PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE LUBRICATION AND COOLING SYSTEM TUBE CLAMP BOLTS ON 793F AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE LUBRICATION AND COOLING SYSTEM TUBE CLAMP BOLTS ON 793F AND 797F OFF-HIGHWAY TRUCKS

Usage:

REBE6535-00

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21Oct2010

U-429

A-346

D-371

O-373

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE LUBRICATION AND COOLING SYSTEM TUBE CLAMP BOLTS ON 793F AND 797F OFF-HIGHWAY TRUCKS
1307 1378 1380		PI31814

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31814" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31814" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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, "7751" as the Group Number, "56" as the 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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COMPLETION DATE	TERMINATION DATE
30Apr2011	31Oct2011

PROBLEM

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The 6V-5815 and 6V-5842 Bolts used on the engine lubrication and cooling system lines need to be replaced on certain 793F and 797F off-highway trucks. The existing bolts may have been installed incorrectly and can loosen or fail.

AFFECTED PRODUCT

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Model	Identification Number
793F	SSP00112-00208
797F	LAJ00141-00207

PARTS NEEDED

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Qty	Part Number	Description
22	6V5815	BOLT
26	6V5839	WASHER-HARD
4	6V5842	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 38% 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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****Parts Stock ****

Rework the following parts engine serial numbers in Dealer Parts Stock. Replace the appropriate bolts and washers on the engine lubrication and cooling system tubes according to the attached Rework Procedure:

797F: LLM00141, 157, 166, 170, 172-174, 180, 181, 183, 185, 191, 201, 221, 226

793F: B7B00147, 150, 155, 160, 168, 174, 189, 195, 197, 202, 216, 217, 220, 252

797 Retrofit: A4K00111 - A4K00120

****Affected Product****

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Replace the appropriate bolts and washers on the engine lubrication and cooling system tubes.

Refer to the attached Rework Procedure for details.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all engines reworked in dealer parts stock.

2.0 hours will be allowed for each engine that is reworked. Include the engine serial number in the claim.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	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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****Parts Stock****

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

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****Affected Product****

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

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING ENGINE LUBRICATION AND COOLING SYSTEM TUBE CLAMP BOLTS

MODELS INVOLVED - 793F and 797F Off-Highway Trucks

Dear Caterpillar Product Owner:

The 6V-5815 and 6V-5842 Bolts used on the engine lubrication and cooling system lines need to be replaced on certain 793F and 797F off-highway trucks. The existing bolts may have been installed incorrectly and can loosen or fail. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 21Oct2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 21Oct2010 Service Letter

Rework Procedure

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Lubrication and Cooling Systems:

NOTE: There are 11 joints on the lubrication and cooling systems that will require this procedure.

1. For each tube end location, remove one bolt and replace with a new 6V-5815 bolt and 6V-5839 Washer.

2. Tighten the newly installed 6V-5815 Bolt to a torque of 55 +/- 10 Nm (40 +/- 7 lbft).

3. Remove the second bolt and replace with a new 6V-5815 bolt and 6V-5839 Washer.

4. Tighten the second newly installed 6V-5815 Bolt to a torque of 55 +/- 10 Nm (40 +/- 7 lbft).

5. Tighten the first bolt and then the second bolt again to a torque of 55 +/- 10 Nm (40 +/- 7 lbft) after the second bolt has been replaced.

6. Repeat this process for each joint shown below.

NOTE: The images show the joints for the C175-20 engine installed in the 797F. The C175-16 installed in the 793F will have the same number of joints in the same respective location.

Follow the procedure to replace the bolts in the joints on the left side of the engine shown Image1.2.1.

Image1.2.1

Follow the procedure to replace the bolts on the joint at the front of the engine shown in Image1.3.1.

NOTE: This joint is located behind the ECM mounting bracket on the 797F.

Image1.3.1

Follow the procedure to replace the bolts and washers on the joints on the right side of the engine shown in Image1.4.1.

Image1.4.1

Lubrication System Only:

NOTE: There are 2 joints on the lubrication system that will require this procedure.

1. For each tube end location, remove one bolt and replace with a new 6V-5842 Bolt and 6V-5839 Washer.

2. Tighten the newly installed 6V-5842 Bolt to a torque of 55 +/- 10 Nm (40 +/- 7 lbft).

3. Remove the second bolt and replace with a new 6V-5842 bolt and 6V-5839 Washer.

4. Tighten the second newly installed 6V-5842 Bolt to a torque of 55 +/- 10 Nm (40 +/- 7 lbft).

5. Tighten the first bolt and then the second bolt again to a torque of 55 +/- 10 Nm (40 +/- 7 lbft) after the second bolt has been replaced.

6. Repeat this process for each joint shown below.

NOTE: Image1.5.1 shows the joints for the C175-20 engine installed in the 797F. The C175-16 installed in the 793F will have the same number of joints in the same respective location.