PRODUCT SUPPORT PROGRAM FOR REWORKING CAB HARNESS ASSEMBLIES OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS Caterpillar


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PRODUCT SUPPORT PROGRAM FOR REWORKING CAB HARNESS ASSEMBLIES OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS [UEBE0683]
ELECTRICAL AND STARTING SYSTEM
WIRING GP
PRODUCT SUPPORT PROGRAM FOR REWORKING CAB HARNESS ASSEMBLIES OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS
UEBE0683-00

27Apr2020


U-253
D-238

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING CAB HARNESS ASSEMBLIES OF CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS

1408
PS46675
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 "PS46675" 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.

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.


TERMINATION DATE

30Apr2022

PROBLEM

The existing harness assemblies can become loose due to poor crimping of the plastic insulated connectors on certain 794 AC, 796 AC, and 798 AC Off-Highway Trucks. These connectors are susceptible to dust and moisture issues if they are not crimped properly.

AFFECTED PRODUCT

Model Identification Number
794 AC HRT00100-00102

MT500142-00144
796 AC  HRZ00500-00507
798 AC  ST700400-00402

PARTS NEEDED

Qty

Part Number Description
145 5P3075 WIRE BK-ELEC 18 GA (DECIMETERS)
10 6A3626 WIRE-BULK 14 GA (DECIMETERS)
16 8T8737 PLUG-SEAL
62 9X3401 PIN-CONNECTOR
62 9X3402 SOCKET-CONNECTOR
4 1028801 KIT-RCPT CONN
6 1028802 KIT-RCPT CONN
4 1028803 KIT-RCPT CONN
2 1261767 PIN-CONNECTOR
2 1261768 SOCKET-CONNECTOR
4 1552255 KIT-PLUG CONN
4 1552260 KIT-PLUG CONN
6 1552270 KIT-PLUG CONN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% 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

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-60000 hrs,
0-84 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 4.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Follow these step to replace the red splices on the various harnesses listed below.

Step 1: Cut the wires, ONE AT A TIME, such that the splices are removed. Cut them as close to the edge of the red splice as possible, to give enough length to add the pin/socket and fit the crimper into the service area.
Image1.1.1
 
Step 2: Add a pin to the end of the wire and insert into position 1 of the receptacle.
Image1.2.1
 
Step 3: Take the length of wire shown in the diagram, add 50mm, and cut one piece of wire to the total length.
Image1.3.1
 
Step 4: Add 2x sockets to the wire, one on each end, and insert into position 1 of the plugs on both ends.
Image1.4.1
 
Step 5: Repeat STEP 2, adding a pin to the other cut wire, then inserting that into position 1 of the new receptacle.
Image1.5.1
 
Step 6: Repeat STEPS 1 - 5, until all splices in the harness bundle are removed.

Step 7: Insert the wedge-locks into all 4x connectors
Image1.6.1
 
Step 8: Connect the jumper harness into the plugs on the cab harness and secure with a tie-strap, if necessary.
 
Image1.8.1
Image1.8.2
Image1.8.3
Image1.8.4
Image1.8.5
Image1.8.6
Image1.8.7
Image1.8.8
Image1.8.9
Image1.8.10
 
 

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