PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING THE PUMP ELECTRONIC TANK UNIT (PETU) HARNESS AND MAIN POWER RELAY ON CERTAIN 785G, 789G, 793F, 794 AC, 797F, AND 798 AC OFF-HIGHWAY TRUCKS, AND 994K WHEEL LOADERS Caterpillar


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PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING THE PUMP ELECTRONIC TANK UNIT (PETU) HARNESS AND MAIN POWER RELAY ON CERTAIN 785G, 789G, 793F, 794 AC, 797F, AND 798 AC OFF-HIGHWAY TRUCKS, AND 994K WHEEL LOADERS [UEBE1107]
ELECTRICAL AND STARTING SYSTEM
WIRING GP
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING THE PUMP ELECTRONIC TANK UNIT (PETU) HARNESS AND MAIN POWER RELAY ON CERTAIN 785G, 789G, 793F, 794 AC, 797F, AND 798 AC OFF-HIGHWAY TRUCKS, AND 994K WHEEL LOADERS
UEBE1107-00

01Oct2020


U-578
D-547

 

Priority

  
  

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING THE PUMP ELECTRONIC TANK UNIT (PETU) HARNESS AND MAIN POWER RELAY ON CERTAIN 785G, 789G, 793F, 794 AC, 797F, AND 798 AC OFF-HIGHWAY TRUCKS, AND 994K WHEEL LOADERS

108J 108H 1408
PI33221
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 "PI33221" 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 "PI33221" as the Part Number, "7751" as the Group Number, "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.


COMPLETION DATE

TERMINATION DATE

30Apr2021 31Oct2021

PROBLEM

The PETU harness and main power relay needs to be inspected, reworked, and possibly replaced on certain 785G, 789G, 793F, 794 AC, 797F, and 798 AC Off-Highway Trucks, and 994K Wheel Loaders. The existing harness could have a potential rub or open wire. The main power relay could have potential corrosion and possibly missing a washer. This could lead to damage to the harness, relay and surrounding components.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
789G  TR200189-00191
793F  D3T00142-00183
794 AC  HRT00100-00106
797F  LTZ00140-00159
798 AC  ST700400-00402
*******Group  2*******
785G  RTL00100, 102-109, 113-116
785G OEM  TRG00100
*******Group  3*******
994K  SMX00201-00210

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
2 4B4277 WASHER
10 7K1181 STRAP-CABLE
1 2418368 SWITCH AS-MAG (IF NEEDED)
1 5091330 HARNESS AS-WRG (IF NEEDED)
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.

*******Group 2*******
2 4B4277 WASHER
10 7K1181 STRAP-CABLE
1 1712208 BREAKER AS-CKT
1 2418368 SWITCH AS-MAG (IF NEEDED)
1 5160917 HARNESS AS-WRG (IF NEEDED)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 43% 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*******
4 4B4277 WASHER
10 7K1181 STRAP-CABLE
2 2418368 SWITCH AS-MAG (IF NEEDED)
1 5112023 HARNESS AS-WRG (IF NEEDED)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 39% 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

NOTE: There is currently a limited supply of parts available for this program. The 509-1330, 511-2023, and 516-0917 Harness Assemblies are frozen and allocation will be manually prioritized until sufficient quantities are available. Please work with your Customer Service Representative for parts availability


WARNING

Before performing this procedure, please disconnect the battery power by turning off the main master battery disconnect switch.

Please follow the recommended lockout/tag out procedure to ensure safe working conditions.

Refer to the attached Rework Procedure.

OWNER NOTIFIAVSION

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

SERVICE CLAIM ALLOWANCES

AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
100%
100%
0%
0%
0%
0%
 NOTE: This is a 8.0-hour job for Group 1

AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
100%
100%
0%
0%
0%
0%
 NOTE: This is a 8.0-hour job for Group 2

AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
100%
100%
0%
0%
0%
0%

 NOTE: This is a 8.0-hour job for Group 3


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
EXAMPLE COPY OF OWNER NOTIFIAVSION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING THE PUMP ELECTRONIC TANK UNIT (PETU) HARNESS AND MAIN POWER RELAY

MODELS INVOLVED - CERTAIN 785G, 789G, 793F, 794 AC, 797F, AND 798 AC OFF-HIGHWAY TRUCKS, AND 994K WHEEL LOADERS

Dear Cat Product Owner:

On the products listed below, the main power relay within the Aftertreatment Pump Electronic Tank Unit needs to be inspected and reworked, and parts may need to be replaced. The existing main power relay can fail and cause harness and surrounding component damage. 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 01Oct2020 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 01Oct2020 Service Letter


Rework Procedure


Group Number 1  
 
Remove the fasteners for the top cover on the PETU.

Save fasteners for reassembly.
Image1.1.1
 
Install two lifting eyes ( Reference part number if needed is 4C-8358) with sufficient thread engagement.

If part number is not available, use any lifting eye with a M10 X 1.5 thread with atleast 15mm of thread length.
Image1.2.1
 
Lift the top cover using the lifting eyes.
Image1.3.1
 
Remove the front cover of the PETU.
Image1.4.1
 
Inspect the main harness for any rubbing/fretting damage.

Please take pictures of any rubbing issues or damages. Pictures can be uploaded to the SIMSi claim.

Use 7K-1181 zip ties to secure harness away from potential rub issues.

Check the two wires to the main power relay for any damage.

If harness is damaged and open wires are noted, please replace it with the 509-1330 harness.
Image1.5.1
 
Remove/pull back the two main relay boot covers.
Image1.6.1
 
Please take a picture of the relay and a close-up picture of the terminals.

Pictures can be uploaded to the SIMSi claim.

Note if a washer is missing between the ring terminal and the nut. Washer will be added later during assembly.

Remove both the terminal nuts.

Remove the relay bracket nuts.

Unplug the relay from the harness.

Remove the relay for inspection.
Image1.7.1
 
Inspect if there is any corrosion in/around the terminals. Typically a green colored copper corrosion is an indicator of corrosion within the relay.

If corrosion is noted, replace relay with a new 241-8368 relay.

If no corrosion is noted, inspect the date code on the bottom of the relay.

The date code will be in a mm/dd/yy format. If the date is before 12/01/15 , replace with a 241-8368 relay.
Image1.8.1
 
Reinstall the relay (same or new) to the PETU panel.

Install the ring terminal in the following sequence:

Install the ring terminal first.
Install a 4B-4277 washer if its missing.
Install the nut.

Hold the ring terminal lead so it doesn?t shift when installing and torquing the nut and make sure the wire is not stressed.

Tighten the nut to 9 Nm +/- 0.5 Nm.

Repeat for the second ring terminal.

Reassemble the rest of the PETU and covers.
Image1.9.1
 
 
Group Number 2  
 
Open the breaker panel door located on the machine platform.
Image2.1.1
 
Remove all the fasteners
Image2.2.1
 
Remove the power cable junction bolts and the power terminals to allow for cover removal.
Image2.3.1
 
Remove the breaker panel cover
Image2.4.1
 
Replace the 80 Amp breaker for the PETU with a 1712208 (60 Amp) breaker.

This 80Amp breaker is the only single breaker in the breaker assembly.

Please refer to REHS1718, "Circuit Breaker Harness Assembly" for proper assembly procedure.

Reassemble the rest of the components in the order it was removed.
Image2.5.1
 
Remove the fasteners for the top cover on the PETU.

Save fasteners for reassembly.

Remove the top cover panels.
Image2.6.1
 
Inspect the main harness for any rubbing/fretting damage.

Check the two wires to the main power relay for any damage.

Please take pictures of any rubbing issues or damages. Pictures can be uploaded to the SIMSi claim.

Use 7K-1181 zip ties to secure harness away from potential rub issues.

If harness is damaged and open wires are noted, please replace it with the 516-0917 harness.
Image2.7.1
 
Remove/pull back the two main relay boot covers.
Image2.8.1
 
Please take a picture of the relay and a close-up picture of the terminals.

Pictures can be uploaded to the SIMSi claim.

Note if a washer is missing between the ring terminal and the nut. Washer will be added later during assembly.

Remove both the terminal nuts.

Remove the relay bracket nuts.

Unplug the relay from the harness.

Remove the relay for inspection.
Image2.9.1
 
Inspect if there is any corrosion in/around the terminals. Typically a green colored copper corrosion is an indicator of corrosion within the relay.

If corrosion is noted, replace relay with a new 241-8368 relay.

If no corrosion is noted, inspect the date code on the bottom of the relay.

The date code will be in a mm/dd/yy format. If the date is before 12/01/15 , replace with a 241-8368 relay.
Image2.10.1
 
Reinstall the relay (same or new) to the PETU panel.

Install the ring terminal in the following sequence:
Install the ring terminal first.
Install a 4B-4277 washer if its missing.
Install the nut.

Hold the ring terminal lead so it doesn?t shift when installing and torquing the nut and make sure the wire is not stressed.

Repeat for the second ring terminal.

Tighten the nut to 9 Nm +/- 0.5 Nm.

Reassemble the rest of the PETU and covers.
Image2.11.1
 
 
Group Number 3  
 
Remove the fasteners for the top cover on the PETU.

Save fasteners for reassembly.

Remove the top cover panels.
Image3.1.1
 
Inspect the main harness for any rubbing/fretting damage.

Please take pictures of any rubbing issues or damages. Pictures can be uploaded to the SIMSi claim.

Use 7K-1181 zip ties to secure harness away from potential rub issues.

Check the two wires to the main power relay for any damage.

There are two power relays for the 994K PETU. Inspect wires on both.

If harness is damaged and open wires are noted, please replace it with the 511-2023 harness.
Image3.2.1
 
Pick one of the two power relays.

Remove/pull back the two main relay boot covers.
Image3.3.1
 
Please take a picture of the relay and a close-up picture of the terminals.

Pictures can be uploaded to the SIMSi claim.

Note if a washer is missing between the ring terminal and the nut. Washer will be added later during assembly.

Remove both the terminal nuts.

Remove the relay bracket nuts.

Unplug the relay from the harness.

Remove the relay for inspection.
Image3.4.1
 
Inspect if there is any corrosion in/around the terminals. Typically a green colored copper corrosion is an indicator of corrosion within the relay.

If corrosion is noted, replace relay with a new 241-8368 relay.

If no corrosion is noted, inspect the date code on the bottom of the relay.

The date code will be in a mm/dd/yy format. If the date is before 12/01/15 , replace with a 241-8368 relay.
Image3.5.1
 
Reinstall the relay (same or new) to the PETU panel.

Install the ring terminal in the following sequence:
Install the ring terminal first.
Install a 4B-4277 washer if its missing.
Install the nut.

Hold the ring terminal lead so it doesn?t shift when installing and torquing the nut and make sure the wire is not stressed.

Tighten the nut to 9 Nm +/- 0.5 Nm.

Repeat for the second ring terminal.

Repeat the same remove inspect procedure for the second power relay.

Reassemble the rest of the PETU and covers.
Image3.6.1
 
 

Information System:

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PRODUCT SUPPORT PROGRAM FOR REPLACING LIFTER COVER BOLTS ON CERTAIN 797F OFF-HIGHWAY TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ROOF HATCH LATCH ON THE REAR ENTRY CAB ON CERTAIN 548 LL, 558 LL, AND 568 LL FORESTRY EXCAVATORS
PRODUCT IMPROVEMENT PROGRAM FOR REWORKING 128-5347 STEERING VALVE GROUPS IN DEALER PART STOCK
PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST GAS VALVE (NRS) VALVE ON CERTAIN ASPHALT COMPACTORS, BACKHOE LOADERS, INDUSTRIAL ENGINES, COMPACT WHEEL LOADERS, MEDIUM EXCAVATORS, SMALL EXCAVATORS, GENERATORS, KNUCKLEBOOM LOADERS, MEDIUM TRACK-TYPE
PRODUCT SUPPORT PROGRAM FOR REWORKING THE NRS VALVE ON CERTAIN INDUSTRIAL ENGINES, FORESTRY EXCAVATORS, LARGE AND MEDIUM EXCAVATORS, LANDFILL COMPACTORS, MEDIUM TRACK-TYPE TRACTORS, MEDIUM WHEELED LOADERS, MOTOR GRADERS, PAVERS, WINDROW ELEVATORS, SM
PRODUCT SUPPORT PROGRAM FOR REPLACING CONNECTING ROD BOLTS ON CERTAIN 793F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE GENERATOR GROUP BELT GUARD ASSEMBLY ON CERTAIN AP300F AND AP355F ASPHALT PAVERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PISTONS ON CERTAIN 793F OFF-HIGHWAY TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING CERTAIN REMAN CYLINDER PACKS SHORT BLOCKS IN DEALER PART STOCK
PRODUCT SUPPORT PROGRAM FOR REPLACING THE HINGE ASSEMBLIES ON CERTAIN 140GC MOTOR GRADER.
PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HOSE AND MOUNTING BRACKET FOR THE AIR LINES GROUP ON CERTAIN 815K AND 816K LANDFILL COMPACTORS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE WATER PUMP ON CERTAIN 745 ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PRODUCT LINK HARDWARE ON CERTAIN 18 MOTOR GRADERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE OIL SCAVENGE PUMP BOLTS ON CERTAIN 797F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE MATERIAL FEED PLANETARY DRIVES ON CERTAIN AP500F, AP555F, AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS
PRODUCT SUPPORT PROGRAM FOR REPLACING TRANSMISSION CLUTCH CONTROL VALVES ON CERTAIN 740 AND 745 ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING TRANSMISSION CLUTCH CONTROL VALVES ON CERTAIN 735C, 740, 740 EJ, 745, AND 745C ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE YOKE ON CERTAIN CS54B AND CP54B VIBRATORY SOIL COMPACTORS