PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER SUPPORTS ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER SUPPORTS ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE0592-02

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12Dec2013

(Revised 20Aug2014)

O-525

U-626

A-432

D-513

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER SUPPORTS ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS
1057 1059 1052 1053		PS52573

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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 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 "PS52573" 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:

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.

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NOTE:	This Revised Service Letter replaces the 12Dec2013 (Revised 25Feb2014) Service Letter. Changes have been made to the Affected Product and Parts Needed.

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TERMINATION DATE

31Dec2015

PROBLEM

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The existing turbocharger supports can develop surface cracks on the oil drain passage on certain 797, 797B, and 797F Off-Highway Trucks. If the existing turbocharger supports crack it can cause oil to weep from the turbocharger supports.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
797F	LAJ00141-00194, 197-230, 232-352, 354, 356, 358, 360, 362, 365, 367-375, 378, 380-385, 387, 389-391, 393-394, 396-397, 399-477, 479-499
797F XQ	WSP00100-00126

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*****Group 2*****
797	5YW00260
797B	JSM00151-00152

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*****Group 3*****
797B	JSM00262, 293

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
16	2M0849	WASHER-HARD
4	3E6785	SEAL-O-RING
16	6V3303	BOLT
4	6V3535	DOWEL
4	8C3107	SEAL-O-RING
2	8M9024	WASHER-HARD
16	8T0162	BOLT
1	8T0355	BOLT-HEX HEAD
1	8T5030	BOLT
16	9X8268	WASHER
4	1370135	DOWEL
1	1383251	SPACER
8	2126932	CLAMP-T'BOLT
16	2190313	CLAMP-T'BOLT
8	2287090	SEAL-O-RING-ORFS
8	2473393	CLAMP-V-BAND
12	2502343	SEAL-O-RING
4	3116030	SCREEN AS
1	3160488	SPACER
4	3343674	HOSE-HUMP
4	3668500	HOSE - HUMP
4	3715943	CLAMP-V-BAND
4	3899659	BELLOWS AS
4	4435940	BELLOWS AS
1	4438431	SUPPORT AS
1	4438433	SUPPORT AS
8	4461290	CLAMP-V-BAND
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.
*****Group 2*****
16	2M0849	WASHER-HARD
4	3E6785	SEAL-O-RING
16	6V3303	BOLT
4	6V3535	DOWEL
4	8C3107	SEAL-O-RING
2	8M9024	WASHER-HARD
16	8T0162	BOLT
1	8T0355	BOLT-HEX HEAD
1	8T5030	BOLT
16	9X8268	WASHER
8	1356259	CLAMP
4	1370135	DOWEL
1	1383251	SPACER
8	2287090	SEAL-O-RING-ORFS
8	2313264	CLAMP-T'BOLT
8	2338484	CLAMP-T'BOLT
8	2473393	CLAMP-V-BAND
12	2502343	SEAL-O-RING
4	3033131	CLAMP-V-BAND
4	3116030	SCREEN AS
4	3157909	BELLOWS AS
1	3160488	SPACER
4	3343674	HOSE-HUMP
4	4435940	BELLOWS AS
1	4438431	SUPPORT AS
1	4438433	SUPPORT AS
8	4461290	CLAMP-V-BAND
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.
*****Group 3*****
16	2M0849	WASHER-HARD
4	3E6785	SEAL-O-RING
16	6V3303	BOLT
4	6V3535	DOWEL
4	8C3107	SEAL-O-RING
2	8M9024	WASHER-HARD
16	8T0162	BOLT
1	8T0355	BOLT-HEX HEAD
1	8T5030	BOLT
16	9X8268	WASHER
8	1356259	CLAMP
4	1370135	DOWEL
1	1383251	SPACER
8	2287090	SEAL-O-RING-ORFS
8	2313264	CLAMP-T'BOLT
8	2338484	CLAMP-T'BOLT
8	2473393	CLAMP-V-BAND
12	2502343	SEAL-O-RING
4	3033131	CLAMP-V-BAND
4	3116030	SCREEN AS
4	3157909	BELLOWS AS
1	3160488	SPACER
4	3343674	HOSE-HUMP
4	4435940	BELLOWS AS
1	4438431	SUPPORT AS
1	4438433	SUPPORT AS
8	4461290	CLAMP-V-BAND
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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If a turbocharger support has cracked, replace both turbocharger supports. Refer to the attached Rework Procedure.

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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%
*****Group 1*****
0-30000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 14.0-hour job for Group 1

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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%
*****Group 2*****
0-30000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 14.0-hour job for Group 2

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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%
*****Group 3*****
0-30000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 14.0-hour job for Group 3

PARTS DISPOSITION

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

Rework Procedure

1.) Remove all 4 Turbochargers. Refer to Disassembly and Assembly Manual KENR8384, "Turbocharger - Remove and Install" for the correct procedure to remove the turbochargers.

2.) Remove the bolts, spacers, and washers from the two engine harness clipping locations on the turbocharger supports.

Image1.2.1

3.) Remove mounting bolts from each turbocharger support and remove both turbocharger supports from the engine.

Image1.3.1

4.) Install 6V-3535 Dowels into the two turbocharger mounting locations on each of the new 441-0732 and 441-0733 Turbocharger Supports. Also install new 137-0135 Dowels, 311-6030 Screens, and 8C-3107 O-Ring Seals into the two turbocharger mounting locations on each of the new 441-0732 and 441-0733 Turbocharger Supports.

Image1.4.1

5.) Install two new 3E-6785 O-Ring Seals onto the bottom sealing surface of each of the new 441-0732 and 441-0733 Turbocharger Supports.

Image1.5.1

6.) Install new 441-0732 and 441-0733 Turbocharger Supports onto the engine. Use 8 new 6V-3303 Bolts and 8 new 9X-8268 Washers in order to mount each of the new supports. Tighten the mounting bolts to standard torque.
Note: The new turbocharger supports no longer utilize the two mounting holes that go into the front face of the front housing.

Image1.6.1

7.) Reinstall the wiring harness clipping points using the new hardware shown below. Longer spacers and bolts are used to maintain correct harness location and orientation.

Image1.7.1

8.) Reinstall all 4 Turbochargers. Refer to Disassembly and Assembly Manual KENR8384, "Turbocharger - Remove and Install" for the correct procedure to install the turbochargers and associated hardware.