PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER GASKET AND MOUNTING BOLTS ON CERTAIN 793, 793B, 793C, AND 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER GASKET AND MOUNTING BOLTS ON CERTAIN 793, 793B, 793C, AND 793D OFF-HIGHWAY TRUCKS

Usage:

TEBE3560-03

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28Sep2015

(Revised 24Oct2016)

R080
R083
R087

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER GASKET AND MOUNTING BOLTS ON CERTAIN 793, 793B, 793C, AND 793D OFF-HIGHWAY TRUCKS
7777 1052 1053		PS90529

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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 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.

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NOTE:	When reporting the repair, use "PS90529" 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.

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NOTE:	This Revised Service Letter replaces the 28Sep2015 (Revised 06Nov2015) Service Letter. Changes have been made to Parts Needed, Action Required, and Rework Procedure.

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TERMINATION DATE

30Sep2017

PROBLEM

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There have been reports of repeat blowout failures of the turbine housing to exhaust manifold gasket, 121-5736. The 5P-7128 high temp bolt is in current use, but there are still blow out failures of the 121-5736 gasket.

AFFECTED PRODUCT

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Model	Identification Number
793	3SJ00011
793B	1HL00016, 23, 42, 44, 55, 106, 126, 198, 246, 257-259, 272-273, 389-390, 399-400, 425, 436, 508, 514-515
793C	4AR00092, 119, 125, 129, 160, 201-203, 205-206, 341 4GZ00107, 118, 199 ATY00240, 242, 949
793D	FDB00110, 177, 181-182, 205, 350-353, 357-358, 362-364, 426, 473-474, 486-488, 501, 503, 588, 590, 594, 600, 602, 606, 732, 781, 821, 823, 894-895, 986-987, 1001-1002, 1004-1005

PARTS NEEDED

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Qty	Part Number	Description
16	1732090	SPACER
16	3767739	BOLT-HEX HEAD
16	3912167	LOCKNUT-FLANGED
4	4890207	GASKET-EXHAUST
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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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Remove the turbocharger and install the 489-0207 exhaust gasket with the current locking thread bolts, spacers, and nuts. 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%
0-7000 hrs, 0-16 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 12.0-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.

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PARTS DISPOSITION

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

Rework Procedure

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See the appropriate Disassembly and Assembly manual for Turbocharger removal and installation.

NOTE: The 300-8579 Bolt has a special locking thread form that deforms the threads in the 310-2233 Nut. The 310-2233 Nut should only be used one time. If the nut has to be loosened or removed, it should be replaced with a new nut.

LH Turbocharger.
The following procedure should be performed by two technicians. It is difficult to properly tighten the turbocharger mounting bolts. With two technicians, one can hold the nut and one can properly tighten the fastener.

1). On the front of the engine, remove the step assembly from the top of the aftercooler housing to provide access to the turbocharger mounting flanges.
2). Remove the clamps and bolts holding the Turbocharger oil drain tubes and the oil drain elbow from the turbochargers. The oil drain elbow must be removed to provide proper access to the turbocharger mounting flange for bolt tightening.
3). Loosen the (16), exhaust elbow to exhaust manifold, support bolts (see image 1.1.1).
4). Remove the current turbocharger mounting hardware and gasket.
5). Use a small flat file to lightly remove carbon and foreign debris from the exhaust manifold and turbocharger mounting flanges. Clean the mounting surface with a shop towel, handi-wipe, and / or approved solvent such as brake cleaner. Raise the turbocharger to allow insertion of the 489-0207 exhaust gasket.
6). Apply 5P-3931 Anti-seize compound to the threads and install the two inboard 300-8579 Bolts and 298-6389 Spacers from the top. Install the 310-2233 Nuts finger tight.
7). Apply 5P-3931 Anti-seize compound to the threads and install in the Rear Outboard position, one 300-8579 Bolt and 298-6389 Spacer from the bottom. Install the 310-2233 Nut finger tight.

NOTE: Grinding of the bolt head flange may be required to prevent interference. Grind the flange back even with the bolt hex head on one flat (See image 1.1.2). If the parts cannot be modified, then new 2N2765 Bolts and 2N2766 Nuts should be installed.

8). Apply 5P-3931 Anti-seize compound to the threads and install from the bottom in the Front Outboard position, one 2N-2765 Bolt and 2N-2766 Nut. Install the nut finger tight. Use the new hardware if the the bolt flange has been reworked or the new fastener fits as-is.
9). Tighten the Turbocharger to exhaust manifold fasteners to a torque of 55 +/- 5 Nm (40 +/- 4 Lb Ft).

NOTE: It is important to achieve proper torque on these fasteners and any variation should be on the high side of the allowance. It is recommended that a MAC XB182, SnapOn FRDH181, or Proto 7118 Torque Adapter (See Images 1.1.7 / 8) be used with a torque wrench to achieve proper tightening of the mounting bolts. It is likely that in some positions an open end wrench will be needed to hold the opposite end of the fastener from turning.

RH Turbocharger.
1). Remove the current mounting hardware and gasket.
2). Use a small flat file to lightly remove carbon and foreign debris from the exhaust manifold and turbocharger mounting flanges. Clean the mounting surface with a shop towel, handi-wipe, and / or approved solvent such as brake cleaner. Raise the turbocharger to allow insertion of the 489-0207 exhaust gasket.
3). Apply 5P-3931 Anti-seize compound to the threads and install the 300-8579 Bolts, 298-6389 Spacers, and the 310-2233 Nuts finger tight. The inboard two bolts are installed facing up and the two outboard bolts are installed facing down.
4). Tighten the Turbocharger to exhaust manifold fasteners to a torque of 55 +/- 5 Nm (40 +/- 4 Lb Ft).(See Note above).
5). Retighten the 2N2765 Bolts and 2N2766 Nuts holding the exhaust elbow to the exhaust manifold supports to 55 +/- 5 Nm (40 +/- 4 Lb Ft).
6). Install the turbocharger oil drain elbows using new 7N-7559 gaskets and reinstall the clamps and bolts on the oil drain tubes removed above.