PRODUCT SUPPORT PROGRAM FOR REWORKING THE WASTEGATE ELBOW ON CERTAIN 797F OFF-HIGHWAY TRUCKS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REWORKING THE WASTEGATE ELBOW ON CERTAIN 797F OFF-HIGHWAY TRUCKS
Usage:
TEBE2905-02
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24Jun2015
(Revised 03Aug2015)
A-225
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Before/After
Parts stock action needed
PRODUCT SUPPORT PROGRAM FOR REWORKING THE WASTEGATE ELBOW ON CERTAIN 797F OFF-HIGHWAY TRUCKS
1057 1067
PS44782
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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 must 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 "PS44782" as the Part Number
and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.
If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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NOTE:
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field,
"7755" as the Group Number, "56" as the 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.
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NOTE:
This Revised Service Letter replaces the 24Jun2015 (Revised 07Jul2015) Service Letter. Changes have been made to Service Claim Allowance Table.
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TERMINATION DATE
30Jun2017
PROBLEM
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The existing wastegate elbow bolts can fail on certain 797F Off-Highway Trucks. If the existing bolts fails it can damage the threads in the turbocharger support casting, and cause unplanned downtime.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 ****
Rework the following engines in dealer parts stock and/or dealer exchange inventory:
797F HAA 282-2060 and 398-1020 Service Replacement C175-20 Engines built LLM01000 - 01441
Rework the existing 448-3596 Elbow per the attached Rework Procedure to add counterbored bolt holes. Install the reworked elbow along with new 478-4865 Bolts.
****Affected Product****
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Rework the existing 448-3596 Elbow per the attached Rework Procedure to add counterbored bolt holes. Install the reworked elbow along with new 478-4865 Bolts.
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SERVICE CLAIM ALLOWANCES
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****Parts Stock****
Submit one claim for all engines reworked in dealer parts stock and/or dealer exchange inventory. Include the engine arrangement numbers and the engine serial numbers in the claim.
6 Hours and the parts that are listed in the Parts Needed will be allowed for each engine that is reworked in dealer parts stock and/or dealer exchange inventory.
****Affected Product****
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-16000 hrs, 0-36 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
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NOTE: This is a 6.0-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.
An allowance of up to $500 will be allowed for machining counterbores into the existing wastegate manifold.
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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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1.) Machine counterbores into the four bolt holes in the 448-3596 Elbow.
Image1.1.1
Image1.1.2
2.) Machine counterbores to a diameter of 25mm and a depth of 45mm from the bottom face of the 448-3596 Elbow. Add a 1mm chamfer to the bottom hole, and add a 45 degree chamfer to the internal transition.
Image1.2.1
Image1.2.2
Image1.2.3
3.) Lubricate the new 478-4865 Bolts with Anti-Seize prior to assembly. Install bolts into reworked 448-3596 Elbow. Tighten the bolts to 240 +/- 40 Nm.
