PRODUCT SUPPORT PROGRAM FOR REPLACING THE INNER AND OUTER DUO-CONE SEALS ON CERTAIN 794 AC, 795F AC, 795F XQ, 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE INNER AND OUTER DUO-CONE SEALS ON CERTAIN 794 AC, 795F AC, 795F XQ, 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS

Usage:

TEBE4671-05

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20Jul2016

(Revised 28Aug2018)

U-377

A-284

D-331

O-329

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE INNER AND OUTER DUO-CONE SEALS ON CERTAIN 794 AC, 795F AC, 795F XQ, 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS
4050 4008		PS53255

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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 "PS53255" 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:

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 the 20Jul2016 (Revised 25Jul2018) Service Letter. Changes have been made to the Parts Needed and Affected Product.

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TERMINATION DATE

31Jul2019

PROBLEM

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The existing inner and/or outer Duo-Cone Seal can leak on certain 794 AC, 795F AC, 795F XQ, 797, 797B, 797F, and 797F XQ Off-Highway Trucks.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
797	5YW00193-00196, 201-203, 210-212, 219-220, 223-239, 241-243, 246, 251-253, 256-259, 261, 266-267, 270-277
797B	JSM00124-00126, 129, 132-134, 137-138, 143, 150-152, 165-190, 195-205, 213-215, 218, 229-235, 239-243, 245-255, 257-260, 262-264, 268-275, 280-295, 297, 299-301, 304-307, 309-310, 318-319, 333-337, 354-363, 366-368, 383-385, 390-392, 396-397, 403, 410-411, 414, 416-417, 419-421, 423, 425, 427-429, 431, 433, 440-445, 447-448, 452, 454-455, 458-460, 463-471, 473-475

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*****Group 2*****
797F	LAJ00141, 145-188, 190-199, 204-226, 229-250, 256-261, 263, 265, 270-275, 277-282, 284, 286, 288-291, 294, 297-302, 304-307, 309-310, 315, 323-326, 329-340, 342, 345-349, 352-364, 366-371, 374-444, 447-457, 462-463, 467, 469-475, 478-482, 484-490, 495-506, 508, 513-522, 526-553, 562-568, 572, 585-595, 597-656
797F XQ	WSP00100-00129

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*****Group 3*****
794 AC	MT500100-00136
795F AC	ERM00151-00300
795F XQ	SNT00100-00105

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	4H6730	SEAL-O-RING - Front Wheel Only
1	5P9519	SEAL-O RING - Rear Wheel Only
1	6V3689	SEAL-O RING - Front Wheel Only
1	7X4781	SEAL-O RING - Rear Wheel Only
1	8M4436	SEAL-O-RING - Front Wheel Only
58	8T0283	BOLT-HEX HEAD - Rear Wheel Only
79	9X8399	WASHER - Rear Wheel Only
1	1131700	SEAL-O-RING - Rear Wheel Only
1	1237274	SEAL-RING - Rear Wheel Only
1	1374350	SEAL-O-RING - Front Wheel Only
1	1397624	SHIM-PACK - Rear Wheel Only
1	1436387	SEAL-O-RING - Rear Wheel Only
1	1438729	SEAL-O-RING - Rear Wheel Only
54	1461799	WASHER-HARD - Rear Wheel Only
54	1470169	BOLT-HEX HEAD - Rear Wheel Only
1	1508793	RING-SEAL - Rear Wheel Only
1	1520985	SEAL-O-RING - Rear Wheel Only
1	1521672	SHIM-PACK - Front Wheel Only
21	1779755	BOLT-HEX HEAD - Rear Wheel Only
1	1863712	SEAL-O-RING - Rear Wheel Only
1	2892270	SEAL-O-RING - Front Wheel Only
1	4229075	SEAL GP-DUO CONE
1	4229076	SEAL GP-DUO CONE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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	4H6730	SEAL-O-RING - Front Wheel Only
1	5P9519	SEAL-O RING - Rear Wheel Only
1	6V3689	SEAL-O RING - Front Wheel Only
1	7X4781	SEAL-O RING - Rear Wheel Only
1	8M4436	SEAL-O-RING - Front Wheel Only
58	8T0283	BOLT-HEX HEAD - Rear Wheel Only
79	9X8399	WASHER - Rear Wheel Only
1	1131700	SEAL-O-RING - Rear Wheel Only
1	1237274	SEAL-RING - Rear Wheel Only
1	1397624	SHIM-PACK - Rear Wheel Only
1	1436387	SEAL-O-RING - Rear Wheel Only
1	1438729	SEAL-O-RING - Rear Wheel Only
54	1461799	WASHER-HARD - Rear Wheel Only
54	1470169	BOLT-HEX HEAD - Rear Wheel Only
1	1508793	RING-SEAL - Rear Wheel Only
1	1520985	SEAL-O-RING - Rear Wheel Only
1	1521672	SHIM-PACK - Front Wheel Only
21	1779755	BOLT-HEX HEAD - Rear Wheel Only
1	1863712	SEAL-O-RING - Rear Wheel Only
1	2892270	SEAL-O-RING - Front Wheel Only
1	4229075	SEAL GP-DUO CONE
1	4229076	SEAL GP-DUO CONE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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*****
1	2S4071	SEAL-O RING
1	7X4781	SEAL-O RING
20	9X8399	WASHER
1	1237274	SEAL-RING
53	1461799	WASHER-HARD - Rear Wheel Only
53	1470169	BOLT-HEX HEAD
1	1508791	SEAL-O-RING
1	1508793	RING-SEAL
20	1779755	BOLT-HEX HEAD
1	1804365	SEAL-O-RING
1	1863712	SEAL-O-RING
1	3144127	RING-TORIC
1	4229075	SEAL GP-DUO CONE
1	4229076	SEAL GP-DUO CONE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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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When a failure is detected, remove the leaking Duo-Cone seal and replace it with a new 422-9075 (inner) and 422-9076 (outer) Duo-Cone Seal.

Note: New field service tool 423-9906 is required to install the 422-9076 Seal. New field service tool 423-9903 is required to install the 422-9075 seal.

For any external Duo-Cone seal leak prepare a site report. Site report should include truck serial number, hours on truck, hours on component, pictures of leak and a determination of severity; a failure is a leak as defined as Condition Three in SEPD1088. Pictures of the external Duo-Cone seal leak must also include the wheel part number and casting date code.

For internal Duo-Cone seal leaks, the site report must include SOS information which has the viscosity readings. Provide this site report with above information to appropriate person to have report entered into SIMSi.

NOTE: The following improvements will also lead to improved Duo-Cone seal life and are highly recommended to be performed in addition to this service letter:

SEBF9356 ? Rework the brake group to provide pressure improvements throughout the brake system. Applies to the following: 795F Series AC (S/N: ERM1-293), 797 (S/N: 5YW1-277), 797B (S/N: JSM1-488), 797F (S/N: LAJ1-535; WSP1-129).

REHS9532 / REHS9533 ? Install new brake cooling lines to reverse flow configuration in order to further reduce brake system pressure. Applies to the following: 797F (S/N: LAJ1-491; WSP1-124).

REHS9540 / REHS9541 ? Install new brake cooling lines to reverse flow configuration in order to further reduce brake system pressure. Applies to the following: 797 (S/N: 5YW1-UP), 797B JSM1-UP).

NOTE: The following service letter will only cover the rear wheels for 794 AC and 795F AC Off-Highway Trucks.
New Brake Cooling Relief Valve, per service letter PS44948 when applicable, will cover the front wheels on 795F AC Off-Highway Trucks only.

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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%
*****Group 1*****
0-6000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 13-24 mo	40.0%	50.0%	0.0%	0.0%	45.0%	50.0%
12001-18000 hrs, 25-36 mo	7.0%	25.0%	0.0%	0.0%	70.0%	75.0%

NOTE: This is a 30.0-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.
NOTE: This is a 30.0-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. NOTE: This is a 30-hour job to replace the Duo-Cone Seals on a front wheel assembly. An additional 30-hours of labor, for a total of 60 hours, will be allowed to replace the Duo-Cone Seals on a rear final drive. NOTE: If performed at PCR, no labor or parts can be claimed.

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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, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 13-24 mo	40.0%	50.0%	0.0%	0.0%	45.0%	50.0%
12001-18000 hrs, 25-36 mo	7.0%	25.0%	0.0%	0.0%	70.0%	75.0%

NOTE: This is a 30.0-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.
NOTE: This is a 30.0-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. NOTE: This is a 30-hour job to replace the Duo-Cone Seals on a front wheel assembly. An additional 30-hours of labor, for a total of 60 hours, will be allowed to replace the Duo-Cone Seals on a rear final drive. NOTE: If performed at PCR, no labor or parts can be claimed.

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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, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 13-24 mo	40.0%	50.0%	0.0%	0.0%	45.0%	50.0%
12001-18000 hrs, 25-36 mo	7.0%	25.0%	0.0%	0.0%	70.0%	75.0%

NOTE: This is a 60.0-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.