PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AFTERCOOLER INLET BELLOWS ON CERTAIN HIGH ALTITUDE 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AFTERCOOLER INLET BELLOWS ON CERTAIN HIGH ALTITUDE 793D OFF-HIGHWAY TRUCKS

Usage:

REBE4289-01

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15Dec2008

(Revised 24Apr2009)

A-530

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AFTERCOOLER INLET BELLOWS ON CERTAIN HIGH ALTITUDE 793D OFF-HIGHWAY TRUCKS
1071		PI31600

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31600" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31600" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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:

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NOTE:	This Revised Service Letter replaces the 15Dec2008 Service Letter. Changes have been made to Rework Procedure to correct part number 1W-2431 Clamp.

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COMPLETION DATE	TERMINATION DATE
30Jun2009	31Dec2009

PROBLEM

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The aftercooler inlet bellows need to be replaced on certain 793D Off Highway Trucks. The existing inlet bellows can crack causing a boost leak.

AFFECTED PRODUCT

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Model	Identification Number
793D	FDB00426-00429, 434-436, 547, 549, 558, 560, 562, 564, 566, 568, 570, 572, 637, 665, 667, 669, 692, 694, 696, 762, 764, 766, 768, 781, 821, 823

PARTS NEEDED

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Qty	Part Number	Description
12	1T0765	BOLT
2	1W2431	CLAMP-V-BAND
12	3V3308	WASHER-HARD
2	1969138	GASKET
2	3253656	BELLOWS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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 213-6557 bellows and replace with the a new 325-3656 Bellows, 1W-2431 Clamps, and 196-9138 Gaskets.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING AFTERCOOLER INLET BELLOWS ON CERTAIN HIGH ALTITUDE 793D OFF HIGHWAY TRUCKS

MODELS INVOLVED - 793D High Altitude Off-Highway Trucks

Dear Caterpillar Product Owner:

The aftercooler inlet bellows need to be replaced on the products listed below. The existing inlet bellows can crack causing a boost leak. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 15Dec2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 15Dec2008 Service Letter

Rework Procedure

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Use this procedure as a guide for installing the bellows assemblies that go between the air outlet of compressor housing for the high pressure turbochargers and the air inlets of the aftercooler. This procedure should be used for installing the bellows whenever a high pressure turbocharger is repaired or a high pressure turbocharger is replaced.

Image1.1.1

1. Loosen the bolts that hold the compressor housing in place on the high pressure turbocharger. This will allow the compressor housing (A) to be rotated.

2. Install a new 196-9138 Gasket (5) and the 325-3656 Bellows Assembly (3) in position on the air inlet (B) of the aftercooler. Loosely install the 1T-0765 Bolts (1) and the 3V-3308 Washers (2) that fasten the bellows assembly to the air inlet of the aftercooler. This will allow the bellows assembly to be moved on the aftercooler.

3. Rotate the compressor housing (A) for the high pressure turbocharger into position. Align the flange on the bellows assembly (3) with the flange on the air outlet of the compressor housing.

4. Install the 1W-2431 Clamp Assembly (4) that fastens the air outlet of the compressor housing (A) to the bellows assembly (3). Tighten the clamp assembly to a torque of 20 +/- 4 N.m (15 +/- 3 lb ft). Completely around the clamp assembly, lightly tap the clamp assembly. Tighten the clamp assembly again to a torque of 20 +/- 4 N.m (15 +/- 3 lb ft).

5. Be sure that the bellows assembly (3) is free to move on the air inlet (B) of the aftercooler. Then tighten the bolts (1) that were loosely installed in Step 2 to a torque of 55 +/- 10 N.m (40 +/- 7 lb ft).

6. Tighten the bolts that were loosened in Step 1.