PRODUCT SUPPORT PROGRAM FOR INSTALLING A CLEAN FUEL MODULE ON CERTAIN 793F, 795F AC, AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A CLEAN FUEL MODULE ON CERTAIN 793F, 795F AC, AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE3436-05

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20Aug2015

(Revised 06Apr2016)

R050
R11B
R120
Z850

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING A CLEAN FUEL MODULE ON CERTAIN 793F, 795F AC, AND 797F OFF-HIGHWAY TRUCKS
1296 1256 1261 1405		PS90523

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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 Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90523" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as 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.

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NOTE:	This Revised Service Letter replaces the 20Aug2015 (Revised 18Dec2015) Service Letter. Changes have been made to the Parts Needed and Action Required.

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TERMINATION DATE

31Aug2017

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 793F, 795F AC, and 797F Off-Highway Trucks. If the existing low pressure fuel system loses prime it can cause machine startability issues and unplanned down time.

The addition of the clean fuel module with 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.

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

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Model	Identification Number
*****Group 1*****
797F	LAJ00148-00150, 158-182, 185-187, 216, 218-221, 230, 233-236, 247-250, 256-261, 263, 265, 397, 406, 408, 411, 414-415, 423, 425-427, 433, 435-438, 467, 471-473, 495-501

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*****Group 2*****
795F AC	ERM00163-00164, 168, 205, 264, 270-276

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

793F

SSP00140-00143, 150-151, 165-168, 187-188, 267-268, 279, 290, 292-295, 298, 303, 311, 317, 320, 329, 331, 340, 346-347, 351, 356, 362-364, 366, 376, 378-380, 395, 397-398, 443, 445, 447, 451, 453, 455, 484-485, 502, 506-507, 513, 527, 548-549, 561, 611, 613, 635, 637, 643-645, 649-652, 685-686, 695, 720, 726, 729, 733, 736, 742-743, 748, 752-754, 756, 765, 772, 783, 786, 815, 821, 830, 848-849, 864, 866-868, 934-936, 940-943, 946, 952-955, 967-975, 978-981, 983-985, 1005-1006

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*****Group 4*****
793F	SSP00770, 782, 1008, 1046-1047, 1055-1056

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 16% 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** (See rework procedure)
1	6V4248	BOLT
1	6V4249	BOLT-HEX HEAD
17	6v5839/">6V5839	WASHER-HARD** (See rework procedure)
8	6V5843	BOLT-HEX HEAD** (See rework procedure)
2	6V7673	BOLT-HEX HEAD
1	6V8149	NUT-HEX
2	6V8336	BOLT
2	6v9028/">6V9028	SEAL-O-RING** (See rework procedure)
3	7K1181	STRAP-CABLE
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** (See rework procedure)
1	8T7876	SEAL-O-RING
3	9X6772	STRAP-CABLE
2	1128186	SEAL-O-RING** (See rework procedure)
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
2	3523965	CLIP-LADDER
1	3523968	CLIP-LADDER
1	3801423	ELBOW** (See rework procedure)
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 (If equipped with fuel heater)
1	4591584	KIT-CFM (If 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 17% 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	1K4649	SPACER
3	1V6645	SPACER
2	5P8245	WASHER-HARD
17	6V1820	BOLT** (See rework procedure)
1	6V4248	BOLT
1	6V4249	BOLT-HEX HEAD
13	6v5839/">6V5839	WASHER-HARD** (See rework procedure)
8	6V5843	BOLT-HEX HEAD** (See rework procedure)
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** (See rework procedure)
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** (See rework procedure)
1	8T7876	SEAL-O-RING
1	1030892	GROMMET
2	1128186	SEAL-O-RING** (See rework procedure)
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	3801423	ELBOW** (See rework procedure)
1	3900533	BELT
1	4207737	SUPPORT
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	4565132	CABLE AS
1	4575212	CABLE AS
1	4591579	KIT-CFM (If equipped with fuel heater)
1	4591582	KIT-CFM (If 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 15% 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	4591579	KIT-CFM (If equipped with fuel heater)
1	4591582	KIT-CFM (If 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 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.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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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*****
0-35000 hrs, 0-60 mo	100.0%	50.0%	0.0%	50.0%	0.0%	0.0%

NOTE: This is a 35.0-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*****
0-35000 hrs, 0-60 mo	100.0%	50.0%	0.0%	50.0%	0.0%	0.0%

NOTE: This is a 35.0-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.

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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 3*****
0-35000 hrs, 0-60 mo	100.0%	50.0%	0.0%	50.0%	0.0%	0.0%

NOTE: This is a 35.0-hour job for Group 3
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 4*****
0-35000 hrs, 0-60 mo	100.0%	50.0%	0.0%	50.0%	0.0%	0.0%

NOTE: This is a 35.0-hour job for Group 4
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.

PARTS DISPOSITION

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

Rework Procedure

GROUP 1 ( 797F )

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

GROUP 2 AND 3 (793F AND 795F )

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 254-6726 elbow to be updated to a 380-1423 elbow to accept the new alternator. The following parts are only required on machines that have the former 254-6726 elbow:
6V-1820 (Qty 2)
6v5839 (Qty 8)
6v9028 (Qty 1)
112-8186 (Qty 2)
8t6850 (Qty 2)
3801423 (Qty 1)
6v5843(Qty 8)
The new 380-1423 elbow was effective with:
B7B01172
B7C01003
JTL01047
THR00100

GROUP 4 ( 793F ALUMBRERA )

Group that has updated alternators from factory and do 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.

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