PRODUCT SUPPORT PROGRAM FOR REPLACING COOLANT TUBES ON CERTAIN 793F AND 795F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING COOLANT TUBES ON CERTAIN 793F AND 795F OFF-HIGHWAY TRUCKS

Usage:

TEBE1381-00

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15Jul2014

U-420

A-304

D-374

O-354

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After Failure Only Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING COOLANT TUBES ON CERTAIN 793F AND 795F OFF-HIGHWAY TRUCKS
1380		PS52715

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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 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 "PS52715" 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.

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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.

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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.

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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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TERMINATION DATE

31Jul2016

PROBLEM

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The 380-1425, 394-1118, 333-3705, and 290-8721 Coolant Tubes can develop a crack at the weld boss locations on certain 793F and 795F Off-Highway Trucks. If the existing tubes develop a crack, they will leak coolant.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
793F	SSP00112-01019
793F AC	EMD00076-00077
793F CMD	RBT00111-00171
793F XQ	SND00100-00131

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*****Group 2*****
795F AC	ERM00153-00289
795F XQ	SNT00100

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1S0994	CLIP-LOOP
1	2Y5829	NUT-HEX
1	6V1820	BOLT
4	6V5839	WASHER-HARD
2	6V5843	BOLT-HEX HEAD
1	6V6560	SEAL-O-RING
1	6V6782	CLIP-TOP
1	6V6783	CLIP-BOTTOM
1	6V7673	BOLT-HEX HEAD
1	6V8149	NUT-HEX
6	6V8397	SEAL-O-RING-ORFS
2	6V9028	SEAL-O-RING
1	6V9850	ADAPTER-ELBOW
2	7D1649	WASHER-HARD
2	7X7910	CLIP
2	7X7911	CLIP-HALF HOOK
2	8T4121	WASHER-HARD
2	8T4133	NUT
2	8T4196	BOLT-HEX HEAD
2	8T6850	SEAL-O-RING
1	8T7489	ADAPTER-STR
2	8T7876	SEAL-O-RING
1	1030892	GROMMET
2	1090080	SEAL-O-RING
1	1128186	SEAL-O-RING
1	1196407	ADAPTER-STR
2	2139397	SEAL-O-RING
2	2177742	GROMMET
1	2416157	PLUG-HD STOR
1	2588738	SEAL-O-RING
2	2594597	SEAL-O-RING
1	3368613	CLIP-LOOP
2	3427962	RING
2	3449286	RING
2	3716761	FLANGE
2	3716763	FLANGE
2	3753192	CLIP-BOTTOM
2	3753193	CLIP-TOP
1	3801423	ELBOW (AS NEEDED)
1	3924074	HOSE AS (AS NEEDED)
1	4523043	TUBE
1	4586019	HOSE AS
1	4586511	TUBE AS
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*****
2	1S0994	CLIP-LOOP
1	2Y5829	NUT-HEX
1	6V1820	BOLT
4	6V5839	WASHER-HARD
2	6V5843	BOLT-HEX HEAD
1	6V6560	SEAL-O-RING
1	6V6782	CLIP-TOP
1	6V6783	CLIP-BOTTOM
1	6V7673	BOLT-HEX HEAD
1	6V8149	NUT-HEX
6	6V8397	SEAL-O-RING-ORFS
2	6V9028	SEAL-O-RING
1	6V9850	ADAPTER-ELBOW
2	7D1649	WASHER-HARD
2	7X7910	CLIP
2	7X7911	CLIP-HALF HOOK
2	8T4121	WASHER-HARD
2	8T4133	NUT
2	8T4196	BOLT-HEX HEAD
2	8T6850	SEAL-O-RING
1	8T7489	ADAPTER-STR
2	8T7876	SEAL-O-RING
1	1030892	GROMMET
2	1090080	SEAL-O-RING
1	1128186	SEAL-O-RING
1	1196407	ADAPTER-STR
2	2139397	SEAL-O-RING
2	2177742	GROMMET
1	2416157	PLUG-HD STOR
1	2588738	SEAL-O-RING
2	2594597	SEAL-O-RING
1	3368613	CLIP-LOOP
2	3427962	RING
2	3449286	RING
2	3716761	FLANGE
2	3716763	FLANGE
2	3753192	CLIP-BOTTOM
2	3753193	CLIP-TOP
1	3801423	ELBOW (AS NEEDED)
1	4523043	TUBE
1	4575641	HOSE AS (AS NEEDED)
1	4586019	HOSE AS
1	4586511	TUBE AS
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

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****Parts Stock ****

Remove all 290-8721 and 380-1425 Tubes from dealer parts stock.

****Affected Product****

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The engine should be inspected prior to ordering parts. Refer to the attached Rework Procedure to determine if all the parts listed under the "Parts Needed" section of this letter are needed.

Replace the coolant tubes. Refer to the attached Rework Procedure.

Note: The new tubes in the Parts Needed do not have the weld bosses to attach vent lines. The new vent line attaches to surrounding castings.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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%
*****Group 1*****
0-18000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 8.0-hour job for Group 1

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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%
*****Group 2*****
0-18000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 8.0-hour job for Group 2

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.

Rework Procedure

Inspect the cast elbow attached to the oil cooler. If there is a tapped hole in the bottom of the elbow, as seen in Image 1.1.1 below, the elbow can be reused. The 380-1423 Elbow and all other parts listed "as needed" will not need to be ordered.

Image1.1.1

Drain coolant from the engine. Remove the coolant tubes identified in Image 1.2.1 below. Remove the elbow identified in Image 1.1.1 only if it does NOT have a tapped hole in the bottom.

Retain all hardware, as some will need to be reused.

Image1.2.1

Install the new tubes, orings, vent line, and hardware identified in Images 1.3.1, 1.3.2, and 1.3.3.

Image1.3.1

Image1.3.2

Image1.3.3

If the initial inspection required the cast elbow to be replaced, install the components identified in Images 1.4.1. Assemble and connect the hose assemblies shown in Image 1.4.2.