PRODUCT IMPROVEMENT PROGRAM FOR REWORKING PARK BRAKE ALARM CIRCUIT ON CERTAIN 794 AC AND MT5300D AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING PARK BRAKE ALARM CIRCUIT ON CERTAIN 794 AC AND MT5300D AC OFF-HIGHWAY TRUCKS

Usage:

TEBE5154-01

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19Sep2016

(Revised 03Oct2016)

U-479

A-349

D-413

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING PARK BRAKE ALARM CIRCUIT ON CERTAIN 794 AC AND MT5300D AC OFF-HIGHWAY TRUCKS
1408 7450 7451		PI11094

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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 must be administered as soon as possible. When reporting the repair, use "PI11094" 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 "PI11094" 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:	This Revised Service Letter replaces the 19Sep2016 Service Letter. Changes have been made to Parts Needed.

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PROBLEM

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794 AC Off-Highway Trucks equipped with standard park brake alarm may allow the alarm to not function. The park brake door alarm will not sound if key switch is turned off, the gear selector has not been placed in 'P' (Park) to apply the park brake and the operator opens the door. This allows the operator to key off, not have the truck in park, and open the cab door with no park brake alarm sound which can result in an unsafe condition.

AFFECTED PRODUCT

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Model	Identification Number
794 AC	MT500100-00112
MT5300D AC	MN500052-00055

PARTS NEEDED

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Qty	Part Number	Description
2	2L8076	TERMINAL
2	8S4626	SPLICE-WIRE
20	1257874	TUBE-BULK
1	3225650	REEL-WIRE
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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The following update to the electrical wiring in the cab addresses the issue by moving the park brake door alarm power source to an un-switched source.

1) Locate wires 41X1 on terminal strip TB15G and 80E1 on TB15D located under the panel on the passenger side dashboard.
2) Remove these two wires from the terminal strip and secure the other wires back in place.
3) Remove the ring terminals from the ends of the wires and extend the wires with splices, using 322-5650 Wire, to TB14B behind the operator gauge cluster.
4) Use 2L-8076 Terminals with insulation 125-7874 Tube to land both wires to TB14B.
5) Insulate the splices and terminals with 125-7874 Tube heat shrink.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		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 1.0-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 NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING PARK BRAKE ALARM CIRCUIT ON CERTAIN 794 AC AND MT5300D AC OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 794 AC and MT5300D AC Off-Highway Trucks

Dear Cat Product Owner:

The park brake alarm circuit needs to be reworked on the products listed below. The existing park brake alarm can fail to sound if the truck is not in park & the key switch is turned off. This may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. By reworking the power source from a switched power source to an un-switched power source will eliminate this risk. You will not be charged for the service performed.

This service letter addresses an issue where the operator turns the key to the off position without placing the machine in park and opening the cab door, the park brake alarm will not sound. By reworking the power source of the park brake alarm from a switched source to an un-switched source, the park brake alarm will remain active whether the key is in the ON or OFF position. This change will activate the park brake alarm when the operator opens the door without first placing the truck in park.

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.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information.

The Product Identification Number (PIN) / Serial Number and Sales Model listed on your product may not match what is listed on this notification letter. Please contact your local Cat dealer for the cross-reference PIN for your product(s).

Please refer the dealer to their Service Letter dated 19Sep2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 19Sep2016 Service Letter