PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR DUCT SPLITTER AND FRAME MOUNTING BRACKET ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR DUCT SPLITTER AND FRAME MOUNTING BRACKET ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS

Usage:

TEBE5590-01

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27Feb2017

(Revised 20Mar2017)

U-106

A-71

D-82

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR DUCT SPLITTER AND FRAME MOUNTING BRACKET ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS
7755 4017		PS45399

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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 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 "PS45399" 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.

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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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NOTE:	This Revised Service Letter replaces the 27Feb2017 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

28Feb2019

PROBLEM

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The existing 442-2895 Duct As. can fail on certain 794 AC Off-Highway Trucks. If the existing duct assembly fails it can result in a loss of cooling capability to the rear wheel motors.

AFFECTED PRODUCT

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Model	Identification Number
794 AC	MN500052-00056 MT500100-00112

PARTS NEEDED

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Qty	Part Number	Description
3	8T4195	BOLT-HEX HEAD
3	1984766	WASHER-HARD
1	5071621	DUCT AS-SPLIT
1	5101926	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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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%
0-30000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-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.

Rework Procedure

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1. Loosen and remove two hose clamps (A) and hose clamp (B). Retain hose clamps for reuse later.

Image1.1.1

2. Remove flex hose (C), (D), and (E) ends from duct assembly (F).

Image1.2.1

3. Remove three bolts (G) and three washers (H). The duct assembly, bolts, and washers will not be reused.

Image1.3.1

4. Mark location of both ends and side of mounting bracket (J) as shown per location (K) to help locate new mounting bracket.

Image1.4.1

5. Remove duct assembly mounting bracket (J) from frame assembly. Cut mounting bracket from frame assembly as shown in two places at location (L). The mounting bracket is welded to the frame assembly with a 3 mm (.12 inch) fillet weld on both sides of plate at location (L). Use caution not to gouge or grind into the parent material underneath mounting bracket. Sand the excess fillet weld material flush with the surrounding metal, using a 36 grit minimum sanding disk.

Image1.5.1

6. Using the marked locations from Step 4 and the reference dimensions as shown in Images 1.6.1 and 1.6.2 tack weld new 510-1926 Bracket As (M) to frame assembly. Reference dimensions are shown in millimeters. Temporally install new 507-1621 Duct As (N) to 510-1926 Bracket As (M)and connect flex hose ends that were removed in Step 2 to new 507-1621 Duct As (N) to ensure proper location of bracket assembly before welding.

Image1.6.1

Image1.6.2

Image1.6.3

7. Once it has been determined that new 510-1926 Bracket As (M) is proper located remove new 507-1621 Duct As (N) that was temporally installed in Step 6. Weld new 510-1926 Bracket As (M) at location (L) with a 3 mm (.12 inch) fillet weld on both sides of plate.

8. Install new 507-1621 Duct As (N) to new 510-1926 Bracket As (M) with three 8T-4195 Bolts (P) and three 198-4766 Washers (Q). Tighten bolts to a torque of 55 +/- 10 Nm (41 +/- 7 lb ft). Slide two hose clamps (A) and hose clamp (B) that were removed in Step 1 over flex hose (C), (D) and (E) ends that were removed in Step 2 . Connect flex hose (C), (D) and (E) ends to new 507-1621 Duct As (N). Position hose clamps properly and tighten.