PRODUCT SUPPORT PROGRAM FOR REPLACING CATWALKS, HANDRAILS, AND MIRRORS ON CERTAIN 789C OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING CATWALKS, HANDRAILS, AND MIRRORS ON CERTAIN 789C OFF-HIGHWAY TRUCKS

Usage:

REBE3047-00

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06Feb2008

U-65

A-55

D-51

O-59

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING CATWALKS, HANDRAILS, AND MIRRORS ON CERTAIN 789C OFF-HIGHWAY TRUCKS
7255 7256 7319		PS51444

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51444" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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TERMINATION DATE

28Feb2010

PROBLEM

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The existing catwalks, handrails, and mirrors can fail on certain 789C Off-Highway Trucks. If the existing components fail, it may result in increased machine downtime.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
789C	2BW00089-00160, 348, 520, 538-544, 578, 605, 616, 631-632, 663-665, 681, 737-738, 743, 749-753, 765-767, 769-770, 772, 777-778, 804-814, 816, 823-828, 855, 865-867, 875-876, 898-899, 907-913, 916, 918-923, 926-929, 940-942, 951-953, 958, 965, 967-982, 1003-1007, 1018-1020, 1027-1030, 1051-1053, 1057-1058, 1076-1082, 1086, 1091, 1106-1108, 1117, 1119-1124, 1127-1128, 1135-1136, 1139-1141, 1144-1145, 1147, 1150, 1162-1167, 1173-1176, 1179-1180, 1182, 1186-1190, 1197-1198, 1201, 1203, 1209-1215, 1217-1218, 1222-1231, 1236, 1248-1253, 1273-1278, 1291-1297, 1299, 1321-1323, 1327-1328

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*******Group 2*******

789C

2BW00303-00347, 500-519, 521-537, 545-577, 579-604, 606-615, 617-630, 633-662, 666-680, 682-736, 739-742, 744-748, 754-764, 768, 771, 773-776, 779-803, 815, 817-822, 829-854, 856-864, 868-874, 877-897, 900-906, 914-915, 917, 924-925, 930-939, 943-950, 954-957, 959-964, 966, 983-1002, 1008-1017, 1021-1026, 1031-1050, 1054-1056, 1059-1075, 1083-1085, 1087-1090, 1092-1105, 1109-1116, 1118, 1125-1126, 1129-1134, 1137-1138, 1142-1143, 1146, 1148-1149, 1151-1161, 1168-1172, 1177-1178, 1181, 1183-1185, 1191-1196, 1199-1200, 1202, 1204-1208, 1216, 1219-1221, 1232-1235, 1237-1247, 1254-1272, 1279-1290, 1298, 1300-1320, 1324-1326

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
8	4L6454	BOLT
8	5P1075	WASHER-HARD
5	5P2228	BOLT
4	5S7379	BOLT
6	7D1649	WASHER-HARD
4	7X0325	BOLT
8	7X0732	WASHER-HARD
24	7X7729	WASHER
4	8T4121	WASHER-HARD
3	8T4136	BOLT
4	8T4137	BOLT
6	8T4183	BOLT
8	8T4185	BOLT
4	8T4186	BOLT
24	8T4195	BOLT
5	8T4223	WASHER-HARD
8	9B7237	BOLT
4	1282477	SPACER
1	1340987	BRACKET AS
2	1340989	BLOCK
1	2507605	BRACKET AS.
1	2662292	MIRROR AS
1	2968210	CATWALK AS.
1	2986396	HANDRAIL AS
1	2996982	CATWALK AS
1	3053023	HANDRAIL AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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.
*****Group 2*****
8	4L6454	BOLT
8	5P1075	WASHER-HARD
5	5P2228	BOLT
4	5S7379	BOLT
6	7D1649	WASHER-HARD
4	7X0325	BOLT
8	7X0732	WASHER-HARD
24	7X7729	WASHER
22	8T4121	WASHER-HARD
3	8T4136	BOLT
4	8T4137	BOLT
6	8T4183	BOLT
8	8T4185	BOLT
4	8T4186	BOLT
24	8T4195	BOLT
5	8T4223	WASHER-HARD
8	9B7237	BOLT
4	1282477	SPACER
1	1340987	BRACKET AS
2	1340989	BLOCK
1	2507605	BRACKET AS.
1	2662292	MIRROR AS
1	2968210	CATWALK AS.
1	2986396	HANDRAIL AS
1	2996982	CATWALK AS
1	2997945	HANDRAIL AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Please refer to Special Instruction REHS4404 - "Installation of Improved Walkway, Handrails, and Mirrors on 789C Off-Highway Trucks".

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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%
*****Group 1*****
0-10000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-20000 hrs, 25-48 mo	33.0%	0.0%	0.0%	0.0%	50.0%	100.0%

NOTE: This is a 8.0-hour job for Group 1
When required, a maximum of $200.00 U.S. will be allowed for labor and materials to fabricate the blocks and shims shown in the illustration within the Special Instruction. When required, an additional 4 hours of labor for installation of the blocks will also be allowed. These expenses should only apply to trucks from 2BW1-1001. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the machine folder for audit purposes.

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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%
*****Group 2*****
0-10000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-20000 hrs, 25-48 mo	33.0%	0.0%	0.0%	0.0%	50.0%	100.0%

NOTE: This is a 8.0-hour job for Group 2
When required, a maximum of $200.00 U.S. will be allowed for labor and materials to fabricate the blocks and shims shown in the illustration within the Special Instruction. When required, an additional 4 hours of labor for installation of the blocks will also be allowed. These expenses should only apply to trucks from 2BW1-1001. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the machine folder for audit purposes.