Usage:
28Sep2016 |
(Revised 02Nov2016) |
Before/After Parts stock action needed | PRODUCT SUPPORT PROGRAM FOR REPLACING THE CLEAN FUEL MODULE ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS |
|
1256 1255 | PS45234 |
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 "PS45234" 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 28Sep2016 (Revised 17Oct2016) Service Letter. Changes have been made to the Rework Procedure. |
TERMINATION DATE |
30Sep2018 |
PROBLEM
The existing 457-5703 Fuel Pump Gp (Clean Fuel Module (CFM)) can fail on certain 794 AC Off-Highway Trucks. If the existing CFM fails it can cause unplanned downtime to repair. |
AFFECTED PRODUCT
Model | Identification Number |
794 AC | MT500100-00112 |
PARTS NEEDED
Qty |
Part Number | Description |
2 | 2256948 | SEAL-O-RING |
2 | 2385084 | SEAL-O-RING-STOR |
1 | 5115018 | PUMP GP-FUEL |
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 457-5703 Fuel Pump Gp (Clean Fuel Module) from dealer parts stock. |
Replace the 457-5703 Fuel Pump Gp with the new 511-5018 Fuel Pump Gp according to the procedure below. Pay attention to the tightening instructions for assembling the new CFM. |
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock. |
0-36 mo |
NOTE: This is a 2.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim. |
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PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
- 797F images have been used as illustration for this procedure. The 794 AC hose and filter assemblies will be different, but the CFM disassembly and assembly remains the same. - Shut off fuel flow. - Disconnect electrical harness and any hoses connected to the CFM. |
- Remove the 3 bolts highlighted in red. |
Image1.2.1 |
- Remove the 4 bolts/nuts highlighted in red. |
Image1.3.1 |
- The 457-5703 Fuel Pump Gp (CFM assembly) (red) can be removed. |
Image1.4.1 |
- Loosen, but do not remove the bolts in red in Image 1.5.1. This allows easier alignment of the bolts for the new CFM. |
Image1.5.1 |
- Replace the 225-6948 O-rings (red) between the filter base and CFM. |
Image1.6.1 |
- Install 511-5018 Fuel Pump Gp (CFM assembly) on filter base, ensuring that 225-6948 O-rings do not fall out. |
Image1.7.1 |
- Start threads on all 7 bolts/nuts highlighted in red |
Image1.8.1 |
- Tighten highlighted 4 bolts to 40+/-7 ft-lb (55+/-10Nm) |
Image1.9.1 |
- Tighten highlighted 3 bolts to 40+/-7 ft-lb (55+/-10Nm). Retighten the 6 bolts you loosened earlier in Image 1.5.1. to 40+\-7 ft-lb (55+/-10Nm). |
Image1.10.1 |
- Reinstall hoses using new 238-5084 seals to CFM at standard torque for non ferrous components - 16 STOR is 90+/-13Nm - 16 ORFS is 110+/-16Nm |
Image1.11.1 |
- Reconnect the CFM power connector and CFM sensor (red). - Cable tie the harness to the CFM?s harness clips. - Open the valves to the CFM (in red). - Close the drain valves on the primary fuel filters (green). - Prime the fuel system. |