PRODUCT SUPPORT PROGRAM FOR INSPECTING WHEEL BEARINGS AND FINAL DRIVE THRUST WASHERS ON CERTAIN 14M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING WHEEL BEARINGS AND FINAL DRIVE THRUST WASHERS ON CERTAIN 14M MOTOR GRADERS

Usage:

TEBE4449-01

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18Apr2016

(Revised 14Jun2016)

M450

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSPECTING WHEEL BEARINGS AND FINAL DRIVE THRUST WASHERS ON CERTAIN 14M MOTOR GRADERS
4050 4201 4006 4208 4063 3261		PS90579

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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 "PS90579" 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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NOTE:	This Revised Service Letter replaces the 18Apr2016 Service Letter. Changes have been made to the Parts Needed and Action Required.

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TERMINATION DATE

30Apr2017

PROBLEM

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The existing wheel bearings and final drive thrust washers can fail on certain 14M Motor Graders. If the existing wheel bearings or final drive thrust washers fail, they can generate debris, causing seal leakage, contamination, and resultant damage.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
14M	R9J01219, 1222-1223, 1227, 1325, 1327-1329, 1332-1333, 1335-1338, 1449-1451, 1453-1458, 1460-1462, 1466

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*****Group 2*****
14M	R9J01331, 1339, 1459

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*****Group 3*****
14M	R9J01212-01213, 1221, 1224-1226, 1324, 1326, 1452

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
3	1U9891	ADDITIVE-OIL (After Failure Only)
4	2G9793	GASKET
4	4B7270	CONE-BEARING
4	5K5288	SEAL GP-DUO CONE
4	5P3490	CONE-RLR BEARING
8	6B3223	CUP-BEARING
4	6G1670	CHAIN GP (After Failure Only)
2	6V8397	SEAL-O-RING-ORFS
4	6V8398	SEAL-O-RING-ORFS
4	7X1548	SEAL-O RING
4	9D1586	SPACER (After Failure Only)
2	9L5650	SEAL-O-RING (After Failure Only)
16	1036169	BOLT-HEX HEAD
4	2204335	SEAL-BRAKE (After Failure Only)
4	2204336	SEAL-BRAKE (After Failure Only)
4	2528678	SPROCKET (After Failure Only)
4	2559331	RING-WEAR (After Failure Only)
2	2594462	RETAINER (After Failure Only)
2	2602989	SHIM PACK (After Failure Only)
8	2669727	GASKET
26	2706942	SHIM
14	2706943	SHIM
20	2706944	SHIM
2	3307851	SEAL-LIP TYPE (After Failure Only)
36	3510925	DISC-FRICTION (After Failure Only)
8	3800473	PIN-COTTER
2	4378977	WASHER-THRUST (After Failure Only)
2	4378978	WASHER-THRUST (After Failure Only)
1	OIL	TANDEM OIL-BULK [200L(26.4gal](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.
*****Group 2*****
3	1U9891	ADDITIVE-OIL (After Failure Only)
4	2G9793	GASKET
4	6G1670	CHAIN GP (After Failure Only)
2	6V8397	SEAL-O-RING-ORFS
2	9L5650	SEAL-O-RING (After Failure Only)
4	2559331	RING-WEAR (After Failure Only)
2	2594462	RETAINER (After Failure Only)
2	2602989	SHIM PACK (After Failure Only)
8	2669727	GASKET
10	2706942	SHIM (After Failure Only)
10	2706943	SHIM (After Failure Only)
4	2706944	SHIM (After Failure Only)
2	3307851	SEAL-LIP TYPE (After Failure Only)
8	3800473	PIN-COTTER
2	4378977	WASHER-THRUST (After Failure Only)
2	4378978	WASHER-THRUST (After Failure Only)
1	OIL	TANDEM OIL-BULK [200L(26.4gal](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.
*****Group 3*****
3	1U9891	ADDITIVE-OIL (After Failure Only)
4	2G9793	GASKET
4	4B7270	CONE-BEARING
4	5K5288	SEAL GP-DUO CONE
4	5P3490	CONE-RLR BEARING
8	6B3223	CUP-BEARING
4	6G1670	CHAIN GP (After Failure Only)
2	6V8397	SEAL-O-RING-ORFS
4	6V8398	SEAL-O-RING-ORFS
4	7X1548	SEAL-O RING
4	9D1586	SPACER (After Failure Only)
16	1036169	BOLT-HEX HEAD
4	2204335	SEAL-BRAKE (After Failure Only)
4	2204336	SEAL-BRAKE (After Failure Only)
4	2528678	SPROCKET (After Failure Only)
8	2669727	GASKET
16	2706942	SHIM
4	2706943	SHIM
16	2706944	SHIM
36	3510925	DISC-FRICTION (After Failure Only)
8	3800473	PIN-COTTER
1	OIL	TANDEM OIL-BULK [200L(26.4gal](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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Wheel bearings should be replaced and preload reset for groups 1 and 3. A new wheel bearing preload procedure, with improved preload setting, and improved assembly process, is now available. Refer to RENR8639, Disassembly and Assembly, for the new rework procedure. Disassemble the wheel group so that both bearings can be replaced. If degradation of the bearings is noted, inspect wheel group components for contamination and damage (friction discs, brake housing, and spindle). Inspect the spindle for signs of stepping where it contacts the bearings. Refer to SEBF9385, Thermal Spray Procedures for Motor Grader Spindle, Table 8 for specifications. Inspect the sprockets for any signs of cracking in the root of the tooth, excessive wear on the contact surface between the sprocket and inner wheel bearing, and any chipping on the teeth of the sprocket. Refer to TIBU6090 for additional information on inspection sprocket surfaces for wear. Rework or replace components as needed. Flush and clean the tandem housing to remove any residual contaminants. Note: it is usual for material to build-up in the bottom of the tandem housing. The presence of material in the bottom of the housing alone does not indicate a failure has occurred. Refer to the Service Manual if/as necessary.

Final drive thrust washers will be inspected using a tandem sag measurement procedure for groups 1 and 2. Note: The measurement is to be taken at the top of the tandem walk way not at the top of the tandem housing for correct measurements. Measurements need to be taken in mm. The height of the walk way is 48 mm above the top of the tandem housing.

1. With the machine on level ground, place a scale between the enclosure on top of the walkway. Record the distance from the enclosure to the edge of the walkway (A)(left and right side)

2. Raise the back of the machine into the air so that the tandem tires are off the ground. Check dimension (B) using the same reference points on the enclosure and the walkway as shown in image 1. (left and right side)

3. Subtract the value A found in Step 1 from the value B found in Step 2, and record this difference on the table. The difference is the tandem sag measurement. NOTE: Record these measurements in the claim story. In addition to the tandem sag measurements all thrust washer end play measurements and final shim pack measurements used (left and right) need to be documented in the service claim story.

If seal leakage is present or the tandem sag measurement is between 5mm and 6mm this repair needs to be done as soon as possible to prevent housing damage. (Measurements need to be recorded in the claim story and note on seal leakage).

This letter supports repair for both tandems, even if only one side meets the tandem sag requirements. Reworking both tandems in the event only one side has failed prevents a repair to the other side at a later date and additional machine down time.

Replace the existing oscillation joint thrust washers, retainers (if needed), and lip seals in the final drive groups. In addition to the D&A, follow the oscillation joint assembly instructions below in the rework procedure for the end play measurement/setting.

If the wheel bearings or tandem thrust washers are being replaced, inspect the tandem chains while they are removed from the unit. Look for excessive play in the rollers, loose engagement of the press fit pins, or severe gouging or material loss on the outer links from abrasive wear with the tandem housing or adjacent chain. Note, the presence of a thrust washer failure or wheel bearing failure alone does not necessitate replacement of the tandem chains. Replace the chains only if visual defects are noted.

Note: add 1.5L of the 1U-9891 oil additive to each tandem if the brake friction material is replaced, tandems flushed, and new oil used.

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Image1

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%
*****Group 1*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	60.0%	70.0%	0.0%	0.0%	30.0%	30.0%
6001-8000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
8001-10000 hrs, 49-60 mo	20.0%	20.0%	0.0%	0.0%	60.0%	80.0%

NOTE: This is a 60.0-hour job for Group 1

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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%
*****Group 2*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	60.0%	70.0%	0.0%	0.0%	30.0%	30.0%
6001-8000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
8001-10000 hrs, 49-60 mo	20.0%	20.0%	0.0%	0.0%	60.0%	80.0%

NOTE: This is a 32.0-hour job for Group 2

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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%
*****Group 3*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	60.0%	70.0%	0.0%	0.0%	30.0%	30.0%
6001-8000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
8001-10000 hrs, 49-60 mo	20.0%	20.0%	0.0%	0.0%	60.0%	80.0%

NOTE: This is a 34.0-hour job for Group 3

PARTS DISPOSITION

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

Rework Procedure

1. Clean and inspect the tandem square housing (291-6872) and the top hat housing (316-9769, 316-9771) to ensure there is no damage to the thrust washer surface area.

2. Remove plug (30) from the square housing.

Image1.1.1

3. Thoroughly apply Dow Corning Molykote BR-2 Plus grease or Cat Advance 3Moly Grease (do not use the Loctite moly paste) to both sides of 255-9331 Wear Rings and set them aside on a clean surface (applying the grease by hand with clean latex or rubber gloves works best).

4. Apply Dow Corning Molykote BR-2 Plus grease or Cat Advance 3Moly Grease to both sides of the inboard thrust washer (437-8977) and place it on the top hat housing. Note the type of grease used in work order service report. Do NOT apply grease to the outboard thrust washer at this time (the correct shim pack must be calculated first). Install the lip seal.

5. Install square housing onto top hat housing. Ensure square housing is positioned so that the hole (from which plug was removed in step 2 above) is oriented upwards. Ensure lip seal goes on over the seal diameter on the top hat housing. NOTE: Wear ring can be installed first if this assembly method is preferred by the service personal.

6. With assistance, line up one greased 255-9331 Wear Ring (orient the split in the wear ring in the 3 o'clock position) and tap it in evenly with a dead blow plastic hammer. Once flush, pull the square housing out approximately 6mm (1/4 inch), ensuring the wear ring stays stationary. This will aid in the alignment and installation of the 2nd wear ring.

7. With assistance, line up the 2nd greased wear ring, orienting the split in the 2nd wear ring in the 9 o'clock position. Tap the 2nd wear ring in with a dead blow plastic hammer until flush. Once flush, pull the square housing out approximately 6mm (1/4 inch), ensuring the wear ring stays stationary. This will aid in the final installation.

8. Using the old or a spare wear ring as a tool, and with assistance, line up the spare wear ring and use it as a driver and tap the 2nd wear ring in completely.

9. Push square housing back in completely. Ensure the 2nd wear ring is not protruding out past the thrust face of the square housing. Wipe off all excess Molykote grease or Cat Advance 3Moly Grease with a dry rag or towel to prepare for the end play measurement.

10. Install retainer plate (259-4462) and 3 bolts (do not install any shims or the thrust washer at this time). Tighten the bolts to a torque of 10 Nm (7.5 lb ft). Using a depth micrometer, measure from the top of the retainer plate to the top hat housing in the 3 measuring hole locations (ensure no burrs are present around measuring holes if the retainer had been drilled on the side with current parts). Record and average the 3 measurements as Dimension (A).

11. Remove retainer plate. Install clean and dry outboard thrust washer (437-8978). Do not install any shims at this time. Install retainer and tighten the 3 bolts to 50 Nm (37 lb ft) to seat the joint. Recheck the bolts to verify torque is achieved. Loosen bolts. Tighten the 3 bolts back to 10 Nm (7.5 lb ft), then recheck the 10 Nm (7.5 lb ft) torque on all three bolts several times until the torque can be achieved.

12. Using depth micrometer, determine the gap by measuring from the top of retainer to the top hat housing in the 3 measuring hole locations. Record and average of the 3 measurements as Dimension (B).

13. Subtract Dimension (A) from Dimension (B). Record the result as dimension (C). Dimension (C) is the final shim pack thickness +0 mm (0.000 inch) -.05 mm (.002 inch). Note: These instructions are written to try to achieve the tightest joint within the specifications. Assemble shim pack using micrometer to measure thickness. Record the measured thickness of the shim pack installed.

14. Remove retainer plate and coat front and back of outboard thrust washer with Dow Corning Molykote or Cat Advance 3Moly Grease. and install shims. Install 3 retainer bolts and tighten to a torque of 10 Nm (7.5 lb ft). Support the top hat housing and verify that the square housing can be rotated a few degrees by hand using a 4.5 ft bar as shown below (housing may have firm resistance). If housing cannot be rotated, add .05mm (.002 inch) to the shim pack and check again after bolts are tightened to the correct torque.

Image1.3.1

15. Ensuring the square housing can be rotated as described above after each tightening process. Tighten to a torque of 10 Nm (7.5 lb ft) 50 Nm (37 lb ft) and 203 Nm (150 lb ft). Install remaining bolts and tighten all bolts to a final torque of 530 Nm (391 lb ft).

16. Record all measurements and the measured thickness of the final shim pack installed.

17. Install plug that was removed from square housing in Step 2 above.

18. Fill the tandems with oil per the O&M manual.

19. Document the baseline tandem to frame (sag) measurements for both final drives per the instructions after 10 minutes of machine operation.

20. Inspect both the left hand and right hand oscillation joint to confirm that the lip seals are not leaking.