PRODUCT SUPPORT PROGRAM FOR REPLACING CRACKED EXHAUST TUBING ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING CRACKED EXHAUST TUBING ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS

Usage:

SEBE9028

January 8, 2005
U-11
A-10
D-10
O-11

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING CRACKED EXHAUST TUBING ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS
1050		PS41693

NOTE: This Program can 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 "PS41693" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, 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.

Termination Date

January 31, 2007

PROBLEM

The exhaust tubing is experiencing cracking due to vibration and relative movement between engine and frame on certain 797 and 797B Off-Highway Trucks. New exhaust tubing components are available.

AFFECTED PRODUCT

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Model	Identification Number
797	5YW1-194, 197-232, 234, 236-257, 260-276
797B	JSM1-124, 127-131, 134-136, 139-149, 151-183

PARTS NEEDED

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Quantity	Part Number	Description
2	7E8452	CLAMP-V-BAND
4	5P1076	WASHER-HARD
2	8T4139	BOLT
2	8T4172	BOLT
2	8T4244	NUT
2	7X7729	WASHER
1	1746325	ELBOW AS.
1	1747926	STRAP AS.
3	1881072	CLAMP
2	2337711	SHIELD - HEA
2	2393114	BELLOWS AS
4	2418492	CLAMP-V-BAND
1	2474178	ELBOW AS.
1	2474179	ELBOW AS.
1	2474180	ELBOW AS.
1	2474181	ELBOW AS.
1	2484871	BRACKET AS.

ACTION REQUIRED

See the attached procedure.

SERVICE CLAIM ALLOWANCES

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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
0-50,000 Hours 0-Up Months	100%	8	0	0	0	0
NOTE: This is a 8-hour job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

REWORK PROCEDURE

1. Remove old 149-3079 Piping Gp per RENR2035. Retain (2) 174-7962 Strap As, (6) 8T4192 bolts and (6) 8T4223 washers for reuse.

2. Install 247-4179 elbow (1) and 188-1072 clamp (2) to turbocharger on the front engine. Tighten clamp to 16 +/- 4 N.m. (12 +/- 3 lb/ft). Tap clamp lightly all around then retighten to 16 +/- 4 N.m. (12 +/- 3 lb/ft) before starting engine. The static inspection torque should be 9 N.m. (7 lb/ft) minimum.

3. Install 239-3114 bellows (3) and 241-8492 clamp (4) to elbow (1).

4. Install 247-4178 elbow (5) and 241-8492 clamp (6) to bellows (3).

5. Install 247-4180 elbow (7) and 188-1072 clamp (8) to turbocharger on rear engine. Tighten clamp to 16 +/- 4 N.m. (12 +/- 3 lb/ft). Tap clamp lightly all around then retighten to 16 +/- 4 N.m. (12 +/- 3 lb/ft) before starting engine. The static inspection torque should be 9 N.m. (7 lb/ft) minimum.

6. Install 239-3114 bellows (9) and 241-8492 clamp (10) to elbow (7).

7. Install 247-4181 elbow (11) and 241-8492 clamp (12) to bellows (9).

8. Install 174-6325 elbow (13) and 188-1072 clamp (14) to elbow (11). Tighten clamp to 16 +/- 4 N.m. (12 +/- 3 lb/ft). Tap clamp lightly all around then retighten to 16 +/- 4 N.m. (12 +/- 3 lb/ft) before starting engine. The static inspection torque should be 9 N.m. (7 lb/ft) minimum.

9. Install 248-4871 bracket (15) and 174-7926 strap (16) to elbow (11) with 8T-4172 bolts and 7X-7729 washers.

10. Install 8T-4139 bolts, 5P-1076 washers and 8T-4244 nuts (17).

11. Install two 154-6351 straps (18) with 8T-4223 washers and 8T-4192 bolts (19).

12. Install 7E-8452 clamps to connect piping (13, 5) to mufflers (not shown). Tighten clamps to 16 +/- 4 N.m. (12 +/- 3 lb/ft). Tap clamps lightly all around then retighten to 16 +/- 4 N.m. (12 +/- 3 lb/ft) before starting engine. The static inspection torque should be 9 N.m. (7 lb/ft) minimum.