PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE REAR CAB SUPPORT ON CERTAIN 789C OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE REAR CAB SUPPORT ON CERTAIN 789C OFF-HIGHWAY TRUCKS

Usage:

SEBE9071

February 21, 2005
U-50
A-37
D-43
O-43

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE REAR CAB SUPPORT ON CERTAIN 789C OFF-HIGHWAY TRUCKS
7266 7301		PI10339

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10339" 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 "PI10339" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The 2283732/">228-3732 Cab Support (Rear) needs to be inspected on certain 789C Off-Highway Trucks. The top and bottom row of bolt holes were incorrectly located on some supports. Bolt holes that are mislocated may cause interference when tightening the bottom row of bolts and result in an inaccurate bolt torque.

AFFECTED PRODUCT

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Model	Identification Number
789C	2BW522-656

PARTS NEEDED

Dealers will need to order parts for this Program.

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Quantity	Part Number	Description
*** New Tooling ***
1 max *	2585686	SOCKET-MODIFIED
1 max *	2626728	REACTION ARM FOR FABRICATING FT-3014
* - A maximum of 1 per job site or location with an affected truck will be allowed.

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Quantity	Part Number	Description
*** Inspect and Replace Bolts/Washers ***
7	1F7464	BOLT
7	5P8250	WASHER-HARD

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Quantity	Part Number	Description
*** Replace Rear Cab Support ***
14	1F7464	BOLT
6	1K9420	BOLT
14	5P8250	WASHER
6	5T5807	RETAINER
12	1630042	MOUNT-CAB
6	1630364	SLEEVE
1	2283732	REAR CAB SUPPORT

ACTION REQUIRED

See the attached procedure.

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.
*** New Tooling ***
100%	n/a	0	0	0	0
NOTE: No labor will be allowed to fabricate the "FT" tool.
NOTE: A maximum of 1 socket and "FT" tool will be allowed per job site or location with an affected truck.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Inspect and Replace Bolts/Washers ***
100%	2	0	0	0	0
NOTE: This is a 2-hour job to inspect and replace the bolts and washers.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Replace Rear Cab Support ***
100%	6	0	0	0	0
NOTE: This is a 6-hour job to replace the rear support.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for 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)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999 SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE REAR CAB SUPPORT ON CERTAIN 789C OFF-HIGHWAY TRUCKS MODELS INVOLVED - 789C OFF-HIGHWAY TRUCKS

Dear Caterpillar Product Owner:

The 2283732/">228-3732 Cab Support (Rear) needs to be inspected on the products listed below. The top and bottom row of bolt holes were incorrectly located on some supports. Bolt holes that are mislocated may cause interference when tightening the bottom row of bolts and result in an inaccurate bolt torque and loosening.

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 February 21, 2005 when scheduling this service. You will not be charged for the service performed.

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 February 21, 2005 Service Letter

REWORK PROCEDURE

REPLACE/TORQUE LOWER BOLTS PROCEDURE

1. Place the 258-5686 Socket-Modified over each of the seven 1F-7464 bolts located on the bottom of the rear cab support. If there is any interference between the socket and the cab support, proceed to the "cab support replacement procedure."

2. If there is no interference, replace each of the lower 1F-7464 bolts one at a time. Tighten each of the 1F-7464 Bolts to a torque value of 900 +/- 100 N*m (662 +/- 74 lb ft) using the following combination of tooling: 258-5686 Socket-Modified, FT-3014 Reaction Arm, 194-7586 Pneumatic Wrench Gp.

REAR CAB SUPPORT REPLACEMENT PROCEDURE

1. Begin by supporting the rear cab support using a suitable lifting device. The rear cab support weighs approximately 232 kg (511 lb).

NOTE: The cab does not need to be removed in order to replace the rear cab support.

2. Remove the six 1K-9420 bolts.

3. Remove the 14 1F-7464 bolts. The cab support should now be free to remove.

4. Discard cab support and all associated mounting hardware. Replace with new parts.

5. Assemble six 163-0364 Sleeves and 12 163-0042 Cab Mounts in the cab mounting holes on the new 2283732/">228-3732 Rear Cab Support.

6. Use a suitable paint remover in order to clean the paint from the mounting flange on the new 2283732/">228-3732 Rear Cab Support.

7. Using a suitable crane, position the new 2283732/">228-3732 Rear Cab Support against the frame mounting flange.

8. Assemble 14 5P-8250 Washers and 14 1F-7464 Bolts. Do not tighten yet.

9. Assemble six 5T-5807 Retainers and six 1K-9420 Bolts. Apply 4C-4030 Thread Lock Compound to 1K-9420 Bolts prior to installation. Tighten 1K-9420 Bolts to a torque value of 1904 +/- 68 N*m (1400 +/- 50 lb ft).

10. Tighten each of the 1F-7464 Bolts to a torque value of 900 +/- 100 N*m (662 +/- 74 lb ft) using the following combination of tooling: 258-5686 Socket-Modified, FT-3014 Reaction Arm, 194-7586 Pneumatic Wrench Gp.