PRODUCT SUPPORT PROGRAM FOR REPLACING OIL COOLERS ON CERTAIN 793F, 795F AC, AND 797 OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING OIL COOLERS ON CERTAIN 793F, 795F AC, AND 797 OFF-HIGHWAY TRUCKS [UEBE0439]

COOLING SYSTEM

COOLER GP

PRODUCT SUPPORT PROGRAM FOR REPLACING OIL COOLERS ON CERTAIN 793F, 795F AC, AND 797 OFF-HIGHWAY TRUCKS

UEBE0439-00

Show/hide table

30Mar2020

U-176

A-135

D-163

O-160

Show/hide table

After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING OIL COOLERS ON CERTAIN 793F, 795F AC, AND 797 OFF-HIGHWAY TRUCKS
1351 1375		PS54304

Show/hide table

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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS54304" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

TERMINATION DATE

31Mar2022

PROBLEM

Show/hide table

Existing oil coolers can fail on certain 793F, 795F AC, 797, 797B, and 797F Off-Highway Trucks. Rubber end sheets within the oil coolers are used to isolate hydraulic fluid and engine coolant and may fail. If the existing oil cooler fails it can drive cross contamination between hydraulic and engine cooling circuits.

This service letter is written only to support rectangular end sheet failures and does not support other oil cooler failure modes.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
793F	D3T00142-00187 SSP00112-01271
793F CMD	RBT00111-00344
793F OEM	SXP00101-00103
793F XQ	SND00100-00133

Show/hide table

*****Group 2*****
797F	LAJ00141-00661 LTZ00140-00162
797F XQ	WSP00100-00129

Show/hide table

*****Group 3*****
795F AC	ERM00151-00300
795F XQ	SNT00100-00105

Show/hide table

*****Group 4*****
797	5YW00260
797B	JSM00128, 131, 141, 146-147, 151-152, 220-225, 236-237, 244, 252, 256, 293, 390

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
2	2H2665	SEAL-O-RING
2	2W4005	RING-RETAINING
2	4W0530	RING-RETAINING
3	5P8428	SEAL-O-RING
3	6J2680	SEAL-O-RING
1	8N8570	RING-RETAINING
2	8T2903	SEAL-O-RING
2	9M2092	SEAL-O-RING
1	20R3096	CORE AS-OCLR (if required)
1	20R3097	CORE AS-OCLR (if required)
2	1241859	SEAL-O-RING
4	2876096	GASKET
1	4385138	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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*****
1	2M9780	SEAL-O-RING-STOR
2	5F8000	SEAL-O RING
1	5S9134	SEAL-O-RING
1	6J2419	SEAL-O RING
2	6V1197	SEAL-O-RING
1	6V4590	SEAL-O RING
1	6V5101	SEAL-O-RING
3	6V8001	SEAL-O-RING
1	8F0212	SEAL-O RING
2	8N8570	RING-RETAINING
4	8T0568	SEAL-O-RING
2	8T2903	SEAL-O-RING
1	20R3094	CORE AS-OCLR (if required)
1	20R3095	CORE AS-OCLR (if required)
6	2876096	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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*****
2	2W4005	RING-RETAINING
1	4W0530	RING-RETAINING
1	6J2680	SEAL-O-RING
1	6V8001	SEAL-O-RING
2	8N8570	RING-RETAINING
2	8T0568	SEAL-O-RING
2	8T2903	SEAL-O-RING
2	9M2092	SEAL-O-RING
1	20R3099	CORE AS-OCLR (if required)
1	20R3100	CORE AS-OCLR (if required)
4	2352482	SEAL-RECTANGULAR
4	2876096	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 4*****
1	20R3095	CORE AS-OCLR (if required)
4	1241859	SEAL-O-RING
2	2147568	SEAL-O-RING-STOR
2	2876096	GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

Show/hide table

This program is only to support rectangular end sheet failures and does not support other oil cooler failure modes.

Utilize machine checks and SOS data to monitor for glycol and water presence in brake oil cooling and power train cooling circuits. If cross communication is detected, remove the bonnets to check for rubber end sheet failure. A typical rubber end sheet failure is shown in Image 1 and Image 2 and can be viewed when the bonnet is removed.

Diagnose and document the failed oil cooler. Replace only the failed cooler. Refer to the following disassembly and assembly instructions.

793F Power Train Oil Cooler Remove and Install in KENR8397
793F Brake Oil Cooler Remove and Install in KENR8579
795F AC Brake Oil Cooler Remove and Install in KENR8727
797F Power Train Oil Cooler Remove and Install in KENR8372
797F Brake Oil Cooler Remove and Install in KENR8382
797B Power Train Cooler Core Assemble in UENR2279

Cross contamination between hydraulic and coolant circuits can occur when rubber end sheets fail. If cross contamination is observed, utilize current best practices to adequately clean and flush the circuits. Verify system cleanliness through machine checks and SOS that systems are ready for operation.

Create a Global Dealer Solution Network (GDSN) Product Health Service Request (SR) with the priority of "Product Inquiry / Informational" and a Workgroup/Subsystem as "Base Machine". Include machine serial number, machine hours, and part hours. Include pictures showing the rubber end sheet failure as well as the part number and date code from the cooler (Example shown in Image 3 and Image 4) and any other failure details. Mention the CPI number 440523 in the CPI field and the service letter program number in the description or title (searchable fields). Populate the part number in the part number field prior to closing the SR at the Dealership without submitting to AVSpare. This will alert the CPI Team that you have documented this failure in Product Support Customer Relationship Management (PSCRM).

Show/hide table

Image1

Image2

Image3

Image4

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-10000 hrs, 0-20 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-18000 hrs, 21-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 11.0-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.
Hours provided include the time to remove coolers, disassemble/assemble with a replacement cooler, and install the coolers.

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-10000 hrs, 0-20 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-18000 hrs, 21-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 11.0-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.
Hours provided include the time to remove coolers, disassemble/assemble with a replacement cooler, and install the coolers.

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-10000 hrs, 0-20 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-18000 hrs, 21-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-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.
Hours provided include the time to remove coolers, disassemble/assemble with a replacement cooler, and install the coolers.

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-10000 hrs, 0-20 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-18000 hrs, 21-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 6.0-hour job for Group 4 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.
Hours provided include the time to remove coolers, disassemble/assemble with a replacement cooler, and install the coolers.

PARTS DISPOSITION

NACD:

Hold all oil coolers with documented failed rubber end sheets for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

EAME, LACD, and APD:

Hold all oil coolers with documented failed rubber end sheets for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.