PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AND REPLACING FUSES AND INSTALLING A GROUND STRAP ON CERTAIN 793F CMD OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AND REPLACING FUSES AND INSTALLING A GROUND STRAP ON CERTAIN 793F CMD OFF-HIGHWAY TRUCKS

Usage:

TEBE0787-00

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11Jun2014

A-245

D-300

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AND REPLACING FUSES AND INSTALLING A GROUND STRAP ON CERTAIN 793F CMD OFF-HIGHWAY TRUCKS
1408 7610 1400 1417 1422		PI32355

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32355" 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 "PI32355" 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:

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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COMPLETION DATE	TERMINATION DATE
31Dec2014	30Jun2015

PROBLEM

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The observed failures of the Ethernet switch have resulted in secondary damage to other electrical components on certain 793F CMD Off-Highway Trucks.

AFFECTED PRODUCT

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Model	Identification Number
793F CMD	RBT00111-00171

PARTS NEEDED

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Qty	Part Number	Description
4	3S2093	STRAP-CABLE
2	7X6315	STRAP-GROUND
4	8T8737	PLUG-SEAL
1	1028804	RECEPTACLE KIT
4	1412759	FUSE-MINI
1	1552271	PLUG KIT-CONN
1	3395314	HOLDER AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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OWNER NOTIFICATION

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

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 0.5-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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XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AND REPLACING FUSES AND INSTALLING A GROUND STRAP ON CERTAIN 793F CMD OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 793F CMD

Dear Cat Product Owner:

The harness wiring for the 341-6783 Ethernet Switch needs to be reworked and the existing fuse for the Ethernet Switch needs to be replaced on 793F CMD Haul Trucks. Failure of the Ethernet Switch could result in additional damage due to insufficient circuit protection. 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. Please refer the dealer to their Service Letter dated 11Jun2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 11Jun2014 Service Letter

Rework Procedure

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Note: The "Autonomy Ready and Fully Autonomous" trucks have a single Advantech switch located behind the cab rear panel. One 5-amp inline fuse needs to be installed in the cab, along with a ground strap for the switch.

Note: The "Fully Autonomous" trucks have three more Advantech Ethernet switches, located in the autonomy cabinet. Three 10-amp fuses need to be REPLACED with three 5-amp fuses, along with a ground strap for each switch.

Prepare the truck for rework:

1. Raise and pin the truck bed.
2. Turn off the engine.
3. Turn off the master power disconnect switch.
4. Lockout the engine starter.

Prep the cab (all trucks) and autonomy enclosure/cabinet (If Applicable):

1. Switch 4 is located inside the access panel on the rear of the cab. Remove the cover plate from the rear of the cab (see Image 1.4.1).

2. Remove the front cover from the autonomy enclosure/cabinet. Note switch 1, 2, and 3 locations as well as the cabinet fuse block (see Image 1.4.2).

3. Remove the cover for the cabinet fuse block

Image1.4.1

Image1.4.2

Ensure Fuse is Seated properly:

1. Open the cover on the in-line fuse holder and ensure the 5-amp fuse is seated/installed properly.

Install 5 Amp In-line Fuse:

1. Disconnect the 4DT power plug from switch 4 (see Image 1.6.1).
2. Connect the inline fuse to the 4DT power plug that was just removed from the switch (see Image 1.6.2).
3. Install the 4DT fuse plug end into the switch (see Image 1.6.3).
4. Use 1-2 zip straps (3S-2093) to secure the inline fuse harness onto the power harness.

Image1.6.1

Image1.6.2

Image1.6.3

Install ground strap on Cab Ethernet Switch:

1. Follow the instructions in the Ground Strap Rework section below to install the ground strap (7X-6315) on the Cab Ethernet Switch.
2. Leave the rear panel open and the bed raised until validation is completed.

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FOR CMD TRUCKS (WITH AUTONOMY CABINETS INSTALLED) ONLY

Prep the autonomy cabinet:
1. Ensure you already performed the Cab Fuse Rework above.
2. Ensure the following
a. The engine is still OFF.
b. The master power disconnect switch is still OFF.
c. The Lockout for the engine starter is still applied.
3. Locate the autonomy cabinet fuse panel (see Image 1.8.1).

Image1.8.1

FOR CMD TRUCKS (WITH AUTONOMY CABINETS INSTALLED) ONLY

Replace the Following Fuses With a 5-Amp Fuse:
1. For Advantech switch 1: Replace the existing 10-Amp Fuse at F19 with a 5-Amp fuse (141-2759).
2. For Advantech switch 2: Replace the existing 10-Amp Fuse at F15 with a 5-Amp fuse (141-2759).
3. For Advantech switch 3: Replace the existing 10-Amp Fuse at F14 with a 5-Amp fuse (141-2759).
See Image 1.9.1 for Fuse locations

Image1.9.1

FOR CMD TRUCKS (WITH AUTONOMY CABINETS INSTALLED) ONLY

Inspect Fuses:
1. Ensure Fuses are seated properly
2. Leave fuse block cover off until validation is completed
3. Follow the instructions in section 6 - Ground Strap Rework below to install the ground strap (7X-6315) on the three Autonomy Cabinet Ethernet switches.

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GROUND STRAP REWORK (to be performed on all Advantech Ethernet Switches):

An additional ground strap needs to be installed to the side housing of the Advantech switch along with the existing housing ground strap (see Image 1.11.1).

1. Remove the screw located on the side of the switch which attaches the housing ground strap.
2. Install the small eyelet of the new ground strap (7X-6315) as depicted and tighten the assembly back in the same location the screw came from (see Image 1.11.2).
3. Remove the mounting bolt and assembly closest to the grounding strap.
4. Install the large eyelet of the ground strap (7X-6315) as depicted and tighten the assembly back in the same mounting location (see Image 1.11.3).

Image1.11.1

Image1.11.2

Image1.11.3

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Rework Validation:

1. Visually inspect the cab Ethernet switch to ensure both the ground strap and the inline fuse has been installed in the cab correctly.
2. If there is an autonomy cabinet installed on the truck, visually inspect the fuse panel to ensure the three fuses (positions F19, F15, and F14) have been replaced in the cabinet fuse block and are seated properly. Also, verify the ground straps have been installed on all switches.
3. Check Switch Power
a. With the engine still OFF.
b. The Lockout for the engine starter still applied.
c. Turn ON the master power disconnect switch.
d. Visually check the Advantech switch power indicator light turns on (is green) on each switch; 1 for the cab and 3 for the cabinet, if applicable (see Image 1.12.1).
4. If no issues are found:
a. Turn off Master Power
b. Replace the Cab, Cabinet, and fuse block covers.