PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE MAIN BEAM AND REAR CAB SUPPORT ON CERTAIN 768C, 769C, 769D, 771C, 771D, 772B, 773B, 773D, 773E, 775B, 775D, 775E, 776, 776B, 777, AND 777B OFF-HIGHWAY TRACTORS AND OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE MAIN BEAM AND REAR CAB SUPPORT ON CERTAIN 768C, 769C, 769D, 771C, 771D, 772B, 773B, 773D, 773E, 775B, 775D, 775E, 776, 776B, 777, AND 777B OFF-HIGHWAY TRACTORS AND OFF-HIGHWAY TRUCKS

Usage:

SEBE9441-01

January 6, 2006
(Revised July 2006)
U-7
A-7
D-7
O-8

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE MAIN BEAM AND REAR CAB SUPPORT ON CERTAIN 768C, 769C, 769D, 771C, 771D, 772B, 773B, 773D, 773E, 775B, 775D, 775E, 776, 776B, 777, AND 777B OFF-HIGHWAY TRACTORS AND OFF-HIGHWAY TRUCKS
7264 7266 7301		PI30835

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30835" 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 "PI30835" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the January 6, 2006 Service Letter. Changes have been made to the Affected Product and Action Required.

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COMPLETION DATE	TERMINATION DATE
July 31, 2006	January 31, 2007

PROBLEM

The rear cab support needs to be inspected and, if necessary, replaced on certain 776, 776B, 777, and 777B Off-Highway Tractors and Off-Highway Trucks. The main beam needs to be inspected and, if necessary reinforced on certain 768C, 769C, 769D, 771C, 771D, 772B, 773B, 773D, 773E, 775B, 775D, and 775E Off-Highway Tractors and Off-Highway Trucks. Corrosion may occur inside the left end of the main beam of the frame and inside the rear cab support. With few exceptions, corrosion will not be apparent from the exterior of machine.

AFFECTED PRODUCT

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Model	Identification Number
768C	02X00001-403
769C	01X00001-502, 504-1210, 1212, 1223, 1225-1875, 1877-1951, 1953-2037, 2039-2146, 2148-2314, 2316-2948, 2950-2956, 2958-3203, 3205-3211, 3213-3221, 3223-3489, 3491-7151, 75387-75396, 75398, 75399, 78001, 78002
769D	5SS00001-652
769D	5TR00001-1054
769D	BBB00001-522
771C	3BJ00001-281
771D	6JR00001-309
771D	6YS00001-441
771D	BCA00001-370
772B	64W00001-137, 143-152, 154-303, 75132, 75133, 75135, 75136, 75138, 75139
773B	63W00001-158, 160-196, 198-213, 215-244, 246-552, 554-625, 627-710, 712-765, 767-778, 780-804, 806-824, 826-903, 905-971, 973-1455, 1457-1488, 1490-1666, 1668-1674, 1676-1785, 1787-1795, 1798-1829, 1831-1906, 1908-1951, 1953-2258, 2260-2340, 2342-2495, 2497-3016, 3018-3376, 3378-3464, 3467-3608, 3610-3794, 3796-3943, 3945-4081, 4083-4614, 4616-4690, 75118, 75119, 75132, 75133, 75200-75208, 75210, 75213, 76002
773D	7CS00001-7445
773D	7ER00001-971
773E	BDA00001-844
775B	7XJ00001-100, 102-208, 210-286, 288-310, 312-345, 76001-76004
775D	6KR00001-380
775D	8AS00001-534, 536-631, 76001
775E	BEC00001-549
776	14H00001-55, 58-217
776B	6JC00001-58, 61-108, 75200, 75201
777	84A00001-128, 130-214, 216-225, 227-231, 233-249, 251-272, 275-295, 297-338, 340-348, 350-373, 375-413, 415-463, 465-478, 480-509, 511-575, 577-702, 704-817, 819, 821, 823-890, 892-944, 946-953, 955-993, 995-1173, 1175-1358, 1360-1546, 1548-1554, 1556-1772, 1776-1789, 75038-75062, 75101-75107, 75120
777B	4YC00001-113, 115-119, 121-129, 131-152, 154-300, 302-305, 307-557, 559-956, 959-1143, 1145-1220, 1222-1468, 1470-1471, 1473-1481, 1483-1492, 1494-1514, 1517-1545, 1547-1866, 75059-75072, 76001-76004

PARTS NEEDED

Dealers will not need to order parts for this Program.

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Quantity	Part Number	Description
n/a	n/a	None Required

ACTION REQUIRED

Dealers will attempt to prioritize machine inspections within their service territory based on service meter hours (SMU). Machines with the highest SMU will be inspected first.

Inspect the main beam of the frame and rear cab support of the machine as indicated in the special instruction specific to the tractor/truck model:

1. For 768C, 769C, 769D, 771C, and 771D, Off-Highway Trucks refer to media number: REHS2536.

2. For 772B, 773B, 773D, 773E, 775B, 775D, and 775E Off-Highway Trucks refer to media number: REHS2537.

3. For 776, 776B, 777, and 777B Off-Highway Trucks refer to media number: REHS1773.

Determine the condition and appropriate repair for the main beam and rear cab support. Notify your customer of the condition of the machine. The results of each machine inspection are to be entered into SIMS. If all thickness measurements were above the minimum, then description code "T" should be used as the SIMS description code. If any thickness measurements were below the minimum, then description code "Z" should be used in SIMS.

After completing the inspection, refer to PS41889. This Service Letter provides details for an exhaust modification and repair options. If you have any questions, please contact your Service Representative for direction.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	2	0	0	0	0
NOTE: This is a 2-hour job to inspect the affected product and notify the customer of the results.
NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE MAIN BEAM AND REAR CAB SUPPORT ON CERTAIN OFF-HIGHWAY TRACTORS AND OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 768C, 769C, 769D, 771C, 771D, 772B, 773B, 773D, 773E, 775B, 775D, 775E, 776, 776B, 777, and 777B Off-Highway Tractors and Off-Highway Trucks

Dear Caterpillar Product Owner:

In some off-highway tractors and off-highway trucks, internal corrosion may have affected the rear cab support and a portion of the frame. To determine if the rear cab support structure is intact, an inspection of the rear cab support and the left side of the main beam is necessary. Based on the results of the inspection, repair of the machine may be required.

Please contact your local Caterpillar dealer immediately to schedule a service appointment. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated January 6, 2006 when scheduling this service.

You will not be charged for the inspection of the machine. Your dealer will advise you of the condition of the rear cab support structure. If repair of the structure is necessary, your dealer will either: 1) repair the rear cab support structure at no charge to you, or 2) advise you of the cost of the required repair.

We regret the inconvenience this may cause you, but urge you to allow your local Caterpillar dealer to inspect and, if necessary, repair your off-highway tractor or truck.

Caterpillar Inc.

Identification #(s)

Attached to January 6, 2006 Service Letter