PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE COMPRESSOR LINE CLAMPS ON CERTAIN 797F OFF-HIGHWAY TRUCKS WITH 4X4 ENGINE SERIAL PREFIX Caterpillar


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PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE COMPRESSOR LINE CLAMPS ON CERTAIN 797F OFF-HIGHWAY TRUCKS WITH 4X4 ENGINE SERIAL PREFIX [UEBE1255]
AIR INLET AND EXHAUST SYSTEM
LINES GP-AIR
PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE COMPRESSOR LINE CLAMPS ON CERTAIN 797F OFF-HIGHWAY TRUCKS WITH 4X4 ENGINE SERIAL PREFIX
UEBE1255-00

01Oct2020


U-580
A-477

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE COMPRESSOR LINE CLAMPS ON CERTAIN 797F OFF-HIGHWAY TRUCKS WITH 4X4 ENGINE SERIAL PREFIX

1803 5502 1071
PS46875
NOTE:

AVSpare’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 AVSpare.

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 "PS46875" 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.

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 AVSpare product analyst.


TERMINATION DATE

31Oct2021

PROBLEM

The existing compressor line clamps can fail on certain 797F Off-Highway Trucks with 4X4 Engine Serial Prefix. If the existing clamps fail it can result in resultant damage to neighboring brackets or the compressor air line tubes. This will result in unplanned downtime.

AFFECTED PRODUCT

Model Identification Number
797F LAJ00195, 231, 257, 377, 379, 544, 546-547, 551, 568, 591-593, 614, 616-617, 620, 622-623, 625-627, 651-652, 660-661

LTZ00140-00162

PARTS NEEDED

Qty

Part Number Description
8 4B4280 WASHER
8 5P1076 WASHER-HARD
8 6V5684 BOLT-HEX HEAD
8 7X0605 WASHER-HARD
8 7X3391 WASHER-HARD
16 1565745 CLAMP-HALF
8 1729966 BOLT-HEX HEAD
8 1984767 WASHER-HARD
8 3569305 SPACER-HARD
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

Replace the 156-5745 Clamps and associated mounting hardware every 3,000 hours. Additionally, check alignment on the clamps and tubes per the attached rework procedure and shim as needed for alignment. Refer to the attached Rework Procedure.
Image1

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-20000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 4.0-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.

Recommended interval is 3,000 hours between clamp replacement.



PARTS DISPOSITION

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


Rework Procedure


 
C175 Compressor Line Clamps Inspection and Rework Procedure

The following Steps will first be completed on one side of the engine and then repeated to on the other side.

Step 1.

Locate and remove half-clamps (156-5745). Orientation of clamps will vary between High altitude and Tier 4 configuration. Leave v-band clamps and bellows installed. See Image1.1.1
Image1.1.1
 
Step 2.

Measure distance from top of tube to top of bracket (see Image1.2.1) at location 1 (see Image1.2.2)

Record distance as A1 (see Image1.2.3)
Image1.2.1
Image1.2.2
Image1.2.3
 
Step 3.

Repeat step 2 at location 2 (see Image1.2.2)

Record distance as A2 (see Image1.2.3)
 
Step 4.

Calculate the value of 'X' for location 1, using the following formula:

55.8 - A1 = 'X'
 
Step 5.

Determine which washer to use based on the value of 'X' (see Image1.5.1)
Image1.5.1
 
Step 6.

Place selected washer on top of the bracket at both bolt holes of location 1 (see Image 1.6.1)
Image1.6.1
 
Step 7.

Reinstall half clamps using bolt (8T-4910) and washer (198-4767), tighten to 100 +/-20 Nm. (See Image 1.7.1)

Ensure new installed washers stay between bracket top surface and half clamp abutment.
Image1.7.1
 
Step 8.

Calculate the value of 'X' for location 2, using the following formula:

55.8 - A2 = 'X'

Step 9.

Repeat steps five (5) through seven (7) for location 2.

Step 10.

Repeat steps one (1) through nine (9) on other side of engine.
 
 

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