PSP FOR ERRATIC OR INTERMITTENT SHIFTING OF THE ICM CONTROLLED TRANSMISSIONS ON CERTAIN 621E, 623E, 627E, 631E, 637E, 651E, AND 657E SCRAPERS; 768C, 772B, AND 776B TRACTORS; AND 769C, 773B, 777B, 785, AND 789 TRUCKS - PS4402 - MAILED US AND CANADA ,
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PSP FOR ERRATIC OR INTERMITTENT SHIFTING OF THE ICM CONTROLLED TRANSMISSIONS ON CERTAIN 621E, 623E, 627E, 631E, 637E, 651E, AND 657E SCRAPERS; 768C, 772B, AND 776B TRACTORS; AND 769C, 773B, 777B, 785, AND 789 TRUCKS - PS4402 - MAILED US AND CANADA , CACO, COFA, BRAZIL, COSA
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.
U-210 A-133 AU-137 B-34 O-129 3150 PS4402 NOTE: This Program can be administered either before or after a failure. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4402" as Part Number, "7755" as Group Number, and "96" as Description Code.
Termination Date
October 31, 1990
Problem
Erratic or intermittent shifting of the ICM controlled transmissions may be a problem due to positioning of the transmission switch on certain 621E, 623E, 627E, 631E, 637E, 651E, and 657E Scrapers; 768C, 772B, and 776B, Tractors; and 769C, 773B, 777B, 785, and 789 Trucks. The new transmission switch shafts are adaptable to all haul unit ICM control transmissions in the field.
Affected Product
Model Identification Number Equipped with Trans S/N 621E 6AB1-1261, 1267 1WE1-1152 2PD1-739 1WE1-1152 8KD1-627 1WE1-1152 623E 6CB1-868 1SE1-756 6YF1-48 1WE1-1152 627E 6EB1-620, 622-626 1TE1-832 6GB1-742, 745 1TE1-832 631E 1AB1-1160, 1162 3TE1-870 1NB1-675 3TE1-870 3ND1-318 3TE1-870 637E 1FB1-374 3TE1-870 1JB1-724 3TE1-870 651E 89Z1-213 4VA1-767 657E 90Z1-193, 195, 196 4VA1-767 2ME1-473 91Z1-362, 364-367 4VA1-767 4YA1-546 768C 02X350-360 8KA1-2391 772B 64W168-177 8AA1-2020 776B 6JC1-76 2PE1-1600 769C 01X2877-4877, 4879- 8KA1-2391 4883, 4885, 4887, 4888 773B 63W1-2770, 2773- 8AA1-2020 2775, 2780-2782 5SC1-66 8AA1-2020 777B 4YC1-1084, 1086, 2PE1-1600 1089, 1090, 1096, 1097 3NF1-34 2PE1-1600 785 8GB1-376 2BE1-720 789 9ZC1-289 2BE1-720
Parts Needed
1 - 7S5757 Clip (Replaces 8S7803) 1 - 6Y9849 Coupling Assembly (657E Trans-Scraper End Only) 1 - 6Y9850 Coupling Assembly (All Except 657E Trans-Scraper) 1 - 9W1409 Control Group (If Needed, See Action Required)
Action Required
If the Affected Product is experiencing erratic shift, skip shift, or no shift situations, the existing coupling assembly (shaft) and control group (switch) may be replaced with a new control group and coupling assembly as shown in the chart. If the new 9W1409 Control Group is already installed, install only the new 6Y9849 or 6Y9850 Coupling Assembly. ICM TRANSMISSION SHAFT Model Coupling Assembly Control Group Shaft (Switch) 657E Scraper 6Y9849 9W1409 (86Z1-293) (If Required) (87Z1-188 (6MB1-105) (Rear Transmission) All Other 6Y9850 9W1409 Affected (If Required) Product
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first 0-4000 100% 1 0 0 0 0 0-24 mo 4001-6000 33 1/3% 0 0 0 50% 1 25-36 mo NOTE: This is a 1-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Caterpillar Information System:
Product Support Program For Repeat Track Joint Failures (Leaks) On D11N Tractors Product Support Program For Repeat Track Joint Failures (Leaks) On D11N Tractors
PSP FOR INSTALLING A NEW DRIVE SHAFT SLIP JOINT GROUP, SPIDER, AND SHAFT ASSEMBLIES IN CERTAIN 518 SKIDDERS AND 518 GRAPPLE SKI DDERS - PS4372 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR INSTALLING A NEW DRIVE SHAFT SLIP JOINT GROUP, SPIDER, AND SHAFT ASSEMBLIES IN CERTAIN 518 SKIDDERS AND 518 GRAPPLE SKI DDERS - PS4372 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA,
PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA
PSP FOR REINFORCING THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4389 - MAILED US AND CANADA, COFA, BRAZIL, CFE L, COSA, LIMITED CACO PSP FOR REINFORCING THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4389 - MAILED US AND CANADA, COFA, BRAZIL, CFE L, COSA, LIMITED CACO
PSP FOR REINFORCING THE FUEL TANK ON CERTAIN 623E SCRAPERS - PS4387 - MAILED US AND CANADA, COFA, COSA, LIMITED CACO PSP FOR REINFORCING THE FUEL TANK ON CERTAIN 623E SCRAPERS - PS4387 - MAILED US AND CANADA, COFA, COSA, LIMITED CACO
PSP FOR WINCH CLUTCH LOCK-UP ON CERTAIN D6H TRACTORS USED IN LOGGING AND PIPELINE APPLICATIONS - PS4363 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA PSP FOR WINCH CLUTCH LOCK-UP ON CERTAIN D6H TRACTORS USED IN LOGGING AND PIPELINE APPLICATIONS - PS4363 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA
PSP FOR UPDATING THE DROPBOX ON CERTAIN 657E SCRAPERS - PS4384 - MAILED US, CANADA, CACO, COFA, COSA PSP FOR UPDATING THE DROPBOX ON CERTAIN 657E SCRAPERS - PS4384 - MAILED US, CANADA, CACO, COFA, COSA
PSP FOR REPAIRING CRACKS IN THE REAR OF THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4377 MAILED US, CANADA, CACO, BR AZIL, CFEL, COSA PSP FOR REPAIRING CRACKS IN THE REAR OF THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4377 MAILED US, CANADA, CACO, BR AZIL, CFEL, COSA
SERVICE LETTER SUPPLEMENT - THE ABOVE MAIL CODE, U-175, WAS NOT PREVIOUSLY USED IN 1989 SERVICE LETTER SUPPLEMENT - THE ABOVE MAIL CODE, U-175, WAS NOT PREVIOUSLY USED IN 1989
PSP FOR INSTALLING NEW ALTERNATOR BELTS, PULLEYS AND GUARDS ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B,785, 789 TRUCKS; 350 8, 3512, 3516 ENGINES (SPARE) - MAILED CACO, COFA, BRAZIL, COSA, LIMITED CFEL PSP FOR INSTALLING NEW ALTERNATOR BELTS, PULLEYS AND GUARDS ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B,785, 789 TRUCKS; 350 8, 3512, 3516 ENGINES (SPARE) - MAILED CACO, COFA, BRAZIL, COSA, LIMITED CFEL
PSP FOR INSTALLING NEW ALTERNATOR BELTS, PULLEYS AND GUARD ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B,785, 789 TRUCKS; 350 8, 3512, 3516 ENGINES (SPARE) - PS4344 - MAILED US AND CANADA PSP FOR INSTALLING NEW ALTERNATOR BELTS, PULLEYS AND GUARD ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B,785, 789 TRUCKS; 350 8, 3512, 3516 ENGINES (SPARE) - PS4344 - MAILED US AND CANADA
PSP FOR REPLACING THE REAR GEAR TRAIN ON CERTAIN D11N TRACTORS AND 3508 ENGINES (SPARE) - PS0410 - MAILED US AND CANADA, COFA COS A, LIMITED CACO - SEE SUPPLEMENT SEBE4196 DATED JANUARY 6, 1990 PSP FOR REPLACING THE REAR GEAR TRAIN ON CERTAIN D11N TRACTORS AND 3508 ENGINES (SPARE) - PS0410 - MAILED US AND CANADA, COFA COS A, LIMITED CACO - SEE SUPPLEMENT SEBE4196 DATED JANUARY 6, 1990
PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H, D5H, AND D6H TRACTORS - PS0395 - MAILED CACO PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H, D5H, AND D6H TRACTORS - PS0395 - MAILED CACO
PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H LGP, D5H LGP, AND D6H LGP TRACTORS - PS0394 - MAILED CACO PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H LGP, D5H LGP, AND D6H LGP TRACTORS - PS0394 - MAILED CACO
PRIORITY - THE LEFT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3436 - MAILED US, CAN ADA PRIORITY - THE LEFT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3436 - MAILED US, CAN ADA
PSP FOR INSTALLING A NEW CAMSHAFT AND LIFTERS IN CERTAIN D11N TRACTORS; 776B TRACTORS; AND 777B, 785 AND 789 TRUCKS - PS0423 - M AILED US AND CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL - NOTE:THIS PROGRAM CANCELED AND REPLACED BY JULY 31, 1990 SL PSP FOR INSTALLING A NEW CAMSHAFT AND LIFTERS IN CERTAIN D11N TRACTORS; 776B TRACTORS; AND 777B, 785 AND 789 TRUCKS - PS0423 - M AILED US AND CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL - NOTE:THIS PROGRAM CANCELED AND REPLACED BY JULY 31, 1990 SL
PRIORITY - NEW FIRE SUPPRESSION CONTROL NEEDS TO BE INSTALLED ON CERTAIN D8N, D9N, D10N, AND D11N TRACTORS; AND 992C LOADERS - P I3435 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA PRIORITY - NEW FIRE SUPPRESSION CONTROL NEEDS TO BE INSTALLED ON CERTAIN D8N, D9N, D10N, AND D11N TRACTORS; AND 992C LOADERS - P I3435 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA
PSP FOR INCREASING THE WELD ON THE TRANSMISSION TUBE ASSEMBLIES (SLIDE TRACKS), AND INSTALLING BEVEL GEAR, BEVEL GEA R SHAFT BEARING, AND RETAINING BOLTS ON CERTAIN D10N TRACTORS - PS4390 - MAILED US AND CANADA, CACO, CFEL, COSA PSP FOR INCREASING THE WELD ON THE TRANSMISSION TUBE ASSEMBLIES (SLIDE TRACKS), AND INSTALLING BEVEL GEAR, BEVEL GEA R SHAFT BEARING, AND RETAINING BOLTS ON CERTAIN D10N TRACTORS - PS4390 - MAILED US AND CANADA, CACO, CFEL, COSA
PSP FOR INSTALLING THERMOCOUPLES TO MONITOR EXHAUST GAS TEMPERATURES ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785 , AND 789 TRUCKS - PS4399 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR INSTALLING THERMOCOUPLES TO MONITOR EXHAUST GAS TEMPERATURES ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785 , AND 789 TRUCKS - PS4399 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PRIORITY - THE RIGHT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3445 - MAILED US AND CAN ADA PRIORITY - THE RIGHT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3445 - MAILED US AND CAN ADA
PARTS STOCK ACTION ONLY:9J0942 PIN ASSEMBLIES IN PARTS STOCK NEED TO BE CHECKED FOR CORRECT LENGTH - PI7227 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY:9J0942 PIN ASSEMBLIES IN PARTS STOCK NEED TO BE CHECKED FOR CORRECT LENGTH - PI7227 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, COSA
Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders
PSP FOR INSTALLING NEW BUCKET TIP ADAPTER ON CERTAIN 235B/C EXCAVATORS AND 988B LOADERS - PS0406 - MAILED US AND CANADA, CFE L, COSA, LIMITED CACO PSP FOR INSTALLING NEW BUCKET TIP ADAPTER ON CERTAIN 235B/C EXCAVATORS AND 988B LOADERS - PS0406 - MAILED US AND CANADA, CFE L, COSA, LIMITED CACO