PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR WHEEL DUO-CONE SEALS ON CERTAIN 770 AND 772 OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR WHEEL DUO-CONE SEALS ON CERTAIN 770 AND 772 OFF-HIGHWAY TRUCKS

Usage:

REBE8919-00

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20Aug2013

U-372

A-252

D-312

O-314

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After Failure Only Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR WHEEL DUO-CONE SEALS ON CERTAIN 770 AND 772 OFF-HIGHWAY TRUCKS
4008 7561 7750		PS52499

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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 "PS52499" 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

31Aug2015

PROBLEM

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The outer duo-cone seal can leak on certain 770 and 772 Off-Highway Trucks. If the existing outer duo-cone seal leaks, brake cooling oil will leak into the wheel/rim. If the leak is severe enough, oil may run down the sidewall of the inner tire and onto the ground.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
770	BZZ00069-00518, 545-676
770 OEM	M7W00103
772	RLB00271-00679
772 OEM	J2M00100-00101

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*****Group 2*****
770	BZZ00677-00870
772	RLB00680-00882

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*****Group 3*****
770	BZZ00519-00544

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	2R0098	SEAL-O RING
4	3K0360	SEAL-O-RING
2	3S3074	SEAL-O RING
4	4J0524	SEAL-O-RING
2	4M0737	SEAL-O RING
16	5P8245	WASHER-HARD
2	6D0692	SEAL-O-RING
2	6F4855	SEAL-O RING
2	6V3538	DOWEL
4	7J9108	SEAL-O-RING-ORFS
10	8T4910	BOLT-HEX HEAD
6	8T6868	BOLT-HEX HEAD
2	9X7550	SEAL-O RING
2	1237267	SEAL-RING
2	1237268	SEAL-RING
2	1378117	SEAL-RING
2	1378119	SEAL-RING
2	2460609	SEAL-RING
2	2460610	SEAL-RING
2	2460611	SEAL-RING
2	2460612	SEAL-RING
2	3144122	SEAL GP-DUO CONE
2	3638811	SHIM GP-RAIL
2	3654922	SEAL GP-DUO CONE
2	3676334	PLATE
2	3859617	RETAINER
2	3900568	HOUSING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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	2R0098	SEAL-O RING
4	3K0360	SEAL-O-RING
2	3S3074	SEAL-O RING
4	4J0524	SEAL-O-RING
2	4M0737	SEAL-O RING
16	5P8245	WASHER-HARD
2	6D0692	SEAL-O-RING
2	6F4855	SEAL-O RING
2	6V3538	DOWEL
4	7J9108	SEAL-O-RING-ORFS
10	8T4910	BOLT-HEX HEAD
6	8T6868	BOLT-HEX HEAD
2	9X7550	SEAL-O RING
2	1237267	SEAL-RING
2	1237268	SEAL-RING
2	1378117	SEAL-RING
2	1378119	SEAL-RING
2	2460609	SEAL-RING
2	2460610	SEAL-RING
2	2460611	SEAL-RING
2	2460612	SEAL-RING
2	3144122	SEAL GP-DUO CONE
2	3638811	SHIM GP-RAIL
2	3654924	SEAL GP-DUO CONE
2	3859617	RETAINER
2	3900568	HOUSING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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	2R0098	SEAL-O RING
4	3K0360	SEAL-O-RING
2	3S3074	SEAL-O RING
4	4J0524	SEAL-O-RING
2	4M0737	SEAL-O RING
16	5P8245	WASHER-HARD
2	6D0692	SEAL-O-RING
2	6F4855	SEAL-O RING
2	6V3538	DOWEL
4	7J9108	SEAL-O-RING-ORFS
10	8T4910	BOLT-HEX HEAD
6	8T6868	BOLT-HEX HEAD
2	9X7550	SEAL-O RING
2	1237267	SEAL-RING
2	1237268	SEAL-RING
2	1378117	SEAL-RING
2	1378119	SEAL-RING
2	2460609	SEAL-RING
2	2460610	SEAL-RING
2	2460611	SEAL-RING
2	2460612	SEAL-RING
2	3144122	SEAL GP-DUO CONE
2	3638811	SHIM GP-RAIL
2	3654922	SEAL GP-DUO CONE
2	3859617	RETAINER
2	3900568	HOUSING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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 350-4340 Duo-cone Seals and 238-6846 Plates from dealer parts stock.

****Affected Product****

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1. Remove the rear tires and rims. Refer to Disassembly and Assembly, "Tire and Rim - Remove and Install".

2. Remove the axle shaft. Refer to Disassembly and Assembly, "Axle Shaft ? Remove and Install".

3. Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove and Install". Retain the original shim pack.

4. Remove the wheel. Refer to Disassembly and Assembly, "Rear Wheel, Bearing, and Duo-Cone Seal ? Remove and Install".

5. Remove the rear brake. Refer to Disassembly and Assembly, "Service and Parking Brake (Rear) ? Remove".

6. Disassemble the rear brake through Step 15 of RENR8273, "Service and Parking Brake (Rear) ? Disassemble". The park brake piston and springs do not need to be removed.

7. Press the 6V-3538 Dowel into the hole in the rectangular lug on the new 390-0568 Housing. Use the alignment mark made on the old housing during disassembly to mark the new housing in the same location. Install housing into anchor using the new bolts and washers. Install the three longer bolts into the holes on each side of the cooling oil passage and in the next hole in the clockwise direction.

8. Reassemble the rest of the brake using new seals and new 367-6334 Plate (Group 1 machines only).

Note: If the 318-2943 Brake Alignment Tool Group is not available, the splines on the wheel may be used to align the discs. To do this, position the wheel with the splined end up. Use an alternate pressure source attached to the "P" port on the brake anchor to retract the park brake piston. The pressure required to release the park brake is 494 psi. To avoid damage to the piston seals, do not exceed 730 psi. Position the brake discs so that they are centered and aligned as much as possible. Slowly lower the brake onto the wheel splines until all of the brake discs are engaged with the wheel splines. Release the pressure to lock the park brake before lifting the brake from the wheel and installing it onto the spindle.

9. Install the brake onto the spindle. Due to the reduced clearance between the new brake housing and the spindle, do not install the 3S-3074 O-ring until after the brake has been installed onto the spindle. Reattach the brake lines.

10. With the 1U-9200 Lever Puller Hoists and 138-7574 Link Brackets used in the removal of the brake, pull the brake inward against the spindle stops.

11. Install the new 385-9617 Duo-Cone Seal Retainer and install the spiral retaining ring into the groove in the spindle. Using a feeler gage, measure the gap between the seal retainer and the spiral retaining ring. Find the maximum thickness that can be inserted snugly between the retainer and the retaining ring without having to use excessive force. Remove the retaining ring and the seal retainer. Install 3S-7034 Seal into groove in the spindle. Install the inner duo-cone seal retainer. Install shims from the 363-8811 Shim Pack equaling the measured thickness +0.00 / - 0.05 mm. Reinstall the spiral retaining ring.

12. Install the duo-cone seals into the brake plate, seal retainer, and wheel.

13. Reinstall the wheel bearings onto the spindle.

14. Reinstall the wheel onto the spindle, using the same wheel bearing shim pack that was removed during disassembly. The wheel bearing preload does not need to be adjusted.

15. Reinstall the final drive, axle shaft, tires, and rims.

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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*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 37-72 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 40.0-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.
Parts and labor are to repair both sides. After failure of one side, both sides must be repaired to implement this program.

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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*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 37-72 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 40.0-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.
Parts and labor are to repair both sides. After failure of one side, both sides must be repaired to implement this program.

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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 3*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 37-72 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 40.0-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.
Parts and labor are to repair both sides. After failure of one side, both sides must be repaired to implement this program.