R NEHS0920-02

March 2006

TOOL
OPERATING
MANUAL
200-4532 Front Wheel Bearing Preload Adjuster for
785, 789, and 793 Off-Highway Trucks

SMCS: 4056-025
Important Safety Information
Think Safety
Most accidents that involve product operation,
maintenance, and repair are caused by failure
to observe basic safety rules or precautions.
An accident can often be avoided by
recognizing potentially hazardous situations
before an accident occurs. A person must be
alert to potential hazards. This person should
also have the necessary training, skills, and
tools to perform these functions properly.
Improper operation, lubrication,
maintenance, or repair of this product can
be dangerous and could result in injury or
death.
Do not operate or perform any lubrication,
maintenance, or repair on this product until
you have read and understood the
operation, lubrication, maintenance, and
repair information.
Safety precautions and warnings are provided
in this manual and on the product. If these
hazard warnings are not heeded, bodily injury
or death could occur to you or to other
persons.
The hazards are identified by the “Safety Alert
Symbol” and followed by a “Signal Word” such
as “DANGER”, “WARNING”, or “CAUTION”.
The Safety Alert “WARNING” label is shown
below.
WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.
2
The message that appears under the warning
explains the hazard and can be either written
or pictorially presented.
Operations that may cause product damage
are identified by “NOTICE” labels on the
product and in this publication.
Caterpillar cannot anticipate every possible
circumstance that might involve a potential
hazard. The warnings in this publication
and on the product are, therefore, not all
inclusive. If a tool, procedure, work
method, or operating technique that is not
specifically recommended by Caterpillar is
used, you must satisfy yourself that it is
safe for you and for others. You should
also ensure that the product will not be
damaged or be made unsafe by the
operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations
in this publication are on the basis of
information that was available at the time that
the publication was written. The specifications,
torques, pressures, measurements,
adjustments, illustrations, and other items can
change at any time. These changes can affect
the service that is given to the product. Obtain
the complete and most current information
before you start any job.
WARNING
When replacement parts are required for this
product, Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type,
strength, and material.
Failure to heed this warning can lead to
premature failures, product damage,
personal injury, or death.
 WARNING
To avoid personal injury or
death, carefully read and
understand all
instructions before
attempting to operate any equipment. Do
not operate or work on a machine unless you
read and understand the instructions and
warnings in this and all other applicable
manuals. Contact Dealer Service Tools for
replacement manuals. Proper care is your
responsibility. Always follow all State and
Federal health and safety laws and/or local
regulations.

To avoid eye injury, always

wear protective glasses or
face shield. Make sure no
one can be injured by
flying objects or debris when using tools or
working on a component.

Personal injury can result

from slips or falls. DO
NOT leave tools or
components laying
around the work area and clean up all spilled
fluids immediately.

Personal injuries
can occur as a
result of using
pressurized air.
Maximum air pressure at the nozzle must be
below 205 kPa (30 psi) for cleaning
purposes. Wear protective clothing,
protective glasses, and a protective face
shield when using pressure air.

3
Introduction
The 200-4532 Front Wheel Bearing Preload
Adjuster is used to accurately determine the
shim thickness required for a proper bearing
preload setting. Because no calculations are
required, adjustment time is reduced, there is
less chance of error, and accuracy is improved
over conventional methods.
The bearing preload adjuster can be used
when the front wheel assembly is in a spindle-
down, vertical orientation, or while the spindle
and wheel are mounted to the truck in a
horizontal orientation.
Included with the bearing preload adjuster is a
precision base plate (ensures accuracy), two
indicators, all attachments, and lifting rings
(used with lifting device). The tool’s rugged
design ensures long life and also helps the
tool to maintain its accuracy.
The bearing preload force applied by this tool
is approximately:
785 — 3311 kg (7300 lbs)
789 — 4263 kg (9400 lbs)
793 — 4581 kg (10,100 lbs)
which represents the same force applied to
the bearings when the wheel assembly is
installed on the truck. The adjuster is
designed with a
785 — 3.43 mm (.135 in)
789 — 3.18 mm (.125 in)
793 — 2.54 mm (.100 in)
offset between the spindle end and surface of
the inner bearing race.
2a 2 3
2b
1
4
5
6 the bearing preload adjuster has been in
4
13 7 one day. The tool should also be reset after
11a,b,c 9 8
0920-01
Illustration 1. 200-4532 Front Wheel Bearing Preload
Adjuster.
(1) Bearing Preload Adjuster. (2) 5/8-11 and M20 Bolts.
(2a) Spherical Washers (5/8 and M20). (2b) Bushing (5/8
and M20). (3) Digital Indicators. (4) Lifting Eyes.
(5) Outer Contact Ring. (6) Base Plate. (7) Calibration
Shims. (8) Shim Retaining Bolts. (9) Leveling Legs.
(11a, b, c) Spacer Plates. (13) M6 Socket Head Cap
Screw.
4
NOTE: The base plate is designed with seven
5/8-11 bolt holes for the 785 and 789 and
seven M20 bolt holes for the 793. Because of
the constant wear to the bolt hole threads from
repeatedly removing and installing the bolts,
this additional set of bolt holes provides
greater tool life. If one hole is damaged, rotate
the bearing preload adjuster and use the other
set of bolt holes. Additionally, if one hole in
each set of bolt holes is damaged on the top
side of the plate, the plate can be flipped over,
providing two more complete sets of bolt
holes.
References
Reference Material
Form No. Title
NEHS0905 245-1893 Calibration Group Used to
Calibrate the Bearing Preload Adjusters for
Off-Highway Trucks
Prior to Adjustment
Procedure
The bearing preload adjuster is shipped from
the factory with leveling legs (9) installed on
top of the base plate. Before using the
bearing preload adjuster, remove the leveling
legs and install them on the bottom of the
plate, making sure the plate sits level. Also,
make sure the indicator tips are not loose.
The bearing preload adjuster should be
allowed to acclimate to the ambient
temperature of the surrounding conditions for
at least four hours prior to being used.
Once the indicators are set to zero, it is not
necessary to reset them after each bearing
preload operation. However, the adjuster
should be set to zero before each work shift, if
storage, or if it has been unused for more than
the fourth bearing preload procedure within
one shift.
Preload Procedure
This procedure is written with the front wheel
assembly in a spindle-down, vertical
orientation. The tool may also be used with
the spindle and wheel mounted to the truck in
a horizontal position by using the swivel lifting
eyes attached on each side of the tool.
Whichever method is used (vertical or
horizontal), the wheel assembly should be
assembled to the point of being ready for the
bearing preload procedure.
NOTICE
Do not use an impact wrench to tighten or
loosen bolts (2) on the bearing preload adjuster.
The vibration of an impact tool can damage the
digital indicators and/or cause incorrect indicator
readings. Always use hand tools to tighten or
loosen the bolts on the bearing preload adjuster.
1. Remove seven bolts (2) from the bearing
preload adjuster and separate it from base
plate (6). Thoroughly clean all bolts and
spherical washers (2) and all mating
surfaces of outer contact ring (5), inner
spacer (10), and base plate (6).
2. Install the correct spherical spacer plate
onto the inner spacer (10). Each model of
truck uses a seperate spacer; one for each
785 (11a), 789 (11b), and 793 (11c) model.
(10) Inner Spacer. (11a, b, c) Spacer Plates.
(13) M6 x 1, 22 mm long Socket Head Cap Screw.
5
11c
11b
11a
0920-07
NOTE: Check for any burrs, nicks, or raised
surfaces which exceed 0.025 mm (.0010 in.)
on or above the surface of both the outer
contact ring and base plate. Remove any
raised surfaces using a file or stone. Raised
surfaces will affect the accuracy of this tool
and the preload adjustment to the wheel
bearing.
3. Lubricate the bolt threads with machine oil
or anti-seize lubricant. Attach the bearing
preload adjuster to base plate using the
seven bolts and spherical washers.
NOTE: The 5/8-11 and M20 bolts require the
appropriate bushings and spherical washers in
the bolt holes.
4. Tighten bolts (2) to [5/8-11, 271 N·m (200
ft/lb) or M20, 339 N·m (250 ft/lb)] using an
alternating diagonal pattern with no more
than one-quarter turn at a time. The
alternating tightening pattern ensures that
the adjuster is tightened evenly onto the
base plate. Do not use an impact wrench
to tighten bolts (2) on the bearing preload
adjuster.
5. Select the units of measure (millimeter or
inch) on the indicators. Set the two digital
indicators to zero by pressing the “zero
button” on each indicator.
6. Loosen and remove the bolts. Use the
same one-quarter turn and alternating
diagonal pattern when loosening the bolts.
Do not use an impact wrench to remove the
bolts.
7. Clean and check the wheel spindle end
and hub contact surface for nicks, burrs, or
raised surfaces. Chase all spindle bolt hole
threads with the appropriate 5/8-11 or M20
x 2.5 tap to ensure the threads are clean
before installing the bolts.
8. Using an overhead lifting device attached
to the center lifting ring (for vertical use) or
two side lifting rings (for horizontal use),
remove the bearing preload adjuster from
the base plate and place it in position on
the race of the inner bearing cone wheel
assembly.
9. Attach the bearing preload adjuster using
bolts. Tighten the bolts to [5/8-11, 271 N·m
(200 ft/lb) or M20, 339 N·m (250 ft/lb)]
using an alternating diagonal pattern with
no more than one-quarter turn at a time.
The alternating tightening pattern ensures
that the adjuster is tightened evenly onto
the wheel spindle. Do not use an impact
wrench to tighten the bolts.
0920-02
Illustration 2. Bearing Preload Adjuster Attached To
Wheel Assembly.
10a. In the vertical position,, release the
parking brake and rotate the wheel at
least three revolutions to allow the
wheel bearing to seat properly.
10b. In the horizontal position,, release the
parking brake and rotate the wheel at
least six revolutions to allow the wheel
bearing to seat properly.
11. Record the readings from each digital
indicator and average these readings to
calculate the correct shim pack thickness.
6
12. Loosen and remove the bolts. Use the
same one-quarter turn and alternating
diagonal pattern when loosening the bolts.
Do not use an impact wrench to remove
the bolts.
13. Using an overhead lifting device, remove
the tool from the wheel assembly.
14. Clean the surface of the outer contact ring
and base plate. Place the bearing
preload adjuster tool onto the base plate
and tighten the bolts, finger tight.
15. Install the shim pack, retainer, and bolts
on the wheel assembly. Tighten the bolts
per Caterpillar specifications. The bearing
preload procedure is now complete.
Indicator Accuracy Check
To check the indicators for accuracy:
1. Remove bolts (2) from the bearing preload
adjuster and separate it from base plate
(6). Thoroughly clean bolts and spherical
washers (2) and all mating surfaces of
outer contact ring (5) and the base plate.
NOTE: Check for any burrs, nicks, or raised
surfaces which exceed 0.025 mm (.0010 in.)
on or above the surface of both the outer
contact ring and base plate. Remove any
raised surfaces using a file or stone. Raised
surfaces will affect the accuracy of this tool
and the preload adjustment to the wheel
bearing.
2. Lubricate the bolt threads with machine oil
or anti-seize lubricant. Attach the bearing
preload adjuster to base plate using the
bolts and spherical washers.
3. Tighten bolts (2) to [5/8-11, 271 N·m (200
ft/lb) or M20, 339 N·m (250 ft/lb)] using an
alternating diagonal pattern with no more
than one-quarter turn at a time. The
alternating tightening pattern ensures that
the adjuster is tightened evenly onto the
base plate. Do not use an impact wrench
to tighten the bolts.
4. Select the units of measure (millimeter or
inch) on the indicators. Set the two digital
indicators to zero by pressing the “zero
button” on each indicator. 3

12
10
5
7 11a, b, c
13
6

0920-04

Illustration 4. Bearing Preload Adjuster Attached To Base

Illustration 3. Set Each Indicator To Zero.
5. Loosen and remove the bolts. Use the
same one-quarter turn and alternating
diagonal pattern when loosening the bolts.
Do not use an impact wrench to remove the
bolts.
6. Remove shims (7) from the base plate by
removing two bolts (8) holding the
calibration shims in place. Position
calibration shims (7), equally spaced,
under outer contact ring (5), as shown.
Plate. (The Illustration Shows The Calibration Tool In The
Compressed State.)
(3) Indicator. (5) Outer Contact Ring. (6) Base Plate.
(7) Calibration Shims. (10) Inner Spacer. (11) Special
Spacer. (11a) 785 Spacer. (11b) 789 Spacer.
(11c) 793 Spacer. (12) Indicator Extension Tip.
(13) M6 x 1, 22 mm long Socket Head Cap Screw.
7. Retighten the bolts to [5/8-11, 271 N·m
(200 ft/lb) or M20, 339 N·m (250 ft/lb)]
using an alternating diagonal pattern with
no more than one-quarter turn at a time.
Do not use an impact wrench to tighten the
bolts.

NOTICE
Make sure the calibration shims are not
underneath or making contact with inner spacer
(10). If the calibration shims are under the inner
spacer when the bearing preload adjuster is
tightened onto the base plate, damage to the
inner spacer or base plate will occur.

7
8. Each indicator reading should be 3.175 mm
±0.051 (.1250 ±.0020 in). If the indicators
do not show this reading:
• clean all mating surfaces and recheck,
• make sure the indicators are securely
fastened to the bearing preload adjuster,
and/or
• make sure the indicator tips are not loose.
After completing these three items, repeat
Steps 3 through 8.
Service and Warranty
Complete and return the attached Warranty
Registration Sheet within two weeks of
receiving the bearing preload adjuster.
This tool should be calibrated a minimum of
every 12 months, using the 245-1893
Calibration Group.
If technical support is required, begin the
process by contacting the Dealer Service
Tools hotline by phone (1-309-675-6277) or
email dealerservicetool_hotline@cat.com.

Serviceable Parts
Part No. Description Qty. Supplier
266-0308 Bolt 5/8-11 x 219.5 mm 7 Caterpillar
(8.5 in.) long
CL-4-SW Spherical Washer 7 Carr-Lane2
(5/8 in.)
6V-8490 M6X1 X 22 mm long 7 Caterpillar
266-0309 M20X2.5 X 220 mm 7 Caterpillar
(8.6 in.) long
CLM-20-SW Spherical Washer (M20) 7 Carr-Lane2
PT61120-0 Battery (Indicator) 1 Starrett1
CR2450 N 3 Volt Lithium Renata3
PT10459 Indicator Extension Tip, 1 Starrett1
101.6 mm (4.00 in.) long
Illustration 5. 2600-0 Indicator, 0.01 mm 2 Starrett1
(.0005 in.) Resolution
1. LS Starrett Company
If the 3.175 mm (.1250 in) reading still cannot Phone: (978) 249-3551
be obtained, contact the Dealer Service Tools Web: www.starrett.com
hotline by phone (1-309-675-6277) or email
2. Carr-Lane Manufacturing Co.
dealerservicetool_hotline@cat.com to obtain
Phone: (314) 647-6200
further technical support contact information.
Web: www.carrlane.com

3. Renata Batteries
Storage Web: www.renata.com

• Hand tighten the bolts holding the

bearing preload adjuster to the base
plate. The springs of the bearing preload For information on service tools or shop supplies,
adjuster should never be stored in a contact Dealer Service Tools on:
compressed position.
Dealer Service Tools
• The tool and base plate should be 501 S. W. Jefferson
covered (kept in the original shipping Peoria, IL U.S.A. 61630-2125
box) to keep out dirt and moisture. U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
• A light coating of oil is recommended to Canada: 1-800-523-8665
World: 1-309-675-6277
prevent rust. Fax: 1-309-494-1355
• Store in a clean, dry environment. dealerservicetool_hotline@cat.com

©2006 Caterpillar NEHS0920-02

All Rights Reserved Printed in U.S.A.