PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FRONT ENGINE STEP ON CERTAIN 797B OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FRONT ENGINE STEP ON CERTAIN 797B OFF-HIGHWAY TRUCKS

Usage:

REBE4399-00

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16Oct2008

U-528

A-438

D-445

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Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FRONT ENGINE STEP ON CERTAIN 797B OFF-HIGHWAY TRUCKS
7254		PI10720

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10720" 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 "PI10720" 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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The front engine step needs to be replaced on certain 797B Off-Highway Trucks. The existing step can fail at the weld joint resulting in a step fracture. Standing on a failed step may present a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
797B	JSM00220-00287, 292-332, 334-367, 369-400

PARTS NEEDED

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Qty	Part Number	Description
1	1864200	STEP 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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****Parts Stock ****

Remove all 186-4200 (engineering change level 00) from dealer parts stock. The change level 01 step can be identified by the weld joint at the front of the step. The change level 00 step uses a skip weld and the change level 01 step incorporates a complete weld. Refer to Image1 - Image3 for clarification.

Image1 - basic step location.
Image2 - complete weld. (Change Level 01)
Image3 - skip weld. (Change Level 00). Remove from Dealer Parts Stock.

****Affected Product****

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Replace the 186-4200 Step (engineering change level 00) with a new 186-4200 step (engineering change level 01). The change level 01 step can be identified by the weld joint at the front of the step. The change level 00 step uses a skip weld and the change level 01 step incorporates a complete weld. Refer to Image1 - Image3 for clarification.

Image1 - basic step location.
Image2 - complete weld. (Change Level 01)
Image3 - skip weld. (Change Level 00)

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Image1

Image2

Image3

OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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 1.0-hour job

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PARTS DISPOSITION

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****Parts Stock****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

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****Affected Product****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FRONT ENGINE STEP ON CERTAIN 797B OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 797B Off-Highway Trucks

Dear Caterpillar Product Owner:

The front engine step needs to be replaced on certain 797B Large Off-Highway Trucks. The existing step can fail at the weld joint resulting in step fracture. Standing on a failed step may result in personal injury or death. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 16Oct2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 16Oct2008 Service Letter