
| 1 | 7S3916 | CLIP |
| 1 | 7S3919 | CLIP |
| 4 | 7V6571 | GROMMET |
| 1 | 8T0643 | BOLT |
| 3 | 8T1889 | CLIP-2 PIECE |
| 3 | 8T1890 | CLIP-2 PIECE |
| 2 | 8T5436 | BOLT-HEX HEAD |
| 2 | 8T6408 | BOLT-HEX HEAD |
| 2 | 8t6850/">8T6850 | SEAL-O-RING (After Failure Only) |
| 1 | 8T7876 | SEAL-O-RING |
| 3 | 9X6772 | STRAP-CABLE |
| 2 | 1128186 | SEAL-O-RING (After Failure Only) |
| 1 | 1129069 | BRACKET |
| 25 | 1257875 | TUBE-BULK |
| 1 | 1258534 | PLATE AS. |
| 1 | 1305300 | CLIP |
| 2 | 1400174 | BOLT-HEX HEAD |
| 16 | 1984766 | WASHER-HARD |
| 1 | 2295465 | VALVE-DUAL |
| 2 | 2588738 | SEAL-O-RING |
| 1 | 2594597 | SEAL-O-RING |
| 1 | 3331207 | IDLER AS |
| 2 | 3449286 | RING |
| 1 | 3516636 | TENSIONER-BELT |
| 2 | 3523965 | CLIP-LADDER |
| 1 | 3523968 | CLIP-LADDER |
| 1 | 3826928 | ELBOW (After Failure Only) |
| 1 | 3900533 | BELT |
| 1 | 4207737 | SUPPORT |
| 1 | 4370125 | ALTERNATOR GP -B |
| 1 | 4471573 | CABLE AS |
| 1 | 4478058 | SUPPORT |
| 1 | 4487924 | PULLEY |
| 1 | 4501429 | TUBE AS |
| 1 | 4510072 | GUARD-ALT |
| 1 | 4510073 | GUARD AS-ALT |
| 1 | 4510074 | GUARD AS-ALT |
| 1 | 4575212 | CABLE AS |
| 1 | 4591583 | KIT-CFM (Trucks equipped with fuel heater) |
| 1 | 4591584 | KIT-CFM (Trucks NOT equipped with fuel heater) |
| 1 | 4638691 | HOSE AS |
| 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 3******* | ||
| 1 | 3924074 | HOSE AS |
| 1 | 4304358 | HOSE AS |
| 1 | 4518540 | HOSE AS |
| 1 | 4518541 | HOSE AS |
| 2 | 4518542 | HOSE AS |
| 1 | 4591579 | KIT-CFM (Trucks equipped with fuel heater) |
| 1 | 4591582 | KIT-CFM (Trucks NOT 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 4******* | ||
| 1 | 4499888 | HOSE AS. |
| 1 | 4528102 | HOSE AS. |
| 1 | 4591583 | KIT-CFM (Trucks equipped with fuel heater) |
| 1 | 4591584 | KIT-CFM (Trucks NOT equipped with fuel heater) |
| 1 | 4638692 | HOSE AS |
| 1 | 4638693 | HOSE AS |
| 1 | 4638694 | HOSE AS |
| 1 | 4638695 | HOSE AS |
| 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. |
||
| *******Group 5******* | ||
| 1 | 3924074 | HOSE AS |
| 1 | 4304358 | HOSE AS |
| 1 | 4591582 | KIT-CFM (Trucks NOT 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
Remove all individual 457-5703 Clean Fuel Modules (Fuel Pump Groups) from dealer parts stock inventory. |
| Groups 1 and 2 require the alternator to be updated. 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. **Older engines may require the 273-4020 elbow to be updated to a 382-6928 elbow to accept the new alternator. The following parts are only required on machines that have the former 273-4020 elbow: 6V-1820 (Qty 2) 6v5839 (Qty 8) 6v9028 (Qty 1) 112-8186 (Qty 2) 8t6850 (Qty 2) 3826928 (Qty 1) 6v5843(Qty 8) The new 382-6928 elbow was effective with: A4K01004 B7B01172 B7C01003 JTL01047 THR00100 Groups 3 and 4 have updated alternators from factory and do not require an electrical upgrade to add the CFM. Group 5 has a larger alternator from the factory and does not require an electrical upgrade to add the CFM. 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. Note that the latest engine software is required to run CFM pump and the CFM must be activated within ET by turning "Electric Fuel Transfer Pump Status" to "Installed" (See Image1). Note that machines updated with the CFM will now use a 4 micron primary fuel filter. This replaces the former 10 micron fuel filter. Failure to use the 4 micron filter will decrease the filtration performance of the system. 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. REHS9557 - Special Instruction to install the CFM on a 793F REHS9558 - Special Instruction to install the CFM on a 795F |
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| Image1 |
SERVICE CLAIM ALLOWANCES
|
Submit one claim for all individual 457-5703 Clean Fuel Modules (Fuel Pump Groups) removed from dealer parts stock inventory. Do not claim any CFMs that are removed from the kits. |