2004/02/09 Caterpillar

New Handrails Improve the Restraint System {7255}

Usage:

789C 2BW

Off-Highway Truck: 789C (S/N: 2BW1-UP)

Description of Change: New front handrails, new rear handrails, and new chain provide an improved restraint system. A new catwalk is also used.

Adaptable To:

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Illustration 1	g01049153
Improved restraint system

The type of truck body determines the part number of the new front handrail. The 231-8775 Handrail As is used on dual slope bodies. The 231-8776 Handrail As is used on flat floor bodies. The new 231-8774 Handrail As (Rear) is used regardless of the type of truck body. The new handrails and the new chain are effective with 789C (S/N: 2BW637-UP) Off-Highway Truck. Use the following procedures to adapt the new parts to all earlier 789C Off-Highway Trucks.

Procedure to Rework the Handrail on a Truck with a Dual Slope Body

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Table 1
Needed Parts
Item	Qty	New Pt. No.	Description
1	1	231-8808 ⁽¹⁾	Walkway As
2	4	1F-0750 ⁽²⁾	Weld Nut
3	1	231-8774	Handrail As
4	1	231-8775	Handrail As
5	2	8X-3838	Chain
6	2	5P-0765	Hose Each hose is 610 ± 5 mm (24 ± 0.2 inch) in length.
7	4	4M-5282	Bolt
8	4	6V-8185	Nut
9	8	8T-4205	Hard Washer

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^( 1 )	This part is not required if you are modifying the existing 149-6890 Walkway As .
^( 2 )	The weld nuts are used to modify the existing walkway assembly. The weld nuts are not required if you are modifying the existing 149-6890 Walkway As .

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Illustration 2	g00956604
Top view of the catwalk group

Remove 8W-4484 Pipe (A). Retain the hardware.

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Illustration 3	g00956642

Modify the existing 149-6890 Walkway As, as shown. See Illustration 3 and Table 4.

Note: A new 231-8808 Walkway As (1) (not shown) can be used instead of modifying the existing walkway.

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Table 2
Item	Dimension
B	13.8 mm (0.54 inch) diameter 4 holes
C	1200.2 mm (47.25 inch)
D	63.5 mm (2.50 inch)
E	50.8 mm (2.00 inch)

Weld four 1F-0750 Weld Nuts (2) (not shown) at the new bolt holes (B) .

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Illustration 4	g00964077

Use the existing hardware to install 231-8774 Handrail As (3) to the walkway.

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Illustration 5	g00956689

Remove 149-6901 Rail As (F). Retain the hardware.

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Illustration 6	g00960371

Use the existing hardware to install 231-8775 Handrail As (4) .

Use the following hardware to install two 8X-3838 Chains (5) and 5P-0765 Hose (6) : four 4M-5282 Bolts (7), four 6V-8185 Nuts (8) and eight 8T-4205 Hard Washers (9) .

Procedure to Rework the Handrail on a Truck with a Flat Floor Body

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Table 3
Needed Parts
Item	Qty	New Pt. No.	Description
1	1	231-8808 ⁽¹⁾	Walkway As
2	4	1F-0750 ⁽²⁾	Weld Nut
3	1	231-8774	Handrail As
4	2	8X-3803 ⁽³⁾	Bracket
5	1	231-8776 ⁽⁴⁾	Handrail As
6	2	8X-3838	Chain
7	2	5P-0765	Hose Each hose is 610 ± 5 mm (24 ± 0.2 inch) in length.
8	4	4M-5282	Bolt
9	4	6V-8185	Nut
10	8	8T-4205	Hard Washer

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^( 1 )	This part is not required if you are modifying the existing 149-6890 Walkway As .
^( 2 )	The weld nuts are used to modify the existing walkway assembly. The weld nuts are not required if you are modifying the existing 149-6890 Walkway As .
^( 3 )	The bracket is used to modify the existing 165-6145 Rail As. The bracket is not required with a new walkway assembly.
^( 4 )	This part is not required if you are modifying the existing 165-6145 Rail As .

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Illustration 7	g00964084

Remove 8W-4484 Pipe (A). Retain the hardware.

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Illustration 8	g00956642

Modify the existing 149-6890 Walkway As, as shown. See Illustration 8 and Table 4.

Note: A new 231-8808 Walkway As (1) (not shown) can be used instead of modifying the existing platform.

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Table 4
Item	Dimension
B	13.8 mm (0.54 inch) diameter 4 holes
C	1200.2 mm (47.25 inch)
D	63.5 mm (2.50 inch)
E	50.8 mm (2.00 inch)

Weld four 1F-0750 Weld Nuts (2) (not shown) at the new bolt holes (B) .

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Illustration 9	g00964088

Use the existing hardware to install 231-8774 Handrail As (3) to the walkway.

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Illustration 10	g00964183
Left side view of handrail assembly (F) 385 ± 3 mm (15.16 ± 0.12 inch) (G) 547 ± 3 mm (21.5± 0.12 inch)

Weld two 8X-3803 Brackets (4) to 165-6145 Rail As .
Note: A new 231-8776 Rail As (5) (not shown) can be used instead of modifying the existing rail assembly.

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Illustration 11	g00964431

Use the following hardware to install two 8X-3838 Chains (6) and 5P-0765 Hose (7) : four 4M-5282 Bolts (8), four 6V-8185 Nuts (9) and eight 8T-4205 Hard Washers (10) .