PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBINE INLET ELBOWS AND THE 475-0889 EXHAUST MANIFOLD ON CERTAIN 797F HIGH ALTITUDE ARRANGEMENT OFF-HIGHWAY TRUCK ENGINES Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBINE INLET ELBOWS AND THE 475-0889 EXHAUST MANIFOLD ON CERTAIN 797F HIGH ALTITUDE ARRANGEMENT OFF-HIGHWAY TRUCK ENGINES

Usage:

TEBE3518-02

01Dec2015
(Revised 13Jun2016)


A-464

 

Before/After

  
 Parts stock action needed 

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBINE INLET ELBOWS AND THE 475-0889 EXHAUST MANIFOLD ON CERTAIN 797F HIGH ALTITUDE ARRANGEMENT OFF-HIGHWAY TRUCK ENGINES

1061
PS44928
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 must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44928" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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, "7755" as the Group Number, "56" as the Description Code.

NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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 01Dec2015 (Revised 03Dec2015) Service Letter. Changes have been made to the Affected Product.


TERMINATION DATE

31Dec2017

PROBLEM

The existing 363-1979 elbow and 475-0889 manifold can fail on certain 797F Off-Highway Trucks with High Altitude Engine Arrangement. If the existing elbows fail, or if the exhaust manifold fails, it can result in exhaust leaks and unplanned downtime.

AFFECTED PRODUCT

Model Identification Number
797F  LAJ00195-00196, 231, 353, 355, 357, 359, 361, 363-364, 366, 376-377, 379, 386, 388, 392, 395, 398, 478, 537, 539, 544-553, 566-568, 572, 585-588, 590-595, 614-615

PARTS NEEDED

Qty

Part Number Description
4 3E8017 LOCKNUT
4 1490206 NUT-HEX
4 1541582 BOLT-HEX HEAD
1 2295333 SEAL
4 3440079 BELLOWS AS
4 3739176 SPACER-EXHAUST
4 3748101 SPACER
8 4346544 CLAMP-V-BAND
1 4798046 MANIFOLD
4 4820381 BOLT-HEX HEAD
2 4837358 ELBOW-EXHAUST
2 4847405 CLAMP-V-BAND
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 31% 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

****Parts Stock ****

Rework the following engines in dealer parts stock and/or dealer exchange inventory:

282-2060 and 398-1020 Service Replacement C175-20 Engines built LLM01000 to LLM01469

Refer to the Action Required for the Affected Product for rework instructions.

 
 
****Affected Product****
Refer to Disassembly and Assembly, UENR3275, "Air Inlet and Exhaust Module", for procedures to replace the exhaust manifold and the turbine inlet elbows.

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for all engines reworked in dealer parts stock and/or dealer exchange inventory. Include the engine serial numbers and arrangement numbers in the claim.

For 282-2060 and 398-1020 Service Replacement C175-20 Engines, 4 hours and the Parts Needed for the Affected Product will be allowed for each engine that is reworked in dealer parts stock and/or dealer exchange inventory.

 
 
****Affected Product****
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-14000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
14001-18000 hrs,
37-48 mo 
100.0%
0.0%
0.0%
0.0%
0.0%
100.0%
 NOTE: This is a 6.0-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.

Part hours based on engine service hours. Documentation of engine hours at time of repair must be included within the claim story.



PARTS DISPOSITION

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

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

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