PRODUCT SUPPORT PROGRAM FOR REPLACING WHEEL BEARINGS USING AN IMPROVED PRELOAD PROCEDURE ON CERTAIN 120M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING WHEEL BEARINGS USING AN IMPROVED PRELOAD PROCEDURE ON CERTAIN 120M MOTOR GRADERS

Usage:

TEBE9157-00

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06May2019

M450

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING WHEEL BEARINGS USING AN IMPROVED PRELOAD PROCEDURE ON CERTAIN 120M MOTOR GRADERS
4267 4251		PS90965

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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 "PS90965" 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

31May2020

PROBLEM

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The existing wheel bearings can fail on certain 120M Series Motor Graders. If the existing wheel bearings fail, they can generate debris and cause other lower powertrain resultant damage mentioned below.

Signs of failure include:
1. Oil leakage from duo cone seal due to severe loss of bearing preload
2. Wheel spindle has loose endplay when tires lifted off ground
3. Abnormal noise coming from wheel during operation

AFFECTED PRODUCT

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Model	Identification Number
120M	B9C01344, 1346, 1359-1360, 1364, 1366, 1368

PARTS NEEDED

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Qty	Part Number	Description
4	2G9789	GASKET (After Failure Only, if needed)
4	4B7270	BEARING-CONE (After Failure Only, if needed)
4	4S5879	SEAL-O-RING (After Failure Only, if needed)
4	5K5288	SEAL GP-DUO CONE (After Failure Only, if needed)
8	6B3223	BEARING-CUP (After Failure Only, if needed)
12	6V3303	BOLT (After Failure Only, if needed)
4	7D8437	CONE-ROLLER BRG (After Failure Only, if needed)
16	7D8439	SHIM (After Failure Only, if needed)
4	7D8441	SHIM (After Failure Only, if needed)
16	9D7047	SHIM (After Failure Only, if needed)
4	2204335	SEAL-BRAKE (After Failure Only, if needed)
4	2204336	SEAL-BRAKE (After Failure Only, if needed)
28	2849557	PLATE (After Failure Only, if needed)
24	3510925	DISC-FRICTION (After Failure Only, if needed)
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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As a preventive action, proceed with the following inspection: lift tires off the ground and check for spindle endplay.

Collect tandem SOS oil sample before beginning teardown and check tandem magnetic plug for debris. However, it is common for material to build up in the bottom of the tandem housing. A failure would be indicated by the symptoms listed below and an indication of contaminated tandem oil. Refer to the Service Manual if/as necessary.

Signs of failure include:
1. Oil leakage from duo cone seal due to severe loss of bearing preload
2. Wheel spindle has loose endplay when tires lifted off ground
3. Abnormal noise coming from wheel during operation

If failure is confirmed by the above symptoms, schedule a repair at first available opportunity to avoid resultant damage. Potential resultant damage may include damage to the following components (in order of likelihood):
1. Sprockets
2. Spindles
3. Chains
4. Brake housings
5. Final drive outboard bearings

A new wheel bearing preload procedure, previously introduced with Service Magazine M0083889, with improved preload setting, and improved assembly process, is now available. Refer to KENR6419, "Service Brake (Wheel Spindle) - Assemble" Disassembly and Assembly procedure for 120M model.

If any one of the four rear wheel groups fail or show severe damage to components, inspect all four wheel groups for any resultant damage. Refer to reuse & salvage guidelines before replacing parts not listed above.

Flush and clean the tandem housing to remove any residual contaminants.

If the wheel bearing failure is severe and contamination was present in tandem oil during operation for some time, then remove tandems and final drive sprockets, and inspect final drive outboard bearings for damage. If the 6V-2449 bearing is found to show signs of failure or beginning to fail please submit a CPI feedback and include clear pictures of the condition of the outboard bearing cone and cup, the thickness of the ?original? shim pack from Factory Assembly, along with any other component damage that is found. For questions, please contact dealer technical communicator (TC).

It is common for the bearing to mill into the sprocket after preload is lost. The amount of wear is limited by the available shim pack height to properly maintain preload. To determine reusability, follow these steps.
1. Check the wear on the sprocket. If the wear is less than 0.5 mm (0.02 inch), then the parts are OK to reuse if bearing preload can properly be set. See REHS8752 for specification of sprocket width.
2. Attempt to reset the bearing preload following process in assembly guide. Reset the preload only if the measured gap between retainer and spindle (dimension X) is greater than 0.050 mm (0.002 inch). If the gap (dimension X) is less than 0.050 mm, sprocket will need to be replaced or reworked per REHS8752.

For rework and salvage instruction, please refer to the following publications:

REHS8752 ?Instructions For Reworking The Tandem Drive Sprockets on Certain 12M, 120M, and 140M Motor Graders?

SEBF9385, ?Thermal Spray Procedures for Motor Grader Spindle (OD)? and
*Note for spindles, to determine reuse or if thermal spray is needed, refer to Image 1.

For the Final Drive Shaft, thermal spray procedure is not recommended. Replace shaft if damaged and outboard bearing journal does not meet OD spec in Image 2 after light polishing.

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Image1

Image2

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%
0-3000 hrs, 0-30 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 31-60 mo	53.0%	50.0%	0.0%	0.0%	35.0%	50.0%
6001-7500 hrs, 61-75 mo	20.0%	25.0%	0.0%	0.0%	60.0%	75.0%

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NOTE: This is a 1.0-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.
Note: If needed, up to 45.0 additional labor hours are allowed to repair all four wheels on an After Failure basis.

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