PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 12V POWER PORT HOUSING ASSEMBLY IN THE CAB DASH PANEL OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 12V POWER PORT HOUSING ASSEMBLY IN THE CAB DASH PANEL OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS [UEBE0558]

ELECTRICAL AND STARTING SYSTEM

ELECTRONICS GP-MACHINE

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 12V POWER PORT HOUSING ASSEMBLY IN THE CAB DASH PANEL OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS

UEBE0558-02

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20Apr2020

(Revised 09Sep2020)

U-209

A-164

D-194

O-194

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 12V POWER PORT HOUSING ASSEMBLY IN THE CAB DASH PANEL OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS
7755 7600 7451		PI33163

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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 as soon as possible. When reporting the repair, use "PI33163" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI33163" as the Part Number, "7751" as the Group Number, "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 20Apr2020 (Revised 08Jun2020) Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Oct2020	30Apr2021

PROBLEM

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The 12V power port housing assembly(117-2311)in the cab dash panel(442-3751) needs to be replaced on certain 794 AC, 796 AC and 798 AC Off-Highway Trucks. The existing 117-2311 Housing As may contact and cause damage to the cab wiring harness routed directly behind the dash panel. The damage may be severe enough to cause the insulation to be cut or removed from the wire(s).

AFFECTED PRODUCT

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Model	Identification Number
794 AC	HRT00100-00106 MN500052-00056 MT500100-00170
796 AC	HRZ00500, 503-507
798 AC	ST300198-00199 ST700400-00402

PARTS NEEDED

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Qty	Part Number	Description
5	3S2093	STRAP-CABLE
12	9X3401	PIN-CONNECTOR
12	9X3402	SOCKET-CONNECTOR
60	1257874	TUBE-BULK
1	3355365	HOUSING AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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OWNER NOTIFIAVSION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFIAVSION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 12V POWER PORT HOUSING ASSEMBLY IN THE CAB DASH PANEL OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 794 AC, 796 AC, and 798 AC Off-Highway Trucks

Dear Cat Product Owner:

The 12V power port housing assembly needs to be replaced on the products listed below. The existing housing assembly can chafe on the dash panel wiring and cause damage to the wiring. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 20Apr2020 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

AVSpare Inc.

Identification #(s)

Attached to 20Apr2020 Service Letter

Rework Procedure

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1. Remove six screws (A) and remove dash panel (B). If required for ease of removal, remove knobs and switches from dash panel (B). Save screws (A) for reuse later.

Image1.1.1

2. Disconnect the two wires connected to the 12 volt power port housing assembly (C). Remove housing assembly (C) from dash panel (B). Housing assembly (C) will not be used.

Image1.2.1

3. Inspect dash panel wiring for damage resulting from housing assembly (C) chaffing on wiring as shown in Image 1.3.1. Remove tie straps on wiring bundle as required to inspect individual wires.

Image1.3.1

4. Repair any damaged dash panel wiring. Remove/replace/repair any affected area of a wire using a combination of 9X-3401 Pins and 9X-3402 Sockets. You may also use 125-7874 Shrink Wrap to repair/cover any additional damaged areas of wire. 125-7874 cannot be used to cover the pin and socket combinations. The pin and socket combination do not require any heat shrink wrap.

5. Once all affected dash panel wiring has been repaired as described in Step 4, re-secure the wiring using 3S-2093 Straps as required.

6. Enlarge existing hole in dash panel (B) to accept new 335-5365 Housing As (C). Reference mounting hole size for housing assembly is 27.86 +/- 0.13 millimeter (1.10 +/- 0.005 inch) diameter. Be careful when enlarging this hole to not damage the electroluminescence backlighting section of the dash panel

7. Install new 335-5365 Housing As (C) in dash panel (B). Tighten nut on housing assembly to 1.69 +/- 0.34 Nm (15 +/- 3 lb in). You may need to test fit the dash panel and adjust the orientation of the socket to adjust for any interference that may still be present.

8. Connect power wire to straight(centered) positive terminal on housing assembly. Connect ground wire to 90 degree bent(offset) negative terminal. You may need to adjust wires accordingly as the dash panel is being installed to ensure there are no interference issues.

9. Re-install dash panel (B) using six screws (A) that were removed in Step 1. Tighten screws to 6 +/- 1 Nm (53 +/- 9 lb in).

10. Test functionality of new power outlet and other electrical systems that were affected by the wire harness repair.