PRODUCT SUPPORT PROGRAM FOR REPLACING THE FLOATING AFTERCOOLER CORE BOLTS ON CERTAIN 797 AND 797B LARGE OFF HIGHWAY TRUCKS

Usage:

SEBE8739-02

April 14, 2004
(Revised February 2005)
U-113
A-76
O-93

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FLOATING AFTERCOOLER CORE BOLTS ON CERTAIN 797 AND 797B LARGE OFF HIGHWAY TRUCKS
1063		PS50808

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 "PS50808" 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.

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 April 14, 2004 (Revised November 2004) Service Letter. Change4s have been made to the Parts Needed and the Rework Procedure.

TERMINATION DATE

July 31, 2005

PROBLEM

The 0L1143 bolts used to hold the aftercooler top cover may break due to improper alignment during assembly, and or incomplete tie bars in the air intake manifold housing. There have also been a few reports of the 0S1590 bolts that hold the air intake manifold housing to the block breaking.

AFFECTED PRODUCT

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Model	Identification Number
797	5YW1-194, 197-232, 234, 236-276
797B	JSM1-123, 127-131, 134-136, 139-149, 151-202

PARTS NEEDED

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Qty	Part Number	Description
20	2615615	Bolt
14	5M2894	Washer ? Hard
6	1U2812	Spacer
12	4S5898	Seal ? O-Ring
4	1090075	Seal ? O-Ring
2	1097411	Seal ? O-Ring
1	1215736	Gasket ? Turbocharger
1	2146043	Manifold - Air
2	2183759	Seal ? O-Ring

NOTE: Parts Required per Aftercooler, if Aftercooler cover bolts are broke and the Air Manifold tie bars are intact and complete:

Reference in SIS Web the 2303802 and 2303803 Lines Group Air for the
location ofthe parts listed.

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Qty	Part Number	Description
14	2615615	Bolt
14	5M2894	Washer

NOTE: Parts Required per Aftercooler if air manifold to block bolts are found broke: Reference in SIS Web the 2303802 and 2303803 Lines Group Air for the location of the
part listed.

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Qty	Part Number	Description
6	1U2812	Spacer
6	2615615	Bolt

NOTE: Additional Parts Required per Aftercooler if Air Manifold tie bars are missing or incomplete: Reference in SIS Web the 2303802 and 2303803 Lines Group Air, 2146042 Aftercooler Group, and the 1843234 Turbocharger Group for the location of the parts listed.

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Qty	Part Number	Description
2	2183759	Seal
4	1090075	Seal
12	4S5898	Seal
1	1215736	Gasket
1	2146043	Manifold
2	1097411	Seal

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-50000	100%	100%	0	0	0	0
NOTE: .5 hour allowed per aftercooler for tie bar inspection. NOTE: .5 hour labor allowed per broken bolt for bolt extraction. NOTE: 1 hour labor allowed per aftercooler for aftercooler bolt (0L1143) replacement. NOTE: 1 hour labor allowed per aftercooler for air intake manifold to block bolt (0S1590) replacement. NOTE: 15 hours labor allowed per aftercooler for intake air manifold (2146043) replacement. NOTE: Labor may be claimed if the repairs are in chassis. Labor may not be claimed if the repair is during an engine overhaul.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

797A trucks that were updated with PS41234 after November 25, 2003 and have reports of aftercooler cover bolts broken additional information will be required in order to qualify for application of this program. The following information will need to be reported to 797 Service Support at 765-448-2274:

Truck Serial Number
Engine Serial Number
Engine Hours
Date and hours when PS41234 was last done.
Location of broken bolts

NOTE: Inspection of the intake manifold to insure the three tie bars are still intact and complete.

NOTE: Do not perform this program until you have read and completely understand it.

If aftercooler top cover bolts (0L1143) are found broken perform the following procedure prior to removing the broken bolts and replacing all the bolts.

Illustration 1

Remove the two 0S0509 bolts (A) holding the 2095241 lifting eye retainer (B) to gain better access to the 8T6762 pipe plug (C).
Remove the 8T6762 pipe plug (C) and insert a borescope in the intake manifold to inspect the three tie bars to make sure they are intact and complete. Refer to Illustration 1.

NOTE: Inspect both front and rear engines.

If all three tie bars are intact and complete reinstall the 8T6762 pipe plug (C) and the 2095241 Lifting Eye Retainer (B) with the two 0S0509 bolts (A) and proceed to step 4. If the tie bars are not complete, replace the intake manifold housing. For instructions to replace the intake manifold housing refer to RENR2276-01.

Illustration 2

Illustration 3

Illustration 4

Remove all the 0L1143 bolts in both the front and rear engines and extract the broken bolts.
Document the bolt location of the broken bolt(s) and save all bolts for warranty purposes.

Illustration 5

Install alignment dowels in the inlet manifold housing hole locations 11 and 14, or 12 and 13, to properly center the aftercooler cover. The dowels should have a 3/8 x 16 thread and the shank should fit snug in the core mounting holes and aftercooler cover mounting holes to insure proper centering of the core and aftercooler cover. See the attached guide dowel print for fabrication dimensions of the dowel. See Illustration 6.

Illustration 6 (Alignment Dowel)

Install all new 2615615 bolts and 5M2894 washers provided.
If air inlet manifold to block bolts (0S1590) are found broken perform the following procedure prior to removing the broken bolts and replacing all the bolts.
Remove all the 0S1590 bolts in both the front and rear engines and extract any broken bolts.
Document the bolt location of the broken bolt(s) and save all bolts for warranty purposes.
Install new 261-5615 bolts and 1U2812 spacers provided. Torque the new bolts to 50 Nm +/- 10 Nm following the sequence in Illustration 7.