PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING REDUNDANT BRAKE PILOT LINE CIRCUIT ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING REDUNDANT BRAKE PILOT LINE CIRCUIT ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS

Usage:

TEBE8380-00

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04Jan2019

U-4

A-2

D-4

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING REDUNDANT BRAKE PILOT LINE CIRCUIT ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS
7755 7554 4257		PI11199

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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 "PI11199" 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 "PI11199" 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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PROBLEM

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Certain 794 AC Off-Highway Trucks do not have a redundant service brake pilot line circuit to enable activation of the service brakes in the event of a single component failure. If a service brake pilot circuit fails a service brake system failure will occur that may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
794 AC	HRT00100 MN500052-00056 MT500100-00136

PARTS NEEDED

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Qty	Part Number	Description
2	4D6466	CLIP
1	6D4246	CLIP-LOOP
1	6V1889	CLIP-LOOP
1	6V8554	NUT-SWIVEL
4	6V8627	ADAPTER-ELBOW
2	6V8641	ADAPTER-STR
1	6V8647	ADAPTER-STR
1	6V8724	ADAPTER-ELBOW 90
1	6V8935	REDUCER
1	6V9835	ADAPTER-TEE
1	6V9836	ADAPTER-TEE
1	6V9837	ADAPTER-TEE
15	7K1181	STRAP-CABLE
1	8T0151	ADAPTER-STR
4	8T4121	WASHER-HARD
2	8T4145	BOLT-HEX HEAD
2	8T4195	BOLT-HEX HEAD
2	9X3402	SOCKET-CONNECTOR
1	0903118	SPLICE-WIRE
1	1552270	KIT-PLUG CONN
4	1984775	WASHER-HARD
1	2147566	SEAL-O-RING-STOR
10	2147568	SEAL-O-RING-STOR
18	2287088	SEAL-O-RING-ORFS
4	2287089	SEAL-O-RING-ORFS
3	2287090	SEAL-O-RING-ORFS
59	3314040	WIRE-BULK (59 DECIMETERS)
2	3445673	NUT-HEX
2	3445675	NUT-HEX
1	4323185	LOCK-NUT
1	4324000	BODY-STRAIGHT
1	4327482	BUSHING-SEALING
1	4328142	VALVE AS
37	4329024	CONDUIT(37 DECIMETERS)
1	4329051	SLEEVE
1	4345499	CAP NUT-CONDUIT
1	4779352	VALVE GP-MTG
1	5249741	SFWR GP-A3003
1	5638135	HOSE AS
1	5638136	HOSE AS
1	5638137	HOSE AS
1	5638138	HOSE AS
1	5638139	HOSE AS
1	5638141	HOSE AS
1	5638142	HOSE AS
1	5638143	HOSE AS
1	5638144	HOSE AS
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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Refer to the Service Manual if/as necessary and see Special Instruction M0098575, "Procedure to Update the Brake Pilot Circuit on Certain 794 AC Off-Highway Trucks" for the rework procedure.

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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 20.0-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 INSTALLING REDUNDANT BRAKE PILOT LINE CIRCUIT ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 794 AC Off-Highway Trucks

Dear Cat Product Owner:

A redundant brake pilot line circuit needs to be installed on the products listed below. These 794 AC Off-Highway Trucks do not have a redundant service brake pilot line circuit to enable activation of the service brakes in the event of a single component failure. If a service brake pilot circuit fails a service brake system failure will occur that may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. . 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.

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. Please refer the dealer to their Service Letter dated 04Jan2019 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 04Jan2019 Service Letter