Usage:
NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5542" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
November 30, 2000Problem
In some extreme applications the standard circle drive pinion shaft may fail on certain 12H, 120H, 135H, 140H, 143H, 160H, and 163H Motor Graders.
Affected Product
Model & Identification Number
12H (4XM420-422, 4XM424-425, 4XM427-462, 4XM464-484, 4XM486, 4XM488, 4XM490, 4XM494, 4XM496, 4XM499-505, 4XM508-518, 4XM520-530, 4XM532-536, 4XM538, 4XM540-596, 4XM598, 4XM600-605, 4XM607-617, 4XM619-636, 4XM638, 4XM640-647, 4XM649-677, 4XM681-683, 4XM685-724, 4XM727-772, 4XM774, 4XM776, 4XM778-780, 4XM782, 4XM784, 4XM790-792, 4XM794-808, 4XM818-834, 4XM836-844, 4XM846-848, 4XM850-863, 4XM865-882, 4XM884-885, 4XM889-892, 4XM894-931, 4XM934-942, 4XM944-945, 4XM947, 4XM949-950, 4XM952-953, 4XM956-957, 4XM959, 4XM961-964, 4XM966-967, 4XM969-970, 4XM973-975, 4XM977-980, 4XM982-984, 4XM986, 4XM988, 4XM990-991, 4XM993-1013, 4XM1015-1018, 4XM1020-1021, 4XM1023-1038, 4XM1041-1058, 4XM1148-1149, 4XM1151-1155, 4XM1157-1159, 4XM1162-1164, 4XM1167, 4XM1170-1172, 4XM1174-1175, 4XM1177, 4XM1180, 4XM1185-1186, 4XM1191, 4XM1193, 4XM1196-1197, 4XM1200, 4XM1202, 4XM1206-1207, 4XM1209, 4XM1210-1211, 4XM1213-1214, 4XM1216-1217, 4XM1219-1224, 4XM1226-1228, 4XM1230-1246, 4XM1248-1255, 4XM1257-1278, 4XM1280-1284, 4XM1286-1287, 4XM1289-1298, 4XM1300-1308, 4XM1310-1318, 4XM1320-1321, 4XM1323, 4XM1325-1358, 4XM1360-1386 8MN420-451 , 8MN460-469, 2LR270-294 , 4ER289 , 4ER291-299, 4ER305-306, 4ER323-345, 4ER347-368, 4ER400-414, 4ER416-431, 2GS270-271 , 2GS274-277, 2GS280-281, 2GS286, 2GS301-309, 2GS313-316, 2GS318)
120H (4MK41, 4MK43-47, 4MK49, 4MK52, 4MK56-57, 4MK59-78, 4MK80-89, 4MK91-102, 4MK104-108, 4MK113, 4MK116, 4MK118, 4MK120-123, 4MK125, 4MK127-131, 4MK134-150, 4MK152-159, 4MK162-164, 4MK166-167, 4MK171-176, 4MK180-189, 4MK191-214, 4MK218-219, 4MK223, 4MK226-231, 4MK287-294, 4MK296-297, 4MK299-300, 4MK302-304, 4MK307-312, 4MK314-317, 4MK319-320, 4MK322-331, 4MK333-347, 4MK351-352 5FM338-352 , 5FM354-359, 5FM361-374, 5FM376, 5FM378-385, 5FM387-410, 5FM412-432, 5FM436-446, 5FM448-459, 5FM463-464, 5FM466-473, 5FM475-479, 5FM481-483, 5FM486-487, 5FM489-493, 5FM495-505, 5FM507-510, 5FM550-598, 5FM600-624, 6NM238-242 , 6NM244-254 6TM338 , 6TM340-345, 6TM356-359 9YR239-242 , 9YR244, 9YR246-249, 9YR251, 9YR274-278, 9YR280, 9YR283, 9YR286-287)
135H (3YK36-38, 3YK40-45, 3YK47-48, 3YK50-73, 3YK75-76, 3YK80-82, 3YK84-92, 3YK94-103, 3YK105-107, 3YK110-113, 3YK115-121, 3YK123-126, 3YK128-131, 3YK134-135, 3YK138-161, 3YK164, 3YK166, 3YK204-213, 3YK215-217, 3YK221-225 8WN230-232 , 8WN236-239, 8WN241-243, 8WN245, 8WN247, 8WN249, 8WN251-253, 8WN255-259, 8WN261-270, 8WN272-278, 8WN291, 8WN293, 8WN296, 8WN296, 8WN299-318)
140H (2ZK63-64, 2ZK66, 2ZK68, 2ZK71-72, 2ZK77, 2ZK79, 2ZK81, 2ZK83, 2ZK85, 2ZK89-91, 2ZK94-95, 2ZK97, 2ZK101-102, 2ZK105-107, 2ZK109-113, 2ZK116-118, 2ZK122-123, 2ZK125, 2ZK130, 2ZK132-134, 2ZK136, 2ZK138, 2ZK141-144, 2ZK147-149, 2ZK151-152, 2ZK155, 2ZK158, 2ZK160, 2ZK162-164, 2ZK166-168, 2ZK170-171, 2ZK174, 2ZK176-177, 2ZK179-180, 2ZK182-183, 2ZK190, 2ZK194, 2ZK196-198, 2ZK203, 2ZK205, 2ZK207-208, 2ZK210, 2ZK213, 2ZK215-216, 2ZK219-221, 2ZK223-224, 2ZK226-229, 2ZK231-234, 2ZK236-237, 2ZK239-241, 2ZK243-247, 2ZK249, 2ZK251, 2ZK254-255, 2ZK257-258, 2ZK260-262, 2ZK265-267, 2ZK270, 2ZK274-277, 2ZK279-281, 2ZK283-284, 2ZK291-293, 2ZK295-300, 2ZK303-306, 2ZK309-310, 2ZK313-316, 2ZK318-319, 2ZK324-325, 2ZK328-329, 2ZK333, 2ZK336-338, 2ZK340-349, 2ZK351, 2ZK354-355, 2ZK357-359, 2ZK361-362, 2ZK364-366, 2ZK369, 2ZK372-373, 2ZK375, 2ZK377, 2ZK380-385, 2ZK392, 2ZK397, 2ZK403-404, 2ZK407-413, 2ZK415-417, 2ZK419, 2ZK423, 2ZK428, 2ZK432-433, 2ZK436, 2ZK441, 2ZK445, 2ZK449-450, 2ZK454, 2ZK457, 2ZK459, 2ZK460-461, 2ZK464, 2ZK468-475, 2ZK477, 2ZK479-480, 2ZK482-485, 2ZK487, 2ZK489, 2ZK491, 2ZK494-495, 2ZK499, 2ZK501-502, 2ZK507-510, 2ZK512-515, 2ZK517, 2ZK517, 2ZK519-521, 2ZK526, 2ZK530, 2ZK533, 2ZK536-537, 2ZK539, 2ZK544-547, 2ZK553-554, 2ZK556-559, 2ZK561-563, 2ZK565-566, 2ZK568-569, 2ZK572-575, 2ZK577-578, 2ZK580-588, 2ZK591, 2ZK595, 2ZK598-599, 2ZK602, 2ZK607, 2ZK612-617, 2ZK621, 2ZK623, 2ZK627, 2ZK630, 2ZK633, 2ZK635, 2ZK638-642, 2ZK644, 2ZK649, 2ZK653-657, 2ZK660-662, 2ZK664, 2ZK666-669, 2ZK671-674, 2ZK676-677, 2ZK679, 2ZK682-685, 2ZK687, 2ZK689, 2ZK692, 2ZK697, 2ZK700, 2ZK703, 2ZK707, 2ZK709-712, 2ZK714-716, 2ZK721-722, 2ZK725-726, 2ZK730-731, 2ZK733, 2ZK737-739, 2ZK744, 2ZK747, 2ZK749, 2ZK751-752, 2ZK755-756, 2ZK762, 2ZK764, 2ZK766-767, 2ZK772, 2ZK775, 2ZK782, 2ZK784-785, 2ZK790-791, 2ZK793-794, 2ZK798-800, 2ZK802-805, 2ZK807-808, 2ZK810-812, 2ZK816, 2ZK822-823, 2ZK827, 2ZK829-830, 2ZK836, 2ZK839-841, 2ZK843, 2ZK847-848, 2ZK856, 2ZK860, 2ZK862, 2ZK866-869, 2ZK872-874, 2ZK877-878, 2ZK880-884, 2ZK887, 2ZK890-891, 2ZK893, 2ZK895, 2ZK897-899, 2ZK901, 2ZK903-904, 2ZK906-907, 2ZK914, 2ZK919, 2ZK921, 2ZK927, 2ZK929-930, 2ZK932, 2ZK935-936, 2ZK948-949, 2ZK951-962, 2ZK965-968, 2ZK970-978, 2ZK980-981, 2ZK983-986, 2ZK990, 2ZK997, 2ZK1001, 2ZK1004-1005, 2ZK1007-1009, 2ZK1012, 2ZK1014, 2ZK1016-1028, 2ZK1037-1040, 2ZK1042, 2ZK1045, 2ZK1046, 2ZK1048-1049, 2ZK1054, 2ZK1058, 2ZK1065-1066, 2ZK1075, 2ZK1078, 2ZK1087, 2ZK1092-1095, 2ZK1098, 2ZK1109, 2ZK1114, 2ZK1116, 2ZK1119, 2ZK1125-1126, 2ZK1129, 2ZK1133-1135, 2ZK1138-1139, 2ZK1141, 2ZK1143-1144, 2ZK1147-1148, 2ZK1152-1157, 2ZK1162, 2ZK1162, 2ZK1165-1166, 2ZK1173-1175, 2ZK1182-1183, 2ZK1187, 2ZK1189, 2ZK1191, 2ZK1193-1194, 2ZK1196-1199, 2ZK1201-1217, 2ZK1220-1227, 2ZK1230-1234, 2ZK1236-1237, 2ZK1240, 2ZK1243, 2ZK1246-1254, 2ZK1260, 2ZK1262-1266, 2ZK1269-1273, 2ZK1277-1283, 2ZK1285-1287, 2ZK1289-1293, 2ZK1295-1300, 2ZK1304, 2ZK1308, 2ZK1312, 2ZK1314, 2ZK1318-1319, 2ZK1321-1322, 2ZK1324, 2ZK1328, 2ZK1330-1331, 2ZK1333-1335, 2ZK1339, 2ZK1341-1343, 2ZK1346, 2ZK1353, 2ZK1357, 2ZK1362, 2ZK1364, 2ZK1368, 2ZK1370-1372, 2ZK1376-1380, 2ZK1382-1383, 2ZK1385, 2ZK1387, 2ZK1393-1394, 2ZK1396, 2ZK1398, 2ZK1400-1402, 2ZK1404, 2ZK1410, 2ZK1412-1414, 2ZK1416, 2ZK1418, 2ZK1422, 2ZK1425-1426, 2ZK1429-1431, 2ZK1433-1436, 2ZK1440-1442, 2ZK1447-1448, 2ZK1450, 2ZK1453-1454, 2ZK1456-1459, 2ZK1461, 2ZK1466, 2ZK1470, 2ZK1472, 2ZK1476, 2ZK1479, 2ZK1481, 2ZK1484, 2ZK1486, 2ZK1488-1491, 2ZK1494-1501, 2ZK1503-1505, 2ZK1717, 2ZK1720, 2ZK1722-1724, 2ZK1726-1728, 2ZK1732, 2ZK1734-1736, 2ZK1741-1742, 2ZK1745-1748, 2ZK1750-1752, 2ZK1754-1755, 2ZK1757, 2ZK1760, 2ZK1763-1764, 2ZK1766, 2ZK1768-1769, 2ZK1771, 2ZK1773-1774, 2ZK1777-1778, 2ZK1780-1781, 2ZK1784-1786, 2ZK1788-1789, 2ZK1791-1792, 2ZK1796-1798, 2ZK1800-1805, 2ZK1807-1810, 2ZK1813, 2ZK1818, 2ZK1820-1821, 2ZK1823, 2ZK1825-1827, 2ZK1829, 2ZK1833-1834, 2ZK1836, 2ZK1840, 2ZK1844-1845, 2ZK1848-1854, 2ZK1856, 2ZK1858, 2ZK1860-1861, 2ZK1863, 2ZK1868-1873, 2ZK1875-1876, 2ZK1878-1880, 2ZK1882-1884, 2ZK1886-1888, 2ZK1890-1892, 2ZK1894-1897, 2ZK1899-1900, 2ZK1902, 2ZK1905-1906, 2ZK1908-1910, 2ZK1912-1913, 2ZK1915-1916, 2ZK1918-1919, 2ZK1921-1922, 2ZK1924-1926, 2ZK1931, 2ZK1934, 2ZK1936-1937, 2ZK1940-1941, 2ZK1943-1944, 2ZK1947-1950, 2ZK1952-1953, 2ZK1957, 2ZK1960-1961, 2ZK1963-1966, 2ZK1968-1972, 2ZK1974-1975, 2ZK1977, 2ZK1979, 2ZK1982, 2ZK1984, 2ZK1987-1988, 2ZK1990-1991, 2ZK1993-1994, 2ZK1998, 2ZK2000, 2ZK2003-2007, 2ZK2011, 2ZK2013-2015, 2ZK2017, 2ZK2023-2026, 2ZK2029-2030, 2ZK2032-2033, 2ZK2035-2038, 2ZK2040-2042, 2ZK2045, 2ZK2048-2054, 2ZK2056, 2ZK2060, 2ZK2062, 2ZK2067-2069, 2ZK2071, 2ZK2075-2077, 2ZK2081-2083, 2ZK2085, 2ZK2087-2088, 2ZK2092-2093, 2ZK2095-2096, 2ZK2100-2103, 2ZK2109, 2ZK2111, 2ZK2113-2116, 2ZK2120-2125, 2ZK2127-2129, 2ZK2131-2133, 2ZK2135, 2ZK2137, 2ZK2140, 2ZK2143 5HM258-294 , 5HM296-680, 5HM683, 5HM685-735, 5HM739-741, 5HM748, 5HM751, 5HM753-758, 5HM761-770, 5HM800-803, 5HM805-823, 5HM825, 5HM827-899, 5HM906-912, 5HM914-915, 5HM917-922, 5HM926-939, 5HM942-954, 5HM956, 5HM958, 5HM960-965, 5HM967-1012, 5HM1014-1016 8JM258-260 8KM361-363 , 8KM367-373, 8KM375-380, 8KM383-384, 8KM386, 8KM388-392 9TN58-94 , 9TN96-98, 9TN120-124, 9TN129-134, 9TN138, 9TN143, 9TN152-155, 9TN158, 9TN161-164, 9TN172-173, 9TN176, 9TN182-186, 9TN190-193, 9TN202-203, 9TN207-209, 9TN212-222, 9TN233-234, 9TN236-244 3AS358-359 , 3AS364-365, 3AS367, 3AS369-372, 3AS374-376, 3AS383-386, 3AS388-391)
143H (1AL28, 1AL30, 1AL35, 1AL37-40, 1AL45-47, 1AL52, 1AL54, 1AL56-57, 1AL68, 1AL72-73, 1AL76, 1AL84-85, 1AL88, 1AL90, 1AL92-93, 1AL97-99, 1AL101-102, 1AL113-116, 1AL128, 1AL138, 1AL140-141, 1AL143, 1AL146, 1AL148-150, 1AL154, 1AL156, 1AL160-161, 1AL163, 1AL166, 1AL168, 1AL171-173, 1AL176, 1AL179, 1AL183, 1AL185, 1AL187, 1AL194, 1AL196-198, 1AL202-203, 1AL205, 1AL212-214, 1AL216, 1AL219, 1AL223, 1AL230-233, 1AL235, 1AL256, 1AL302, 1AL306-307, 1AL310-314, 1AL316-317, 1AL321, 1AL323, 1AL326, 1AL328, 1AL336)
160H (9EJ38-46, 9EJ48, 9EJ49-50, 9EJ50, 9EJ52-53, 9EJ55-61, 9EJ66, 9EJ68, 9EJ74, 9EJ77-78, 9EJ81, 9EJ87, 9EJ90, 9EJ92-95, 9EJ102, 9EJ108-109, 9EJ133-135, 9EJ141, 9EJ153, 9EJ165-167, 9EJ171, 9EJ180, 9EJ183, 9EJ187, 9EJ190, 9EJ193-194, 9EJ199, 9EJ203, 9EJ206, 9EJ208-210, 9EJ218-220, 9EJ222-223, 9EJ241, 9EJ255-256, 9EJ258, 9EJ260, 9EJ263, 9EJ265, 9EJ269-274, 9EJ277, 9EJ280-283, 9EJ285-286, 9EJ288, 9EJ293-294, 9EJ308, 9EJ310, 9EJ318, 9EJ321, 9EJ332-334, 9EJ336, 9EJ338, 9EJ341, 9EJ344-345, 9EJ347-349, 9EJ362-363, 9EJ368-371, 9EJ376, 9EJ378-379, 9EJ420-422, 9EJ425-426, 9EJ428, 9EJ431, 9EJ433, 9EJ435, 9EJ437, 9EJ439, 9EJ441, 9EJ444, 9EJ447, 9EJ451, 9EJ455, 9EJ462-463 2FM331-332 , 2FM336, 2FM338-341, 2FM343 3GM31-36 6WM331 , 6WM333-340 2HS331-333 , 2HS337)
163H (5AK25, 5AK34, 5AK36, 5AK38-41, 5AK51, 5AK57, 5AK67, 5AK69-70, 5AK79, 5AK82-83, 5AK85-86, 5AK91, 5AK94, 5AK99, 5AK104, 5AK120, 5AK123-124, 5AK126, 5AK128, 5AK132-134)
Parts Needed
- 2 - 1B4038 CUP-ROLLER B
- 10 - 7D8983 SHIM
- 6 - 7D8984 SHIM
- 2 - 8D7425 WASHER-THRUS
- 1 - 4F9653 SEAL-O-RING
- 5 - 2G0478 DISC
- 1 - 6G1908 HOUSING AS-D
- 1 - 6G5532 SHAFT-DR PIN
- 1 - 6G5533 GEAR-WORM
- 1 - 6G5534 COVER AS
- 1 - 6G5538 COVER
- 1 - 6G5539 GASKET
- 2 - 6G5542 SPACER
- 6 - 6G5543 SHIM
- 9 - 6G5544 SHIM
- 1 - 6G5547 PLATE
- 1 - 6G5548 SPACER
- 1 - 6G6122 SPRING-DISC
- 1 - 1H7339 SEAL-O-RING
- 1 - 2H9247 SEAL-O-RING
- 1 - 5H4909 SEAL-O-RING
- 3 - 5P8245 WASHER-HARD
- 3 - 0S1585 BOLT
- 3 - 5S7379 BOLT
- 4 - 8T4896 WASHER
- 1 - 9W6645 SEAL G
- 6 - 6Y7953 DISC-FRICTIO
- 10 - 7D8983 SHIM
Action Required
See the attached procedure.
Service Claim Allowances
NOTE: This is an 8-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
If the pinion shaft breaks under normal use replace the circle drive gp with the 5T0570 Circle Drive Gp. Remove the 110-4656 Circle Drive Gp. from machine. Disassemble the following parts and set aside to reuse with the new parts to build the 5T0570 Slip Clutch Gp.
- 1-105-3196 MOTOR GP AND THE S1585 MTG BOLTS & 5P8245 WASHERS
- 1-2G6695 BRACKET WITH 1F7958 NUTS AND 5P8245 WASHERS
- 1-9D1491 COUPLING
- 1-4H6996 PIN
- 2-1B4046 CONE-BRG
- 1-9D1142 WORM
- 1-8W5092 PINION
- 1-8D7424 SPACER
- 1-8D7423 LOCK
- 1-1A1415 NUT
- 1-2G6695 BRACKET WITH 1F7958 NUTS AND 5P8245 WASHERS
1. Assemble 6G5533 Gear to 6G5532 Shaft with 6G5542 Spacer in gear bore. See Detail "C" on Illustration 1. Assemble (6) 6Y7953 Friction Discs and (5) 2G0478 Discs, (1) 6G5542 Spacer, (1) 6G6122 Spring, and (1) 6G5548 Spacer respectively.
2. To preload shaft assembly, using dial gage, install 6G5543 & 6G5544 Shims until shims are 2.05 to 2.55 mm below the top of spacer 6G5548.
3. Install 6G5547 Plate and three S1585 Bolts and 5P8245 Washers and tighten to 130 ±7 N·m.
4. Oil bearing surface of shaft and install one 8D7425 Thrust Washer to bottom of shaft assembly. Set shaft assembly aside for later use.
5. Install one 1B4038 Bearing Cup (for worm shaft) into new 6G1908 Housing As.
6. Remove the 105-3196 Motor from the 2G6695 Bracket (from assembly that was removed from old housing). Put bracket in position on new circle drive housing.
NOTE: Do not install o'ring seal or shims at this time. Install 1F7985 Nuts but leave loose.
Attach a magnetic base dial indicator onto the bracket with dial indicator against worm assembly. Tighten nuts while rotating worm until the worm end play is zero.
7. Measure the distance between 2G6695 Bracket and circle drive hsg with a feeler gage.
8. Remove dial indicator and bracket and using the correct amount of shims to give a preload dimension of 0.0 to 0.13 mm (.00 to .005 in).
9. Install 2H9247 Seal on bracket and install bracket to circle drive hsg.
10. With circle drive hsg setting on it's side, install the pinion shaft assembly (that was assembled in Step 1). Rotating the worm shaft at the same time will ease installation of the pinion shaft.
11. Install 1H7339 Seal on motor and install motor and coupling on worm assembly.
12. Clean the 5K5288 Duo Cone Seal Gp and install one half into bottom of circle drive hsg. Install one half of seal into th 8W5092 Pinion Gear. Install one 8D7425 Washer on top of pinion and assemble pinion on end of shaft assembly. Install 4F9653 Seal on bottom of pinion, along with 8D7424 Spacer, 8D7423 Lock and 1A1415 Nut. Tighten nut to 325 ±27 N·m. Bend lock out on flat of nut.
13. Install 6G5534 Cover As. to top of circle drive hsg, and fill with oil.
Illustration 1 - Part 1 of 3
Illustration 1 - Part 2 of 3
Illustration 1 - Part 3 of 3