PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ELBOW ASSEMBLIES AND CLAMPS THAT ATTACH TO THE MUFFLER ON HIGH ALTITUDE APPLICATION 797 AND 797B OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ELBOW ASSEMBLIES AND CLAMPS THAT ATTACH TO THE MUFFLER ON HIGH ALTITUDE APPLICATION 797 AND 797B OFF-HIGHWAY TRUCKS

Usage:

REBE2390-01

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09Nov2007

(Revised 16Jan2008)

A-468

D-471

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After Failure Only Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST ELBOW ASSEMBLIES AND CLAMPS THAT ATTACH TO THE MUFFLER ON HIGH ALTITUDE APPLICATION 797 AND 797B OFF-HIGHWAY TRUCKS
1061		PS51388

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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 "PS51388" 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:

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.

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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.

NOTE:	This Revised Service Letter replaces the 09Nov2007 Service Letter. Changes have been made to the Service Claim Allowances.

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TERMINATION DATE

30Nov2009

PROBLEM

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The existing clamped joint between the muffler and exhaust elbow can fail on 797 and 797B Off-Highway Trucks. If the existing clamped joint fails, it can cause exhaust leakage at the joint along with potential failure of the clamp and at the flange of the exhaust elbow and muffler.

AFFECTED PRODUCT

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Model	Identification Number
797	5YW00195-00196, 233, 235, 258-259, 277
797B	JSM00125-00126, 132-133, 137-138, 150, 214-215, 288-291

PARTS NEEDED

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Qty	Part Number	Description
2	7E8452	CLAMP-V-BAND
1	2536176	ELBOW AS.
1	2536177	ELBOW AS.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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 ****

Remove all 253-6176 Elbow As. (Engineering Change 00) and 253-6177 Elbow As. (Engineering Change 00) from dealer parts stock. For help in understanding the difference between the old and new engineering change (e/c) levels for the exhaust elbows, please reference the following pictures.

Image1

Image2

****Affected Product****

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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%
0-20000 hrs, 0-36 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
NOTE: If there has been a previous repair, part age will apply. Retain a copy of the previous repair in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

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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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Rework Procedure

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Note: All parts will be reused except for the (2) 7E-8452 Clamps, 253-6176 Elbow As., and 253-6177 Elbow As.
-Remove (2) 7E-8452 Clamps from 253-6176 Elbow As. and 253-6177 Elbow As.
-Remove 233-7711 Shield-Heat and 241-8492 Clamp-V-Band from 253-6176 Elbow As.
-Remove 233-7711 Shield-Heat and 241-8492 Clamp-V-Band from 253-6177 Elbow As.
-Remove (6) 8T-4192 Bolts, (6) 8T-4223 Washers to remove (2) 154-6351 Straps from Elbow assemblies.
-Remove 253-6176 Elbow As. and 253-6177 Elbow As. from chassis with a suitable lifting device.
-Inspect flange face and tube on muffler at end that is connected to elbow assemblies for damage. Replace if damage is found on flange face or cracking is found.

-Install new 253-6176 Elbow As. to front exhaust tube using a suitable lifting device and secure with 241-8492 clamp. Leave clamp loose for adjustment. Install 7E-8452 clamp to Elbow As. and Muffler As., leave clamp loose for adjustment.
-Install new 253-6177 Elbow As. to rear exhaust tube using a suitable lifting device and secure with 241-8492 Clamp. Leave clamp loose for adjustment. Install clamp 7E-8452 Clamp to Elbow As. and Muffler As., leave clamp loose for adjustment.
-Install (2) 154-6351 Strip with (6) 8T-4192 Bolts and (6) 8T-4223 Washers to bracket on frame to secure Elbow Assemblies.
-Tighten 241-8492 Clamp to 11.3 Nm.
-Tighten (2) 7E-8452 Clamp to 16 +/- 4 Nm. Tap clamp lightly all around and retighten clamps to 16 +/- 4 Nm.
-The static inspection torque should be 9 Nm minimum.
-Install (2) 233-7711 Shield-Heat to Bellow Assemblies.