PRODUCT SUPPORT PROGRAM FOR REPLACING THE 1ST PLANETARY REACTION HUB ON CERTAIN 789D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 1ST PLANETARY REACTION HUB ON CERTAIN 789D OFF-HIGHWAY TRUCKS

Usage:

TEBE4363-00

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28Mar2016

H160

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 1ST PLANETARY REACTION HUB ON CERTAIN 789D OFF-HIGHWAY TRUCKS
4050 4084		PS90572

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90572" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "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.

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TERMINATION DATE

31Mar2017

PROBLEM

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The 344-5163 Final Drive Groups on certain 789D Off-Highway Trucks can generate elevated iron and copper in the SOS analysis. The elevated iron and copper is a result of premature wear of the 1066531/">106-6531 Reaction Hub and the 8W-3215 1st Reduction Carrier.

AFFECTED PRODUCT

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Model	Identification Number
789D	SPD00276, 297-298, 308, 312, 435, 446, 448, 475, 477, 500-501, 531-533, 539, 552, 629-630, 632, 636, 693-695

PARTS NEEDED

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Qty	Part Number	Description
15	2H3856	BOLT (After Failure Only)
1	6D1355	SEAL-O-RING (After Failure Only)
1	6G6523	WASHER-THRUST (After Failure Only)
8	6H1717	BOLT (After Failure Only)
1	6V6557	SEAL-O RING (After Failure Only)
4	7I5540	SHAFT (After Failure Only)
2	8B1312	DOWEL (After Failure Only)
4	8W3088	PLATE (After Failure Only)
1	8W3215	CARRIER AS-INNER (After Failure Only)
4	8W6910	SHIM-PACK (After Failure Only)
1	8X8439	SHIM-PACK (After Failure Only)
1	1066531	HUB (After Failure Only)
4	1171005	GEAR-PLANET (After Failure Only)
4	1743040	BEARING AS. (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Remove hub cap to inspect each final drive. If metal debris in the form of chips, flakes and fine debris is noted on the magnetic plug in the final drive group, the 8W-3215 Carrier should be replaced. The magnetic plug in the final drive must include visible iron particles. Consideration for elevated iron/copper in SOS samples is also allowed.

Removal of final drives will be allowed if it is deemed a shop repair is required and allowed to be claimed. Reference the allowance table for hours allowed for removal of the final and labor hours allowed.

Repeat failures will be allowed to be claimed.

If the spline teeth between the hub and carrier displays wear to the point where material is beginning to "roll" on the edge (metal deformation), and there is a visible gap on the back side of the tooth, then the carrier will be replaced.

Hub replacement is determined via inspection with the same criteria as the carrier, at the time of carrier replacement and will be claimable as needed.

Reference UENR1065 for the "Disassembly and Assembly: 789D and 789D XQ Highway Trucks Power Train" for this work.

The dealer will responsible for ensuring proper operating procedures are being applied, including but not limited to payload management, and maintaining a 2nd gear lock while loaded to reduce the amount of peak-torque shifts during loaded, uphill transport.

NOTES
Replace 1066531 (hub), 1171005 (planet gears) based on further inspection if initial inspection determines carrier should be replaced.

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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%
0-11000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
11001-12000 hrs, 37-40 mo	93.0%	100.0%	0.0%	0.0%	5.0%	0.0%
12001-13000 hrs, 41-44 mo	87.0%	50.0%	0.0%	0.0%	10.0%	50.0%
13001-14000 hrs, 45-48 mo	73.0%	25.0%	0.0%	0.0%	20.0%	75.0%
14001-16000 hrs, 49-56 mo	33.0%	0.0%	0.0%	0.0%	50.0%	100.0%

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NOTE: This is a 4.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Removal of Hub cap to inspect is a 2-hrs job per side or 4-hour job per truck. 0-10K Hours carrier only in the field is a 5 hour job per side. 0-10K Hours carrier and hub in the field is a 24 hour job per side. It is up to repairing dealer discretion as to when the 106-5631 hub should be replaced beyond 10K hours. Repairs beyond 10,000 should be considered for an out of chassis repair and customer participating betterment. If finals are removed from chassis for shop repair, 24 hours will be allowed for R&I per side. 40 hours will be allowed for shop labor per final drive.