Product Support Program For Reworking The 1Q5569 Pump Transfer Gear Group On Certain 140G Motor Graders Equipped With A 3Z4880 Or 3Z4940 Modification - 140G All Wheel Drive (AWD) Motor Graders Caterpillar

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.

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4575" as Part Number, "7755" as Group Number, and "96" as Description Code.

Termination Date

Problem

Lock installation that is not correct, shaft taper that is not correct, or key slot depth that is not to the correct depth may shorten the service life of the 1Q5569 Pump Transfer Gear Group on certain 140G Motor Graders equipped with a 3Z4880 or 3Z4940 Modification - 140G All Wheel Drive (AWD) Motor Graders.

Affected Product
Model & Identification Number

140G (72V11031, 72V11038, 72V11047, 72V11065, 72V11081, 72V11099, 72V11111, 72V11136, 72V11149, 72V11162, 72V11175, 72V11190, 72V11202, 72V11218, 72V11229, 72V11243, 72V11805, 72V11822, 72V11837, 72V11858, 72V11861, 72V11878, 72V11895, 72V11910, 72V11929, 72V11934, 72V11947, 72V11960, 72V11967, 72V11974, 72V11978, 72V11986, 72V11996, 72V12007, 72V12011, 72V12021, 72V12027, 72V12034, 72V12038, 72V12046, 72V12055, 72V12060, 72V12068, 72V12078, 72V12083, 72V12091, 72V12138, 72V12176, 72V12201, 72V12226, 72V12234, 72V12243, 72V12253, 72V12259, 72V12272, 72V12281, 72V12287, 72V12296, 72V12306, 72V12315, 72V12326, 72V12333, 72V12342, 72V12351, 72V12361, 72V12374, 72V12385, 72V12394, 72V12404, 72V12411, 72V12421, 72V12430, 72V12440, 72V12448, 72V12457, 72V12462, 72V12471, 72V12475, 72V12480, 72V12489, 72V12498, 72V12506, 72V12515, 72V12519, 72V12525, 72V12533, 72V12542, 72V12550, 72V12561, 72V12569, 72V12578, 72V12586, 72V12595, 72V12630, 72V12611, 72V12620, 72V12627, 72V12634, 72V12639, 72V12648, 72V12658, 72V12666, 72V12674, 72V12684, 72V12692, 72V12701, 72V12714, 72V12723, 72V12732, 72V12740, 72V12758, 72V12766, 72V12775, 72V12784, 72V12792, 72V12802, 72V12809, 72V12818, 72V12827, 72V12836, 72V12844, 72V12854, 72V12862, 72V12870, 72V12879, 72V12888, 72V12896, 72V12904, 72V12914, 72V12923, 72V12932, 72V12941, 72V12950, 72V12959, 72V12968, 72V12977, 72V12985, 72V12993, 72V13001, 72V13010, 72V13019, 72V13027, 72V13036, 72V13043, 72V13052, 72V13060, 72V13069, 72V13074, 72V13083, 72V13091, 72V13100, 72V13105, 72V13114, 72V13118, 72V13127, 72V13134, 72V13143, 72V13152, 72V13157, 72V13171, 72V13202, 72V13213, 72V13221, 72V13238, 72V13254, 72V13263, 72V13275, 72V13287, 72V13401, 72V13410, 72V13424, 72V13433, 72V13441, 72V13454, 72V13465, 72V13478, 72V13487, 72V13497, 72V13506, 72V13516, 72V13525, 72V13534)

Parts Needed

1 - 0A1925 Cone

1 - 1B3955 Cup

1 - 8B7614 Nut

1 - 3D9125 Cone

1 - 3D9126 Cup

1 - 1N5970 Lock

1 - 1Q5577 Gasket Kit

1 - 1Q6030 Washer

1 - 1Q6173 Shaft

1 - 7X4795 Seal

1 - 9X7698 Seal

Action Required

Refer to the Service Manual and the Supplementary Product Support Literature (SEBF0600). Replace the existing parts with the new parts as described in the attached procedure.

Service Claim Allowances

NOTE: This is a 7-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Do the following steps with the motor grader in a straight (not articulated) position.

1. Remove two 5S7379 Bolts and 5P1075 Washers from the drive shaft shield. See Illustration 1.

Illustration 1 - Drive Shaft Shield Group

2. Remove four 5C6565 Bolts and 8T7971 Washers from the drive shaft shield. See Illustration 1.

3. Remove one 8W5867 Shield Assembly and one 8W5868 Shield thru the RH side of the motor grader.

Do the following steps with the motor grader fully articulated to the left.

4. Disconnect 5K7577 Hose Assembly from manifold on platform. See Illustration 2.

Illustration 2 - Remove Grease Lines Group

Do the following steps with the motor grader fully articulated to the right.

5. Drain oil from transfer gear group case by removing the 9S4191 Plug from the manifold on the RH rear side of the front frame. See Illustration 2. Clean and install plug after oil is drained.

6. Remove 6G4240 Universal Joint Gp. (Drive Shaft). See Illustration 3.

Illustration 3 - Pump Drive Group

7. Remove the left hand 0L1329 Bolt and loosen right hand 0L1329 Bolt. See Illustration 4.

Illustration 4 - Transfer Gear Group

8. Remove four 7B3235 Bolts and 5P8245 Washers. See Illustration 4.

9. Rotate the left end of the 1Q5555 Plate (Illustration #4), (pivot around loose 7B3235 Bolt) rearward to provide access to the 051588 Bolts which fasten the 1Q5577 Hub to the case. See Illustration 5. It may be necessary to raise case with bar to move plate.

Illustration 5 - Transfer Gear Group

10. Remove eight 0S1588 Bolts and 9F5644 Washers. Remove hub assembly from the case. See Illustration 5.

11. Remove 1D5120 Nut and 5P8248 Washer from the existing 1Q5612 Shaft. See Illustration 3.

12. Remove 7D9267 Yoke and 1B8737 Key the existing 1Q5612 Shaft. See Illustration 3.

13. Remove the existing 7X4775 Seal from 1Q5838 Hub. See Illustration 6.

Illustration 6 - Hub Assembly

14. Straighten bent tab of 1N5970 Nut Lock from slot in 8B7614 Nut. Remove nut, lock and the existing 388401 Washer. See Illustration 6. Do not reuse these parts.

15. Remove shaft assembly from hub.

16. Remove 9L2336 Ring from the existing 1Q5612 Shaft. See Illustration 6.

17. Press the existing 1Q5612 Shaft from 1Q5611 Gear and 3D9125 Bearing. Insure that 1Q5612 Key is clear of all supports. The shaft and bearing will not be reused.

18. Heat 1Q5611 Gear and new 3D9125 Bearing to 177°C (350°F) in oven.

19. Install 9L2336 Ring on new 1Q6173 Shaft.

20. Install 1Q5575 Key in new 1Q6173 Shaft.

21. Install hot, 1Q5611 Gear (teeth away from taper on shaft) on new 1Q6173 Shaft. Insure that the gear contacts the 9L2336 Ring.

22. Install hot, 3D9125 Bearing (tapered roller toward taper on shaft) on new 1Q6173 Shaft. Insure that bearings contact gear.

23. Remove 5K7577 Hose Assembly from elbow in hub. Install grease fitting so hub can be lubricated before installation in motor grader. See Illustration 2.

24. Remove 1B3955 Cup, 3D9126 Cup, 0A1925 Cone, and 7X4795 Seal from hub. See Illustration 6. These parts will not be reused.

25. Clean hub, remove shims from flange. The shims will not be reused.

26. Install new 1B3955 Cup, 3D9126 Cup and 7X4795 Seal in the hub. Make sure the O.D. of the seal is coated with 6V6640 Gasket Maker or 7M7260 Liquid Gasket before installing it in the hub. Insure that the parts contact the shoulder if their counterbore. See Illustration 6.

27. Install shaft assembly into hub.

28. Install new 0A1925 Cone over shaft and in hub. See Illustration 6.

29. Install new 1Q6030 Washer over shaft.

30. Install new 1N5970 Nut Lock over shaft.

31. Install new 8B7614 Nut (chamfer towards lock) on shaft.

32. Tighten nut until bearings have slight preload.

33. Loosen nut until a maximum of .05 mm (.002") end play is maintained and a slot in the nut aligns with a tang on the nut lock.

34. Bend tang into slot.

35. Install new 9X7698 Seal over shaft/in hub. See Illustration 6. Coat I.D. of seal with 6V6640 Gasket Maker or 7M7260 Liquid Gasket.

36. Apply 5P3931 Anti-Seize Compound to the taper of the shaft.

37. Install 7D9267 Yoke, 1B8737 Key, 5P8248 Washer, and 1D5120 Nut on shaft. Tighten nut to 180 ± 14 N·m (133 Lb Ft).

38. Lubricate grease fitting in elbow on hub with 2S3230 Bearing Lubricant until it comes from relief valve opposite the fitting. See Illustration 5.

39. Remove grease fitting and install 5K7577 Hose Assembly removed in Step #23.

40. Coat mounting faces of hub and case with 3S6252 Silocone Sealant.

41. Install hub as. in case using two .4 mm (.015") shims from the 1Q5577 Gasket Kit.

42. Install and tighten the 0S1588 Bolts and 9F5644 Washers which fasten hub as to case. Tighten to 42 ± 7 N·m (31 ± 5 Lb Ft).

43. Measure backlash using a dial indicator placed on the 7D9267 Yoke. See Illustration 3. Backlash should be .18 mm - .28 mm (.007" - .011"). To adjust backlash, add shims to increase and remove shims to reduce backlash.

44. Fill gearbox with HYDO, DEO, or EO SAE 30W Oil by removing level plug from front of gearbox and fill through coupling on remote location on the right hand side of motor grader. See Illustration 2 & 4.

NOTE: Use mating coupling 1P2376. Maintain the oil level plug opening. Install level plug and coupling cap.

45. Rotate 1Q5555 Plate to its original position and fasten to 3Z4688 Plate Assembly with four 7B3235 Bolts and 5P8245 Washers. See Illustration 4. Fasten plate as. to frame with 0L1329 Bolts.

46. Install 6G4240 Universal Joint Group. Tighten bolts to 55 ± 7 N·m (40 ± 5 Lb Ft).

Do the following steps with the motor grader fully articulated to the left.

47. Install the 8W5867 and 8W5868 Drive Shaft Guards. See Illustration 1. Use 5S7379 Bolts, 5P1075 Washers, 5C6565 Bolts, and 8T7971 Washers.

48. Connect 5K7577 Hose Assembly to manifold on platform.