PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST BELLOWS ON CERTAIN 795F, AND 797F OFF-HIGHWAY TRUCKS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST BELLOWS ON CERTAIN 795F, AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE3948-07

27Jan2016
(Revised 29Nov2016)


U-616
A-35

 

Before/After

  
 Parts stock action needed 

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST BELLOWS ON CERTAIN 795F, AND 797F OFF-HIGHWAY TRUCKS

1059 7750
PS44971
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 "PS44971" 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:

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.

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.

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.

 
NOTE:

This Revised Service Letter replaces the 27Jan2016 (Revised 22Nov2016) Service Letter. Changes have been made to the Service Claim Allowances.


TERMINATION DATE

31Jan2018

PROBLEM

The existing 466-4983 Exhaust Bellows can fail on 795F, and 797F Off-Highway Trucks. Cracks and small broken pieces have been observed on the outlet spacer.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
797F  LAJ00195-00196, 231, 353, 355, 357, 359, 361, 363-364, 366, 376-377, 379, 386, 388, 392, 395, 398, 478, 537, 539, 544-553, 566-568, 572, 585-595, 597-598
*******Group  2*******
797F  LAJ00148-00150, 158-182, 185-187, 216-221, 230, 232-250, 256-261, 263, 265, 273-274, 278-279, 281, 284, 286, 288-290, 294, 299, 301-302, 304, 306-307, 314-315, 319, 323-324, 342, 345-348, 352, 354, 356, 367, 369, 371, 374, 397, 401-402, 404-406, 408, 410-411, 414-415, 418-420, 422-441, 447-450, 453-457, 462-463, 467, 469-475, 479-482, 484-490, 495-501, 599-602
*******Group  3*******
795F AC  ERM00163-00164, 168-169, 205, 264, 270-276

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
8 5P8245 WASHER-HARD
12 6V3303 BOLT
8 7D1649 WASHER-HARD
72 8T7353 BOLT-HEX HEAD
72 8T7934 WASHER-HARD
8 1193450 SPACER
12 1984768 WASHER-HARD
2 2418492 CLAMP-V-BAND
20 2464924 GASKET
8 2473393 CLAMP-V-BAND
4 2894082 BOLT-HEX HEAD
8 3145638 BOLT-HEX HEAD
2 3440079 BELLOWS AS
8 3450888 SPACER
4 3595228 BOLT-HIGH TEMP
8 3605871 BOLT-HEX HEAD
4 3899659 BELLOWS AS
4 3915101 SPACER-EXHAUST
4 3915102 SPACER-EXHAUST
8 3924421 SPRING-DISC
4 4346544 CLAMP-V-BAND
36 4674241 CLAMP-V-BAND
18 4853800 BELLOWS AS
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.

*******Group 2*******
8 5P8245 WASHER-HARD
12 6V3303 BOLT
8 7D1649 WASHER-HARD
8 1193450 SPACER
12 1984768 WASHER-HARD
2 2418492 CLAMP-V-BAND
8 2473393 CLAMP-V-BAND
4 2894082 BOLT-HEX HEAD
4 3595228 BOLT-HIGH TEMP
8 3605871 BOLT-HEX HEAD
4 3899659 BELLOWS AS
4 3915101 SPACER-EXHAUST
4 3915102 SPACER-EXHAUST
8 3924421 SPRING-DISC
36 4674241 CLAMP-V-BAND
18 4853800 BELLOWS AS
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.

*******Group 3*******
28 4674241 CLAMP-V-BAND
14 4853800 BELLOWS AS
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

****Parts Stock ****

Rework the following engines in dealer parts stock and/or dealer exchange inventory:


795F LAA/HAA
288-8962, 314-2486, 365-9324, 365-9325, 398-1019, 423-7577, 423-7578, 423-7580, 423-7582, 20R-1492, 20R-1493,20R4667 Service Replacement C175-16 Engines built JTL01000-01178, ZK401000-04022, HN300100-00106.

797F LAA/HAA
262-1300, 282-2060, 286-3503, 398-1020, 330-0200, 286-3503, 360-1647, 365-9323, 365-9326, 365-9327, 365-9328, 365-9329, 417-0588, 418-8764, 421-3013, 421-3014, 423-3501, 423-3502, 20R-1363, 20R-1494, 20R-1495, 20R-1496, 20R-1497, 20R4668 Service Replacement C175-20 Engines built LLM01000-01473 ZK300100-02092, HN400100-00125.

Replace the exhaust bellows and clamps.

Refer to Special Instruction, REHS7883 for the correct bellows replacement procedure.

Refer to Special Instruction, REHS9564 for additional information pertaining to bellows inspection and installation.

 
 
****Affected Product****
Replace the exhaust bellows and clamps.

Refer to Special Instruction, REHS7883 for the correct bellows replacement procedure.

Refer to Special Instruction, REHS9564 for additional information pertaining to bellows inspection and installation.

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit a claim for the engines reworked in dealer parts stock and/or dealer exchange inventory.

C175-20 Parts Stock Engines:

10 hours will be allowed for each engine that is reworked.

For High Altitude Engine Arrangements, the Parts Needed for Group 1 will be allowed for each engine that is reworked.

For Low Altitude Engine Arrangements, the Parts Needed for Group 2 will be allowed for each engine that is reworked.


C175-16 Parts Stock Engines:

8 hours will be allowed for each engine that is reworked.

The Parts Needed for Group 3 will be allowed for each engine that is reworked.

Include engine serial numbers and arrangement numbers in the claims story.

 
 
****Affected Product****
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-20000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 26.0-hour job for Group 1

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.


Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-10000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
10001-15000 hrs,
25-36 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 26.0-hour job for Group 2

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.


Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-10000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
10001-15000 hrs,
25-36 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 14.0-hour job for Group 3

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.




PARTS DISPOSITION

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

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

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