PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN CHASSIS HARNESS ON CERTAIN 773G AND 775G OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN CHASSIS HARNESS ON CERTAIN 773G AND 775G OFF-HIGHWAY TRUCKS

Usage:

TEBE2040-00

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18Nov2014

U-684

A-509

D-602

O-594

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN CHASSIS HARNESS ON CERTAIN 773G AND 775G OFF-HIGHWAY TRUCKS
1408		PS52818

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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 "PS52818" 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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TERMINATION DATE

30Nov2016

PROBLEM

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The existing 3170765/">317-0765 Main Chassis Harness can rub underneath the cab and fail on certain 773G and 775G Off-Highway Trucks. If the existing main chassis harness rubs underneath of the cab it can cause various electrical faults resulting in extensive electrical troubleshooting to locate the failure.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
773G	JWS00162-00226 MWH00151-00301
773G OEM	T5S00101-00119 T5T00101-00102
775G	MJS00273-00360 RFM00251-00536
775G OEM	T5F00101 T5W00101-00110

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*****Group 2*****
773G	JWS00227-00296 MWH00302-00360
773G OEM	T5S00120-00123 T5T00103
775G	MJS00361-00433 RFM00537-00725

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
40	7K1181	STRAP-CABLE
80	2062726	GUARD-HOSE (80 CENTIMETERS)
1	3170765	HARNESS ASSEMBLY
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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*****
40	7K1181	STRAP-CABLE
80	2062726	GUARD-HOSE (80 CENTIMETERS)
1	3170765	HARNESS ASSEMBLY
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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Replace the existing 3170765/">317-0765 Main Chassis Harness with a new 3170765/">317-0765 Harness. Install 80 cm (31.5 inches) of 206-2726 Spiral Guard on the harness in the area located underneath the cab. Refer to the attached rework procedure.

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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*****
0-8000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 12.0-hour job for Group 1

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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*****
0-8000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 12.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Refer to the Service Manual if/as necessary.

Image1.1.1

1. Remove the cover from rear of the cab and disconnect the electrical harness, rear view camera cable if equipped, and cab ground strap.
2. Disconnect the hydraulic lines routing to the steering hand metering unit (HMU).
3. Disconnect the heating and air conditioning lines from the bottom of the cab and disconnect the windshield washer fluid line from the windshield wiper arm.
4. Remove the hood.
5. Remove the four bolts and pins from the cab and remove the cab.
6. Disconnect the 3170765/">317-0765 Harness from the remaining connectors that it is attached to.
7. Remove the existing cable ties, remove and retain the existing clips, and remove the 3170765/">317-0765 Harness.

Image1.2.1

8. Remove the boss if one is present in the location shown in Image 1.2.1.
9. Install the new 3170765/">317-0765 Harness, connect it to the existing connectors, and secure it with the existing clips and new 7K-1181 Cable Ties in the existing clipping locations.

Image1.3.1

10. Install 80 cm (31.5 inches) of 206-2726 Spiral Guard to the 3170765/">317-0765 Harness between location A and B in Image 1.3.1. Radius the ends of the 206-2726 Spiral Guard so it installs easily over the braiding on the 3170765/">317-0765 Harness.
11. Install the cab using the existing hardware.
12. Install the hood using the existing hardware.
13. Connect the air conditioning connections and windshield washer fluid line.
14. Connect they hydraulic lines to the steering hand metering unit (HMU).
15. Connect the 3170765/">317-0765 Harness to the connectors in the rear of the cab, connect the rear view camera cable if equipped, and connect the cab ground strap.
16. Install the cover over the harness connections with the existing hardware.