PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MUFFLER ON CERTAIN 311D, 312D, AND 313D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MUFFLER ON CERTAIN 311D, 312D, AND 313D EXCAVATORS

Usage:

TEBE4026-02

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28Apr2016

(Revised 10Oct2016)

D-184

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST MUFFLER ON CERTAIN 311D, 312D, AND 313D EXCAVATORS
1062		PS53202

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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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53202" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 28Apr2016 (Revised 09Aug2016) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Apr2018

PROBLEM

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The existing 2396659/">239-6659 Muffler can crack on certain 311D, 312D, and 313D Excavators. If the existing Muffler fails, it may cause engine exhaust gas to leak.

AFFECTED PRODUCT

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Model	Identification Number
311D	AKW00625, 628, 630-632, 785-786, 1107, 1125, 1139, 1513, 1539-1540, 1547
312D	FBJ00376, 397, 401, 403, 436, 584, 623, 663, 668, 683, 710, 730, 734, 769, 787, 792, 796-797, 800, 806-807, 809, 837-840, 842-844, 850-851, 855, 1004, 1023-1024, 1061, 1066-1067, 1069, 1072-1073, 1405, 1411, 1423-1424, 1426, 1430-1432, 1460, 1462, 1467, 1492, 1505, 1511, 1522-1523, 1527, 1551, 1564, 1571, 1573-1574, 1576, 1589, 1591, 1643, 1648, 1650-1651, 1657, 1671, 1674, 1676, 1679, 1772-1774, 1776, 1778-1779, 1781, 1783, 1785-1786, 2079, 2110, 2119, 2132, 2139, 2144, 2158, 2169, 2173, 2242, 2245-2246, 2250, 2252-2254, 2256, 2258, 2265-2266, 2269, 2285, 2293, 2297-2299, 2344-2345, 2347, 2352, 2358, 2381, 2395, 2405, 2413, 2418, 2439-2440, 2444, 2452, 2460, 2519, 2690, 2702, 2708, 2714, 2722, 2725, 2735, 2743, 2764, 2784, 2786, 2793, 2802, 2818, 2825, 2849, 2856, 2876-2877, 2882, 3019, 3024-3025, 3449, 3488, 3504, 3511, 3530, 3537, 3541, 3545-3546, 3557, 3566, 3572-3573, 3575, 3577, 3579-3580, 3582, 3587, 3590-3592, 3594-3597, 3599-3601, 3603-3604, 3607, 3610-3614, 3618, 3623-3624, 3629, 3631-3633, 3639-3640, 3643, 3645-3646, 3648, 3651-3652, 3654, 3656-3657, 3661, 3663, 3665-3668, 3670, 3674, 3678-3679, 3682, 3686-3689, 3691-3700, 3704, 3706, 3708-3709, 3712-3713, 3716, 3718, 3723-3724, 3727-3728, 3730, 3733, 3737-3738, 3740-3741, 3747-3748, 3750, 3753, 3761-3762, 3766-3767, 3770, 3777-3778, 3780, 3785-3787, 3792-3794, 3797, 3799-3800, 3802, 3804-3805, 3810-3811, 3815, 3819-3820, 3826, 3832, 3835-3836, 3838, 3841, 3848, 3853, 3860, 3864, 3868, 3871, 3881, 3884, 3887, 3889, 3891-3893, 3901, 3904, 3940, 3946, 3950, 3953, 3959, 4142, 4147, 4153, 4209, 4216, 4218, 4222, 4237, 4240, 4257, 4264, 4276, 4279-4280, 4288, 4304, 4306, 4314, 4317, 4328, 4334, 4351, 4366, 4480, 4493, 4496, 4498, 4518, 4541, 4583, 4592, 4616, 4650, 4669, 4677, 4689, 4691
313D CR	LCE00506, 841, 848, 931, 943

PARTS NEEDED

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Qty	Part Number	Description
1	5I7639	CLAMP AS
1	5I7937	GASKET
6	6V8231	NUT-HEX
3	1968015	STUD
1	2396659	MUFFLER
1	5012401	BELLOWS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Replace the existing 2396659/">239-6659 Muffler with a brand new 2396659/">239-6659 Muffler and add the 501-2401 Bellows As (flexible tube) between the muffler and the turbocharger. Refer to Image1. Refer to the attached Rework Procedure.

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Image1

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%
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-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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1. Remove the existing following components from the engine:

2396659/">239-6659 Muffler (Qty 1)
5I-7848 U-Bolt (Qty 2) (retain for re-use)
5I-7639 Clamp As. (Qty 1)
196-8013 Pipe (Qty 1)
196-8014 Bracket (Qty 1) (retain for re-use)
196-8012 Bracket (Qty 1) (retain for re-use)
5I-7937 Gasket (Qty 1)
196-8015 Stud (Qty 3)

Refer to Image1.1.1.

Image1.1.1

2. Modify the new 5I-7639 Clamp Assembly (refer to Image1.2.1) and the new 2396659/">239-6659 Muffler (refer to Image1.2.2).

Image1.2.1

Image1.2.2

3. Assemble the 196-8014 Bracket and the 196-8012 Bracket which was removed in Step 1. The alignment for both brackets for the muffler will need to be adjusted. Assemble the right and left bracket to the flywheel housing. The dimension of A and B (both to the center of U-bolt hole) must be 253mm and parallel to each other. Tighten the four bolts to a specified torque of 43 +/-5 N.m. Refer to Image1.3.1.

Image1.3.1

4. Assemble the new 196-8015 Stud and set the new 5I-7937 Gasket to the turbocharger. Tighten the stud to a specified torque of 23 +/-2 N.m.

5. Assemble the new 501-2401 Bellows Assembly to the new muffler which was modified in Step 2. Insert the 501-2401 Bellows Assembly to the new 5I-7639 Clamp Assembly which was modified in Step 2, and join them with the muffler.

6. Place the muffler, that was assembled in Step 5, in the proper position. Tighten the nuts (double nuts) in the turbocharger side, avoiding any overload to the bellows, to a specified torque of 36 +/- 6 N.m. Fix the U-bolt to the bracket ensuring that there is no inclination in the muffler. Tighten the upper nuts to a specified torque of 35 +/- 6 N.m and the bottom nuts to a specified torque of 10 +/- 2 N.m, avoiding any overload to the muffler. Refer to Image1.6.1, 1.6.2, and 1.6.3.