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

30Mar2020


U-176
A-135
D-163
O-160

 

After Failure Only

  
  

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

1351 1375
PS54304
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.

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

31Mar2022

PROBLEM

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

Model Identification Number
*******Group  1*******
793F D3T00142-00187

SSP00112-01271
793F CMD  RBT00111-00344
793F OEM  SXP00101-00103
793F XQ  SND00100-00133
*******Group  2*******
797F LAJ00141-00661

LTZ00140-00162
797F XQ  WSP00100-00129
*******Group  3*******
795F AC  ERM00151-00300
795F XQ  SNT00100-00105
*******Group  4*******
797  5YW00260
797B  JSM00128, 131, 141, 146-147, 151-152, 220-225, 236-237, 244, 252, 256, 293, 390

PARTS NEEDED

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

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).
Image1
Image2
Image3
Image4

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
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.

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
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.

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
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.

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
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.
 
 
 

Information System:

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE FUEL TANK ON CERTAIN 24 MOTOR GRADERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 460-6957 TUBE ASSEMBLY SUPPORT BRACKET IN THE WATER LINES GROUP ON CERTAIN 777E OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING PL042 OR PL141 DEVICES WITH A PL243 OR PL131 ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT SUPPORT PROGRAM FOR REPLACING A PL240 OR PL241 RADIO WITH A PL243 4G CELLULAR RADIO ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT SUPPORT PROGRAM FOR INSTALLATION OF A DIODE ON CERTAIN 548, 558, AND 568 FORESTRY EXCAVATORS
PRODUCT SUPPORT PROGRAM FOR ADDING HOSE GUARD TO THE LOWER TRANSMISSION HOSE ON CERTAIN 775G OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR INSTALLING DIESEL EXHAUST FLUID (DEF) SUPPLY HOSE INSULATION ON CERTAIN R1700 AND R2900 LOAD HAUL DUMP MACHINES
PRODUCT SUPPORT PROGRAM FOR REPLACING PL240B WITH A PL243 4G CELLULAR RADIO ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT SUPPORT PROGRAM FOR REPLACING PL542 V1 TO PL542 V2 CELLULAR RADIO SYSTEMS ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE SOFTWARE ON CERTAIN 777E, 777F, AND 777G OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING PL141 TO PL131 AND PLG641V1 TO PLG641V2 ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT SUPPORT PROGRAM FOR REPLACING PL641I V1 OR PL042 RADIOS TO PL641I V2 OR PL243 4G CELLULAR RADIO ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PARK BRAKE PISTON OR SLEEVE ON CERTAIN R2900 AND R2900G LOAD HAUL DUMP MACHINES
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING 521-0747 IMU CABLE ASSEMBLIES FROM DEALER PART STOCK
PRODUCT SUPPORT PROGRAM FOR REPLACING THE DEF INJECTOR ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING 5465409 SPEED SENSORS ON CERTAIN REMAN 20R7980 TRANSMISSIONS IN DEALER PARTS STOCK
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING 0T-0244 BOLT WITH 8S-4723 BOLT IN 4671742 SUSPENSION SEAT ON CERTAIN R1700 LOAD HAUL DUMP MACHINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE STARTING MOTOR ON CERTAIN CCS9, CP54B, CP56B, CP68B, CP74B, CS54B, CS56B, CS64B, CS66B, CS68B, CS74B, CS76B, AND CS78B COMPACTORS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING THE 356-4199 PINION SHAFT FROM DEALER PART STOCK
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE AXLE OIL LEVEL ON CERTAIN VIBRATORY SOIL COMPACTORS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR INTAKE TUBE ASSEMBLY SUPPORTS AND MOUNTING HARDWARE ON CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING CERTAIN LIFTER COVER ASSEMBLIES ON CERTAIN 797F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR TIGHTENING OR REPLACING MISSING VALVE MOUNTING BOLTS ON THE HOIST VALVE MOUNTING BRACKET OF CERTAIN 785,789, AND 793 OFF-HIGHWAY TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE REAR AXLE PINION SHAFT ON CERTAIN 980L, 980M, AND 982M WHEEL LOADERS