PRODUCT SUPPORT PROGRAM FOR INSTALLING A SECONDARY FUEL FILTER SUPPORT ON CERTAIN 797B AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A SECONDARY FUEL FILTER SUPPORT ON CERTAIN 797B AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE3834-01

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07Dec2015

(Revised 20May2016)

R120

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING A SECONDARY FUEL FILTER SUPPORT ON CERTAIN 797B AND 797F OFF-HIGHWAY TRUCKS
7777 1261 1263		PS90544

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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 "PS90544" 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 07Dec2015 Service Letter. Changes have been made to the Service Claim Allowances.

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TERMINATION DATE

31Dec2017

PROBLEM

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The fuel filter support comes loose on C175-20 engines in 797B Retrofit and 797F Off-Highway Trucks resulting in unplanned downtime. The 8T-0644 bolts securing fuel filter base support to engine break causing the support to be supported by the fuel line.

AFFECTED PRODUCT

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Model	Identification Number
797B	JSM00293
797F	LAJ00148-00150, 158-182, 185-187, 216-221, 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

PARTS NEEDED

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Qty	Part Number	Description
3	8T0441	BOLT-HEX HEAD
1	8T0722	BOLT-HEX HEAD
4	8T7934	WASHER-HARD
5	1061242	SPACER
5	3720687	BOLT-HEX HEAD
1	4688629	SUPPORT 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.

ACTION REQUIRED

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A 468-8629 Support Assembly for the fuel filters is now used on C175-20 Off-Highway Truck Engines. The 468-8629 Support Assembly mounts behind the existing 319-6980 Support Assembly. The additional support allows for the elimination of the 4 long bolts and spacers that mounted the bottom of the support to the engine oil pan. The new support mounts the fuel filter support up to oil pan rail to provide additional support and stiffness.

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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%
0-36000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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With the engine at a temperature that is safe to work on, remove the fuel line clamps, two above the filter base and two behind the filter canisters, supporting the filter assembly remove the bolts (x12) that are attaching the filter assembly to the filter support assembly (319-6980), lower the filter assembly enough to provide access to the lower filter support assembly fasteners that screw into the oil pan and the front lower bolt that only screws into the filter support assembly, remove all of these bolts, washers and spacers, remove the 5 oil pan bolts immediately behind the filter support assembly as indicated in the attached image.Clean the pan rail surface of built up dirt and any other material that will stop the support from seating properly onto the pan rail surface.

Place the lower support assembly (468-8629) behind the filter support assembly, flat surface to the oil pan flange and the flange with the welded threaded spacers to the filter support assembly, replace the 5 spacers 198-4767 with 106-1242 and bolts 6V-5696 with 372-0687 that were on the oil pan to block, using the new bolts (1x 8T-0722, 3x 8T-0441) with new washers 8T-7934 attach the filter support assembly to the new lower filter support assembly. Tighten fasteners (M10 to 70+/-15 N.m ), (M12 to 120+/-20 N.m), recheck the torque on all fasteners.

Reattach the fuel filter assembly to the filter support assembly, reattach the fuel filter line supports, tighten fasteners M10 to 55+/-10 N.m