PRODUCT SUPPORT PROGRAM FOR REPLACING THE 325-1410 AND 325-1412 WATER SEAL ASSEMBLIES ON CERTAIN 5130B EXCAVATORS,777C, 777D, 785, 785B, 789, 793, 793B, 793C, 793D AND 797B OFF-HIGHWAY TRUCKS, 854G, AND 854K WHEEL DOZERS, 992G, 994, 994D, AND 994F WH Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 325-1410 AND 325-1412 WATER SEAL ASSEMBLIES ON CERTAIN 5130B EXCAVATORS,777C, 777D, 785, 785B, 789, 793, 793B, 793C, 793D AND 797B OFF-HIGHWAY TRUCKS, 854G, AND 854K WHEEL DOZERS, 992G, 994, 994D, AND 994F WH

Usage:

REBE8433-07

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19Jun2012

(Revised 17May2013)

E250
E253
E254
E350
E351
E357
E480
E490
E493
H070
H160
H162
H163
H167
H168
H169
H16C
H177
H17A
H330
N184
Z800
Z850
Z86A

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Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 325-1410 AND 325-1412 WATER SEAL ASSEMBLIES ON CERTAIN 5130B EXCAVATORS,777C, 777D, 785, 785B, 789, 793, 793B, 793C, 793D AND 797B OFF-HIGHWAY TRUCKS, 854G, AND 854K WHEEL DOZERS, 992G, 994, 994D, AND 994F WHEEL LOADERS, D11N D11R, AND D11R CD TRACK-TYPE TRACTORS
1100 7555		PS60034

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NOTE:

This Containment Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:

When reporting the repair, use "PS60034" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "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 19Jun2012 (Revised 04Feb2013) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Jun2014

PROBLEM

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The existing 325-1410 and 325-1412 Water Seal Assemblies can tear their top or bottom O-rings on certain 5130B Excavators, 777C, 777D, 785, 785B, 789, 793, 793B, 793C, 793D, and 797B Off-Highway Trucks, 854G, and 854K Wheel Dozers, 992G, 994, 994D, and 994F Wheel Loaders, D11N, D11R, and D11R CD Track-Type Tractors. If the existing water ferrule tears it can/will result in external coolant leaks that must be fixed.

AFFECTED PRODUCT

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Model	Identification Number
5130B	4CS00140
777B	4YC00427, 1083-1084, 1107, 1273, 1315, 75062
777C	4XJ00274, 510, 512-513, 655, 659
777D	3PR00159, 170, 313, 787 AGC00224, 380, 394, 459, 475, 477, 509, 1034, 1116-1119, 1148-1150, 1160, 1203, 1279-1281, 1371-1372, 1577, 1581, 1598, 1603
785	8GB00246, 392, 460, 468, 472, 488, 674
785B	6HK00744, 751
789	9ZC00111, 117, 129, 146-147, 149-151, 185, 193, 195, 224-225, 227-228, 235, 270, 274, 277-278, 281-282, 285, 313, 319-320, 322, 324-325, 327, 329, 333, 350, 371, 373, 380, 382-383, 387, 390, 392, 401, 420, 446, 468-469, 486, 488-489, 496, 511-512, 530-533, 556, 577, 579, 590, 598, 607
793	3SJ00006-00007, 11, 15-16, 19-21, 23, 25, 28-34, 38-39, 47
793B	1HL00012, 14-16, 20-24, 34-39, 42-48, 53-54, 57-62, 73-79, 81-82, 106, 122, 131-145, 149, 151-152, 177-181, 184-185, 187-190, 192, 198, 201-204, 206, 210-215, 222-226, 236-237, 261-262, 264, 269-270, 278-282, 301-303, 305-306, 316-319, 325-326, 329-330, 333-334, 337, 339-340, 342-344, 348, 351, 357-360, 376-377, 380, 384, 392-397, 399-405, 411-413, 415, 421, 425-427, 434-437, 441, 451, 504, 523
793C	4AR00078, 80-81, 88-90, 92-95, 97, 119, 124-126, 128-129, 139-141, 150, 164, 167-169, 173, 176, 179, 183, 195, 290-293, 299-305, 307, 366-367, 400-404 4GZ00096, 162-164, 237-238, 243-244, 254-255, 75001-75002 ATY00183, 203, 210, 233, 246-247, 250, 435-439, 480-481, 546, 658-659, 664, 744-748, 768-771, 800-810, 823-827, 838, 841-843, 845, 857-858, 975, 985-989
793D	FDB00107, 109, 120, 142-145, 178, 183, 188, 190-192, 199-202, 208, 219-222, 228-230, 232-234, 266, 271-272, 280, 287, 293-294, 304, 311-313, 372-373, 379-382, 394-402, 404-405, 409, 415-418, 421-422, 430-431, 437, 442-445, 453-457, 461-462, 469-472, 484-485, 502-506, 524-527, 546, 556-557, 559, 561, 563, 565, 582-583, 585, 587, 589, 591, 593, 613, 618, 623, 629, 640, 645, 649, 653, 657, 659, 661, 663, 671-681, 683, 685, 687, 689, 691, 695, 697, 701, 731-733, 739-740, 751-752, 759, 761, 772, 775-776, 783, 789-790, 802-806, 810-813, 825, 847-850, 864-865, 875-878, 1009-1011, 1027, 1029, 1065-1066, 1068, 1075, 1202-1206, 1301-1302, 1354-1357
797B	JSM00203-00205, 218, 304-307, 309-310, 440-441
854G	A4W00201, 212, 214, 278 AMP00306, 320-322, 354-355
854K	22100300, 309, 328
992G	7HR00083, 268, 292 ADZ00378, 491, 610 AZX00320-00321, 439, 443, 446, 455, 565, 567, 679, 700
994	9YF00057, 135-136
994D	3TZ00253
994F	44200150, 202, 207, 209, 257, 305, 323
D11N	4HK00368, 376, 412, 439, 447, 455, 520, 530, 533, 549, 583, 617, 631 74Z00261, 299, 407, 441, 503, 647-649, 670, 718, 744, 839, 865, 881, 951, 954, 966, 1047, 1126, 1147, 75295
D11R	7PZ00546, 552, 620, 672, 717, 903, 924, 961, 971, 1130, 1201, 1229, 1237, 1266, 1307, 1370-1371, 1377, 1379, 1407, 1418, 1574, 1580, 1585, 1619, 75028, 75032-75033, 75035, 75042-75043 8ZR00354, 380, 420, 75002 9TR00204, 221, 299, 301, 360, 367, 375, 387, 440
D11R CD	AAF00138, 160-162, 167, 171, 176, 179, 184-185, 211, 246, 266-267, 272

PARTS NEEDED

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Qty	Part Number	Description
4	5M2894	WASHER-HARD
4	5P3875	BOLT-HEX HEAD
1	1106994	PLATE-SPACER
6	1310420	FASTENER GP
2	1310421	FASTENER GP
4	2032163	SPACER-HIGH TEMP
1	2454907	SEAL-FUEL SYSTEM
1	2454908	SEAL-FUEL SYSTEM
1	3550776	KIT-GASKET(SCH)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 10% 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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Perform the cylinder head reseal using the required parts for each cylinder head that is leaking.

Refer to the engine's Disassembly and Assembly manual.

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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%
0-10000 hrs, 0-20 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-14000 hrs, 21-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 12.0-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.
This program is applicable per cylinder head. Individual engines can have multiple claims. An additional 3 hours is allowed for resealing cylinders 1, 2, 11, 13, 15 and 16 due to the physical constraints for resealing within the chassis.

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