PRODUCT SUPPORT PROGRAM FOR INSTALLING CIRCUIT PROTECTION ON THE PRELUBE CIRCUIT ON CERTAIN 793F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING CIRCUIT PROTECTION ON THE PRELUBE CIRCUIT ON CERTAIN 793F OFF-HIGHWAY TRUCKS

Usage:

TEBE6396-00

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21Jul2017

L100

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING CIRCUIT PROTECTION ON THE PRELUBE CIRCUIT ON CERTAIN 793F OFF-HIGHWAY TRUCKS
1469 1420 1408 1402		PS90725

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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 Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90725" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "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 Caterpillar product analyst.

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TERMINATION DATE

31Jul2019

PROBLEM

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Certain 793F Off-Highway Trucks do not have short circuit protection in the prelube electrical circuit. The addition of a fuse will help protect the system against a short to ground.

AFFECTED PRODUCT

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Model	Identification Number
793F	SSP00791, 856

PARTS NEEDED

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Qty	Part Number	Description
2	5C7261	NUT-HEX
2	5C9553	BOLT-HEX HEAD
3	7K1181	STRAP-CABLE
2	7X0608	WASHER-HARD
6	7X7729	WASHER-HARD
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
2	8T4136	BOLT-HEX HEAD
1	8T4185	BOLT-HEX HEAD
1	8T4195	BOLT-HEX HEAD
2	9X8256	WASHER
1	0919035	SPACER-HARD
2	1774562	GROMMET
1	2042281	STRAP-CABLE
2	2643617	LOCKWASHER
1	2672744	FUSE AS-HOLDER
1	3088161	COVER-TERMINAL
1	3268116	FUSE
1	3289944	BOOT-JCT BLOCK
3	3445675	NUT-HEX
1	4469281	BRACKET AS
1	4469282	CABLE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Use the attached Rework Procedure to install an in-line fuse in the prelube electrical circuit.

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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%
0-20000 hrs, 0-96 mo	100.0%	100.0%	0.0%	0.0%	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.

Rework Procedure

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This procedure will require changes to the main battery power circuit. Ensure that the Main Power Disconnect is locked-out and tagged prior to proceeding with these instructions. Follow the machine shutdown procedure listed in the Operation and Maintenance Manual and obey all safety rules.

Locate the existing circuit breaker box on the inside of the LH frame rail and remove the top cover.

Image1.2.1

Pull back the terminal boot and remove the middle cable from the junction block. Remove the terminal boot from the end of the cable and discard. Install the new 328-9944 Protective Cover on the junction block stud.

Image1.3.1

Remove the P-Clip, mounting hardware and the rubber grommet from supporting the middle cable on the RH side of the circuit breaker box. Save all hardware to be used later. Remove the cable from the circuit breaker box.

Image1.4.1

Remove the rubber grommet and the rubber plug from both sides of the circuit breaker box. Swap their positions (Left to Right on both sides of the box) and install them on the opposite sides of the box.

Image1.5.1

Mount the 267-2744 Fuse Holder to the 446-9281 Bracket using the two 5C-9553 Bolts and two 9X-8256 Washers. Tighten the mounting bolts to 4 Nm.

Then align the holes on the mounting bracket to the existing holes on the bottom of the circuit breaker box and attach using two 8T-4136 Bolts, four 7X-7729 Washers, and two 344-5675 Hex Nuts.

Image1.6.1

Insert the new 47469282 Cable through the grommet on the LH side of the circuit breaker box and attach it to the lower LH junction block location using the existing hardware that is retaining the bus bar. Tighten to 55Nm.

Image1.7.1

Remove the P-Clip and grommet that is supporting the existing cable on the RH side of the circuit breaker box, and relocate it to the next lower boss on the frame, as shown in the picture below.

Image1.8.1

Route the new cable under the circuit breaker box and loosely install the 8T-1889 and 8T-1890 P-clips and 1774562 Grommet to the under side of the box using one 8T-4136 Bolt, two 8T-4121 Washers, and 344-5675 Hex Nut.

Image1.9.1

Route the existing cable, on the RH side of the circuit breaker box, to the underside of the box. Loosely install 8T-1889 and 8T-1890 P-clips and 1774562 Grommet to the under side of the box using a new 8T-4185 Bolt, new 091-9035 Spacer and the existing two washers and hex nut removed prior. Install the new terminal cover on the end of the 308-8161 Cable.

Image1.10.1

Install the 326-8116 300 Amp Fuse and both cables onto the fuse holder
using two 264-3617 Lock Washers, two 7X-0608 Flat Washers and two 5C-
7261 Hex Nuts using the hardware stack up in Image1.11.1.

While holding the cables in alignment, tighten the two nuts in the fuse holder to 14 Nm.

Image1.11.1

Close the protective lid on the fuse holder and secure it in place with the single 204-2281 Tie Strap.

Secure the terminal protectors to each cable using the three 7K-1181 Tie Straps.

Image1.12.1

Ensure that the battery cables are routed in a way so they will not make contact or rub on any other hardware. Tighten the P-Clips mounting bolts to hold the battery cables in this location.

Install the top lid to the circuit breaker box.

Following all safety rules, close the master disconnect switch and place the key switch into the "Crank" Position. Ensure that the prelube pumps runs and operates properly.