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

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

Usage:

TEBE8683-01

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26Mar2019

(Revised 01Apr2019)

U-181

A-151

D-157

O-164

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXHAUST BELLOWS ON CERTAIN 795F AC AND 795F XQ OFF-HIGHWAY TRUCKS
1061		PS46197

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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 "PS46197" 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:

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 26Mar2019 Service Letter. Changes have been made to add a Service Claim Allowances age/hour note.

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TERMINATION DATE

31Mar2021

PROBLEM

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The existing 306-0297 Exhaust Bellows may fail on certain 795F AC and 795F XQ Off-Highway Trucks. If the existing 306-0297 Exhaust Bellows fail, it will result in an exhaust leak and downtime to repair. The failure may be attributed to both the current design and poor alignment.

AFFECTED PRODUCT

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Model	Identification Number
795F AC	ERM00153-00300
795F XQ	SNT00100-00105

PARTS NEEDED

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Qty	Part Number	Description
4	3028136	CLAMP-V-BAND
2	4567005	BELLOWS AS
2	4710307	TOOL-ALIGNMENT(Maximum 2 tools per branch / fleet)
2	4797624	INSULATION
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 27% 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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A new 456-7005 Bellows Assembly and accompanying heat shield, with improved service life, have been identified. An 471-0307 Alignment Tool has been designed to use prior to assembling the new 456-7005 Bellows Assembly and heat shield. The new 471-0307 Alignment Tool and new 456-7005 Bellows Assembly are drop-in replacements for the existing 306-0297 Exhaust Bellow.

NOTE: This update must be applied using the 471-0307 Alignment Tool.

NOTE: Only two 471-0307 Alignment Tools should be ordered for each work site/branch performing this update.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-7000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
7001-14000 hrs, 13-90 mo	67.0%	100.0%	0.0%	0.0%	25.0%	0.0%
14001-21000 hrs, 91-94 mo	33.0%	100.0%	0.0%	0.0%	50.0%	0.0%

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NOTE: This is a 2.0-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.
Note: This update must be applied using the 471-0307 Alignment Tool. Note: Up to a maximum of $1,188.00 US Dollars can be claimed for a 471-0307 Alignment Tool. Two alignment tools can be claimed per branch / fleet. If it is ever required, the dealer should justify, in writing, when an alignment tool is claimed for quantities of more than 2 per branch / fleet.

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PARTS DISPOSITION

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

Rework Procedure

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Refer to the Service Manual if/as necessary.

1. Remove the existing bellows. Retain the clamps to use with the 471-0307 Alignment Tool. Refer to Image1.1.1.

Image1.1.1

2. Loosen, but do not remove, all clamps for the exhaust system. Refer to Image1.2.1.

Image1.2.1

3. Install the 471-0307 Alignment Tool into each exhaust routing using the clamps that were removed. Refer to Image1.3.1.

4. Once the 471-0307 Alignment Tool is installed, insure alignment, then tighten all of the clamps to hold the exhaust routing in the new position.

5. Once all the clamps are tightened, remove the 471-0307 Alignment Tool.