PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST GAS BACK PRESSURE VALVE AND ASSOCIATED PIPEWORK ON CERTAIN 963K TRACK-TYPE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST GAS BACK PRESSURE VALVE AND ASSOCIATED PIPEWORK ON CERTAIN 963K TRACK-TYPE LOADERS

Usage:

TEBE7894-00

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31Jul2018

U-444

A-329

D-391

O-398

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST GAS BACK PRESSURE VALVE AND ASSOCIATED PIPEWORK ON CERTAIN 963K TRACK-TYPE LOADERS
1050 1061 108P 108N 5137 5479 1082		PS53832

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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 "PS53832" 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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TERMINATION DATE

31Jul2020

PROBLEM

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The 3905194/">390-5194 Exhaust Gas Valve Gp can fail on certain 963K Track-Type Loaders. This is due to the vibration characteristics of the valve's current position that can lead to clutch wear and failure to operate effectively. The valve may be off-center when not powered or the valve may not move or close fully when commanded.

The fault results in the aftertreatment system being unable to regenerate. One of the following event codes may be active:

E1265 DPF Active Regeneration Inhibited Due to Low Exhaust Gas Pressure
E1645 Aftertreatment Active Regeneration Inhibited Due to Low Exhaust Pressure

AFFECTED PRODUCT

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Model	Identification Number
963K	LBL00100-00782, 786-787

PARTS NEEDED

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Qty	Part Number	Description
3	7K1181	STRAP-CABLE
3	7T1099	LINK
1	2179039	STRAP-CABLE
1	3435907	CLAMP V-BAND
1	3561219	CLIP-FIR TREE
1	3595885	CLAMP AS.
1	3629401	BELLOWS AS.
2	3672071	CLAMP
1	3905194	VALVE GP-EXHAUST
1	4220768	ELBOW AS-EXH
1	5530138	TUBE AS-EXHAUST
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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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%
0-5000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-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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Follow the Troubleshooting procedures for the active event codes.

If a fault is found with the exhaust back pressure valve, install a replacement 3905194/">390-5194 Exhaust Gas Valve Gp (NRS). Refer to Disassembly and Assembly, "Exhaust Back Pressure Valve - Remove and Install".

Replace the exhaust gas back pressure valve and associated pipework to reposition the valve closer to the turbocharger. Refer to Image1.1.1.

Image1.1.1

The revised location of the back pressure valve may cause an interference with the machine wiring harness. Add three weld links to the frame in the positions indicated in Image1.2.1, Image1.2.2, and Image1.2.3. Re-route the harness with cable straps through the new weld links to avoid an interference with the back pressure valve.