PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BOLTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BOLTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS

Usage:

TEBE4693-00

Show/hide table

20May2016

H160
H163
H169

Show/hide table

Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE AFTERCOOLER BOLTS ON CERTAIN 793D OFF-HIGHWAY TRUCKS
1071 1052		PS90597

Show/hide table

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 Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

Show/hide table

NOTE:	When reporting the repair, use "PS90597" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as 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.

Show/hide table

TERMINATION DATE

31May2017

PROBLEM

Show/hide table

The 261-5604 or 165-3935 Bolts (depending on previous repairs) for the aftercooler, as directed for use in TIBU5975, are experiencing failures. When these bolts fail, it will typically lead to a boost leak.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
793D	FDB00109, 266, 372, 379-382, 394-396, 402, 404-405, 409, 415-418, 421-422, 456-457, 461-462, 469-472, 484-485, 502, 504-506, 524-527, 546, 613, 618, 623, 629, 640, 645, 649, 653, 657, 659, 661, 663, 671-679, 685, 731, 733, 739-740, 759, 761, 772, 775-776, 783, 789-790, 802-806, 810-813, 825, 847-850, 875-878

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
12	3767740	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

Show/hide table

Replace the existing 261-5604 or 165-3935 Bolts with new 376-7740 bolts on a 4000 hour interval to prevent fatigue failures. The 376-7740 bolts are made from a more thermally compliant material for high temperature applications. Reuse the washers and spacers. There are 12 bolts per engine. Retightening this bolted joint with new hardware will reduce the occurrence of fatigue failures of the bolts resulting in boost pressure leaks.

Use the following tightening procedure when you install the new hardware for the aftercooler. Refer to Image 1 for the bolt locations, and Image 2 for the tightening sequence.

1. Tighten the bolts in the numerical sequence to 24 Nm (18 lb ft).

2. Tighten the bolts again in the numerical sequence to 47 Nm (35 lb ft).

Image 1 Bolt Location - (1) 376-7740 Bolts
Image 2 Tightening Sequence

Show/hide table

Image1

Image2

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-16000 hrs, 0-20 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 3.0-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.
Service letter allowed to be completed and claimed at 4,000 hour intervals.

Show/hide table