PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING SPINDLE HOUSINGS ON CERTAIN 12M, 120M, 140M, AND 160M MOTOR GRADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING SPINDLE HOUSINGS ON CERTAIN 12M, 120M, 140M, AND 160M MOTOR GRADERS

Usage:

REBE6347-03

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11Aug2010

(Revised 11Apr2011)

U-316

A-245

D-270

O-274

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING SPINDLE HOUSINGS ON CERTAIN 12M, 120M, 140M, AND 160M MOTOR GRADERS
4234 5225 4313 4305		PI10815

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10815" 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 "PI10815" 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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NOTE:	This Revised Service Letter replaces the 11Aug2010 (Revised 15Oct2010) Service Letter. Changes have been made to the Problem, Parts Needed, Action Required, and Service Claim Allowances.

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PROBLEM

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The 266-9731 and 266-9732 Spindle Housings, under certain conditions, may develop a crack and fracture near the tie rod ball stud on certain 12M, 120M, 140M and 160M Motor Graders. This may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. These spindle housings need to be inspected and repaired or replaced depending upon the results of the inspection.

AFFECTED PRODUCT

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Model	Identification Number
120M	B9C00130-00143, 145-182, 184-590, 592-655 B9N00140, 143, 147-334
12M	B9F00012-00553, 555-727, 729-730, 733-736, 738-742, 745-753, 756-771, 773-776, 778-781, 783-798, 800, 802-806, 809-829, 836-869, 872-876, 881 B9R00024-00025, 27-45, 47-82, 84-159, 164-165, 168
140M	B9D00125-00128, 130-135, 137-157, 159-380, 382-472, 474-558, 561-701, 703-735, 737-740, 742-762, 764-765, 767-923, 925-932, 934-944, 946-953, 955-994, 996-1017, 1019-1033, 1036-1039, 1041-1055, 1058-1095, 1097-1098, 1100-1114, 1116-1119, 1121-1122, 1124-1126, 1128-1173, 1175-1178, 1180-1183, 1185-1190, 1192-1194, 1196-1219, 1221-1223, 1225-1227, 1229-1235, 1237-1243, 1245-1247, 1249-1264, 1266-1285, 1287-1289, 1291-1296, 1299-1313, 1315-1357, 1359-1361, 1363-1369, 1372-1375, 1377-1380, 1382-1385, 1387-1389, 1391-1394, 1396-1398, 1400-1402, 1404-1411, 1413-1461, 1463-1705, 1707-1897, 1899-1910, 1912-1915, 1917-1919, 1921-1944, 1946-1950, 1952-2268, 2270-2279, 2284-2286, 2288-2295, 2297-2364, 2366-2371, 2373-2378, 2380-2460, 2462-2464, 2466-2468, 2470-2476, 2478-2480, 2482-2488, 2490-2507, 2510, 2513-2514, 2518, 2520-2524, 2527, 2529-2562, 2564-2583, 2586-2587, 2589-2593, 2595-2597, 2599, 2602, 2604-2605, 2607-2663, 2666, 2668, 2671-2691, 2693-2726 B9M00144-00159, 161-169, 173-175, 186-187, 190, 207, 216, 220, 223, 226-227, 230, 233, 236-238, 240, 243-244, 250, 253-254, 257-259, 261-262, 265, 268-269, 271, 273-274, 276-278, 281-282, 285-289, 292-301, 320, 343, 353, 355-360, 365, 367-369, 371-373, 375, 377, 379, 381, 383-391, 393-395, 398-399, 402-405, 407-410, 413-418, 420, 422-427, 430-433, 435, 437, 439, 442-445, 447, 449-452, 454-456, 458, 469-470, 472-473, 475-478, 484-485, 487, 489-490, 492, 494-497, 499-500, 502-503, 505-508, 510, 512-513, 515, 517-520, 522-524, 527-528, 530, 532, 534-535, 537, 540-542, 544, 546-547, 549-637, 639-813, 815-973, 975-982
160M	B9E00118-00193, 196-204, 206, 208-215, 218-226, 228-233, 235-238, 240, 242-243, 245-254, 256-395, 397-457 B9L00166-00186, 188, 190, 197, 202, 206-207, 209, 211, 216-218, 223-225, 228-237, 239, 241-242, 244-254, 264-269, 273, 278, 281, 284, 288-296, 298-325, 327, 329-335, 337, 339-347, 351, 353, 356-360, 363-365, 367-370, 372-376, 378-390, 392-491

PARTS NEEDED

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Qty	Part Number	Description
6	2G3865	SHIM (After Failure Only)
4	2G8615	WASHER-THRUST (After Failure Only)
2	2G8626	WASHER-THRUST (After Failure Only)
4	2G8777	SEAL (After Failure Only)
2	2J8163	SEAL-O RING (After Failure Only)
2	3B4618	COTTER (AS REQUIRED)
2	5K5288	SEAL GP-DUO CONE (After Failure Only)
2	7D8636	CONE-BEARING (After Failure Only)
2	7D8637	CUP-BEARING (After Failure Only)
2	7D8643	RETAINER (After Failure Only)
2	0300060	CUP-ROLLER BRG (After Failure Only)
2	0300061	CONE-ROLLER BRG (After Failure Only)
2	2770648	SEAL-BOOT (AS REQUIRED)
2	3142606	SEAL-BOOT (AS REQUIRED)
2	3657662	PLATE
2	3657663	PLATE
1	3659252	HOUSING-SPINDLE (After Failure Only)
1	3659253	HOUSING-SPINDLE (After Failure Only)
1	BULK(OIL)	TDTO 30WT OIL - 0.5 LITERS (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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NOTE: The 3657662 and 3657663 Plates are the only parts needed for before failure repairs.

Refer to the Service Manual as necessary and see Special Instruction REHS4269 "Rework Procedure for the Spindle Housing for Certain M Series Motor Graders".

The special instruction is divided into four sections. The "Machine Preparation," "Inspection Procedure," and "Plate Installation Procedure" sections must be performed on all machines. The "Repair Procedure" section will only be performed on machines that have a cracked spindle housing.

All inspections and repairs should be considered before failure unless the crack is visible at the maximum depth of 10 mm (0.39 inch), and the crack is within 15 mm (0.60 inch) of the top of the casting. (See Step 3 of the "Repair Procedure" in the special instruction.) If replacement of one of the spindle housings is required per Step 3 the repair should be considered after failure. It is important to make sure the claim is coded correctly.

As of the date of this revision after failure replacement of the spindle housing should be claimed as part of this service letter. If a spindle housing replacement is required, order and install the parts identified as "After Failure Only". In the claim text, specify "spindle housing replacement required." The after failure parts should be installed as soon as possible even if the machine is temporarily returned to service after making all weld repairs.

NOTE: Machines that were previously repaired and returned to service, where the repair was coded after failure, will have the spindle housing replaced as part of a new service letter. The new service letter will be released as soon as the parts and the affected product list are available. Make sure claims for machines already returned to service are filed as soon as possible to facilitate release of the new service letter.

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OWNER NOTIFICATION

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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%	100%	0%	0%	0%	0%

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NOTE: This is a 6.0-hour job
The 6 hours of labor covers inspecting and welding the plates to both spindle housings as specified in the Special Instructions. If fabricating plates per Special Instructions, a maximum of $275 US dollars will be allowed for labor and materials. Do not claim the 365-7662 or 365-7663 if the plates are dealer fabricated. When required, a maximum of 2 additional hours per machine will be allowed for weld repair of spindle housing cracks. When required, a maximum of 10 additional hours per side will be allowed for replacing the spindle housing.

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PARTS DISPOSITION

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

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

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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 INSPECTING AND REWORKING SPINDLE HOUSINGS ON CERTAIN 12M, 120M, 140M, AND 160M MOTOR GRADERS

MODELS INVOLVED - 12M, 120M, 140M, AND 160M MOTOR GRADERS

Dear Caterpillar Product Owner:

The 266-9731 and 266-9732 Spindle Housings need to be reworked on the products listed below. The existing spindle housing tie rod support arm can crack and fracture. Failure of the spindle housing tie rod support arm may cause a loss of steering and may, in conjunction with other factors or circumstances, result in a risk of 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 11Aug2010 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 11Aug2010 Service Letter