DOOR GP-CAB 2230616 - Caterpillar

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Rework exhaust system. Refer to the attached Rework Procedure.
To protect the detonation and thermocouple harnesses from exhaust gas leaks, perform REBE5494 as applicable.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-8000 hrs,
0-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 0.0%
8001-16000 hrs,
61-72 mo 80.0% 0.0% 0.0% 0.0% 20.0% 0.0%
16001-24000 hrs,
73-84 mo 60.0% 0.0% 0.0% 0.0% 40.0% 0.0%
24001-32000 hrs,
85-96 mo 40.0% 0.0% 0.0% 0.0% 60.0% 0.0%
32001-40000 hrs,
97-108 mo 20.0% 0.0% 0.0% 0.0% 80.0% 0.0%
This is a 0.0-hour job
Total Labor hours for complete repair of Bellows and Manifold covered in this program is not to exceed 25 Hours. All labor should be claimed according to the pro-rate schedule in Image 1.1.
This service claims allowance table applies to the exhaust manifold castings and wiring harnesses only. Parts included are: 200-6551, 200-6552, 206-4171, 206-4807, 220-2339, and 230-3411. Refer to pro-rate schedule in Image 1.1 for other parts claims allowance.
Parts identified in the parts list "As Required", should only be replaced as needed (Refer to attached Rework Procedure).
Image1.1
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to appropriate Service Manual as necessary.
1) Identify location of exhaust leak.
2) Disassemble the exhaust manifold system in accordance to the Disassembly and Assembly manual.
3) Remove any burnt wiring harnesses. The detonation and/or thermocouple harnesses are located below the exhaust manifolds.
4) Clean exhaust manifold castings for reuse. It may be difficult to clean the seal groove of the manifolds due to excessive corrosion. Special cleaning methods and tools, such as a needle gun or glass beading, may be necessary to clean the seal groove. Manifolds should be replaced only if they are not reusable after attempted cleaning.
Manifold castings should be replaced if: 1) cleaning cannot get the seal groove clean enough to allow a new seal to fit evenly in the groove, 2) cleaning the seal groove shows that the seal groove has corroded extensively and the new seal will not stay retained properly in the groove.
Image 1.1.1 is an example of an uncleaned seal groove.
Image1.1.1
5) Install any required wiring harnesses. Wiring harnesses should only be replaced if they are burnt through the harness braiding and wires are damaged.
6) Reassemble the exhaust system per the Disassembly and Assembly manual.
Special attention should be used to ensure good alignment of exhaust bellows between manifold sections. Good alignment is critical to achieving expected bellows life.
Use nickel based anti-sieze compound, see TIBU5269 on fastners during reassembly.
7) Load test unit and inspect for any exhaust leaks.