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 Caterpillar

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 [UEBE0505]

AIR INLET AND EXHAUST SYSTEM

LINES GP-AIR

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

UEBE0505-01

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03Jun2020

(Revised 16Jul2020)

U-362

A-305

D-347

O-342

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Before/After	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
7755 1051 1071		PS46751

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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 must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46751" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the 03Jun2020 Service Letter. Changes have been made to the Affected Product and Parts Needed.

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TERMINATION DATE

30Jun2022

PROBLEM

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The existing air intake tube assembly mounting hardware can loosen or fail on certain 794 AC, 796 AC, and 798 AC Off-Highway Trucks. If the existing mounting hardware loosens or fails it can dislodge the air intake tube assembly.

AFFECTED PRODUCT

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Model	Identification Number
794 AC	HRT00100 MN500052-00056 MT500100-00175
796 AC	HRZ00500, 503-508
798 AC	ST300198-00199 ST700400-00402

PARTS NEEDED

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Qty	Part Number	Description
28	6V7744	LOCKNUT
56	8T4121	WASHER-HARD
28	8T6466	BOLT-HEX HEAD
14	1628284	BOLT-HEX HEAD
14	3328888	SPACER-HARD
14	4422672	WASHER-MOUNT
14	5892254	SUPPORT
14	5892716	NUT-M12X1.75
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-60000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 12.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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1. Remove all air intake tube assembly mounting hardware. Remove the top support on tube assembly. The mounting hardware and the top support will not be reused. Remove bottom support (A) on tube assembly and save for reuse.

2. Loosely assembly each 589-2254 Support (1) to underneath side of platform assembly in same location as the removed supports as shown in Image 1.2.1. Use one 162-8284 Bolt (2), one 332-8888 Spacer (3), one 442-2672 Washer-Mount (4) and one 589-2716 Nut (5) to assemble the 589-2254 Support (1) to the platform assembly.

Note: Make certain that the grooves in 589-2716 Nut (5) are positioned correctly. The grooves must be aligned in the channel (B) edges as shown in Image 1.2.2.

Image1.2.1

Image1.2.2

3. Loosely assembly each support (A) to 589-2254 Support (1) using two 8T-6466 Bolts (6), four 8T-4121 Washers (7) and two 6V-7744 Locknuts (8).

4. Position and align 589-2254 Support (1) and support (A) on tube assembly so that all mounting hardware is perpendicular to the center line of the tube assembly.

5. Tighten 162-8284 Bolts (2) to 82 +/- 12 Nm (60 +/- 9 lb ft).

6. Tighten 6V-7744 Locknuts (8) to 30 +/- 7 Nm (22 +/- 5 lb ft).