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

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

Usage:

TEBE3952-02

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18Nov2015

(Revised 28Nov2017)

N030
N184
N18D
P280
P291
R080
R120
T120
T122
U066
U068

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING A CLEAN FUEL MODULE ON CERTAIN 797F AND 797F XQ OFF-HIGHWAY TRUCKS
1261 1274 1405 1380 1408		PS44916

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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 "PS44916" 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 18Nov2015 (Revised 03Mar2016) Service Letter. Changes have been made to the Termination Date , Affected Product, and Parts Needed.

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TERMINATION DATE

31May2018

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 797F XQ 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	LAJ00231, 262, 264, 266-269, 273-274, 276, 278-279, 281, 283-285, 287, 289, 292-296, 301-302, 304, 306-307, 315, 323-324, 342, 345-348, 352, 354, 356, 367, 369, 371, 374, 380-382, 393-394, 401-405, 407, 409-410, 418-420, 428-431, 441, 447-466, 469-470, 474-477, 483, 486-494, 507, 509-536, 538, 543-558
797F XQ	WSP00100-00129

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*****Group 2*****
797F	LAJ00183-00184, 188, 195-196, 217, 224-226

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 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 2*****
1	1S7251	TERMINAL-RING
2	1V6645	SPACER
1	2A2677	SPACER-STUD
1	2G1134	GROMMET
1	2Y5829	NUT-HEX
1	3E2343	TEE
1	4B4280	WASHER
2	4I3398	PLATE
1	4P7428	CLIP-LADDER
2	5C7621	PANEL LH
2	5C9553	BOLT-HEX HEAD
4	5G3676	GROMMET
4	5P4116	WASHER-HARD
2	5P6264	GROMMET
11	6D3479	CLIP-LOOP
7	6V0826	GROMMET
1	6V1820	BOLT
2	6V4249	BOLT-HEX HEAD
6	6V5839	WASHER-HARD
2	6V5842	BOLT-HEX HEAD
4	6V7978	SCREW-MACHINE
1	7D5206	CAP-DUST
1	7D5208	COUPLER-QDISC
6	7S3916	CLIP
6	7S3919	CLIP
23	7V6571	GROMMET
2	7X0608	WASHER-HARD
1	7X0752	BOSS-WELD
6	7X7729	WASHER-HARD
1	8D9423	ADAPTER-STR
2	8N0869	COVER-TERMINAL
34	8T1889	CLIP-2 PIECE
34	8T1890	CLIP-2 PIECE
1	8T3490	NUT-WELD
1	8T3734	BOSS-WELD
6	8T3851	BOSS-WELD
40	8T4121	WASHER-HARD
12	8T4133	NUT
14	8T4136	BOLT-HEX HEAD
5	8T4137	BOLT-HEX HEAD
1	8T4172	BOLT-HEX HEAD
1	8T4178	BOLT-HEX HEAD
1	8T4179	BOLT-HEX HEAD
1	8T4185	BOLT-HEX HEAD
4	8T4189	BOLT-HEX HEAD
4	8T4192	BOLT-HEX HEAD
2	8T4195	BOLT-HEX HEAD
1	8T4198	BOLT-HEX HEAD
5	8T4223	WASHER-HARD
1	8T4244	NUT-HEX
1	8T4935	BOSS-WELD
1	8T5005	BOLT-HEX HEAD
2	8T6466	BOLT-HEX HEAD
1	9R4581	PLATE
6	9X8250	CLIP
2	9X8256	WASHER
1	0026454	ADAPTER-STR
3	0908747	SPACER
1	0919035	SPACER-HARD
2	0969986	BOLT-HEX HEAD
1	1081672	SEAL-HOLE
1	1325789	CLIP-LADDER
3	1337810	STUD-TAPERLOCK
1	1379199	GROMMET
232	1598049	CABLE-BULK
2	1712215	BREAKER AS-CKT
6	1774562	GROMMET
6	1984767	WASHER-HARD
1	1997854	SPACER-HARD
1	2042281	STRAP-CABLE
1	2057299	CLIP-LOOP
1	2167790	TERMINAL-RING
2	2310336	STUD-TAPERLOCK
1	2597140	STUD-TAPERLOCK
3	2636726	SEAL
2	2643617	LOCKWASHER
1	2672744	FUSE AS-HOLDER
1	2746085	STUD-TAPERLOCK
1	2786389	STUD-TAPERLOCK
1	2823736	STUD-BOLT
1	2866192	SPACER
1	2884402	STUD-TAPERLOCK
7	2884403	STUD-TAPERLOCK
1	2887158	STUD
3	3023908	SPACER-HARD
2	3091905	STUD-TAPERLOCK
10	3114859	TUBE-BULK
1	3160487	SPACER-HARD
1	3207919	PLATE
1	3268116	FUSE
1	3283585	BLOCK AS-JCT
2	3289944	BOOT-JCT BLOCK
13	3445675	NUT-HEX
1	3453683	COVER
1	3453684	BOX AS.-BREAKER
1	3653245	HOSE AS
1	3653246	HOSE AS
1	3653247	PLATE
1	3731104	HOSE AS
1	3731105	HOSE AS
1	3979301	SPACER-HARD
1	4462342	HOSE AS (if NOT equipped with fuel heater)
1	4469281	BRACKET AS
1	4469282	CABLE AS
1	4517288	HOSE AS (if equipped with fuel heater)
1	4565132	CABLE AS
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)
1	5114409	CABLE 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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For LAJ00001-00533 and WSP00001-00129, 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

Group 2 requires the circuit breaker box location to be updated. Refer to REHS9332 on instructions on how to perform this update.

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
REHS9332 - Procedure to Relocate the Circuit Breaker Group on the 797F Off-Highway Truck

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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	100.0%	50.0%	0.0%	50.0%	0.0%	0.0%

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	100.0%	50.0%	0.0%	50.0%	0.0%	0.0%

NOTE: This is a 54.0-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. If REHS9332 has previously been applied to the machine, follow the part and labor allowances for group 1.