Procedure to Install a New Drive Axle group on Certain CP/CS Compactors{3282} Caterpillar

Paving Compactor:

CP-533 (S/N: 3ZL1-UP; 5AL1-UP)

CP-533C (S/N: 3XN1-UP; 3YN1-UP)

CP-563C (S/N: 5JN1-UP; 5KN1-UP)

CS-533 (S/N: 3BL1-UP; 4HL1-UP)

CS-533C (S/N: 2WN1-UP; 2XN1-UP)

CS-563 (S/N: 8XF1-UP; CGG1-UP)

CS-563C (S/N: 4KN1-UP; 4LN1-UP)

CS-573C (S/N: 6LN1-UP)

CS-583C (S/N: 7NN1-UP)

Vibratory Soil Compactor:

CP-563 (S/N: 1YJ1-UP; 5AJ1-UP)

Introduction

Disregard Special Instruction, REHS4559 18 August, "Procedure to Install a New Axle on Soil Compactors" and instead refer to the following Special Instruction.

A new 315-1260 Drive Axle Gp is now used on the machines listed above. The 315-1260 Drive Axle Gp replaces the 117-7531 Axle , 138-2497 Axle , 136-8872 Drive Axle Gp , and 168-8693 Axle , which are not equipped with brakes.

The 286-0873 Drive Axle Gp replaces the 117-7530 Axle , 136-8873 Axle , 136-8874 Drive Axle Gp , 138-2496 Axle , and 168-8694 Axle , which are equipped with brakes.

The Special Instruction provides the necessary information in order to install a 315-1260 Drive Axle Gp on the machines listed above.

Note: Machines equipped with the axle brakes may require additional parts and modifications, which are not covered in this Special Instruction.

Important Safety Information

Note: Do not perform any procedure in this Special Instruction until you read the information and you understand the information. Do not order any parts until you have read the information and understand the information.

Clean all surfaces and remove burrs from all areas where parts are to be installed. Chase all tapped holes used for mounting purposes.

Work safely. 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 must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Reference

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceOperation and Maintenance Manual, KEBU7569, "Tire Inflation Pressure Adjustment"

ReferenceDisassembly and Assembly Manual

Required Parts List

Procedure to Install the New Drive Axle Group

1. Move the machine to a smooth level surface.

2. Stop the engine.

3. Remove the wheel assemblies from the machine. Refer to Disassembly and Assembly, "Wheel Assembly, Remove & Install Wheel Assembly" for your machine.

4. Drain the axle and planetary oil.

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Illustration 1	g03644732

5. Support the axle propel motor (A) with a hydraulic jack. Remove the four bolts and washers for axle propel motor (A) to planetary. Separate axle propel motor (A) from the planetary.

6. Remove the drive axle from the machine. refer to Disassembly and Assembly, "Axle, Remove & Install Axle" for your machine.

7. Discard the axle, and mounting hardware.

   Note: The weight of the axle is 385 kg (849 lb).

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Illustration 2	g03644738
(C) 270.8 mm (10.66 inch) (D) 162 mm (6.4 inch) (E) 108.1 mm (4.25 inch) (F) 54.1 mm (2.13 inch) (G) 108.6 mm (4.27 inch) (H) 32 mm (1.2 inch) (J) 80 mm (3.1 inch) (K) 150 mm (5.9 inch) (L) 21.5 mm (0.85 inch) of diameter on four location (M) 30 mm (1.2 inch) (N) 4.9 mm (0.19 inch) (P) 167.1 mm (6.58 inch) (R) 10 mm (0.4 inch)

8. Fabricate two mounting plates (B) as per dimensions shown in Illustration 2.

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Illustration 3	g03644739
Top view of frame assembly (S) 162 mm (6.4 inch) (T) 1110 mm (43.7 inch) (U) 80 mm (3.1 inch)

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Illustration 4	g03645348

9. Position fabricated plates (B) to the top side of mounting plate (V) for both sides. The hole locations must match the dimensions as shown in Illustration 3.

10. Mark the location for new holes on mounting plates (V) and remove fabricated plates (B) .

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Illustration 5	g03645376

11. Slot the existing holes (X) of mounting plate (V) to the marks.

    Note: Holes (X) on the axle mounting plate must be slotted. The slotted holes can be made by using a torch. The hole diameter should be 22.0 ± 0.5 mm (0.87 ± 0.02 inch).

12. Verify that the axle aligns with the slotted holes.

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Illustration 6	g03645377
(W1) 3 mm (0.1 inch) fillet weld on all around the plate surface

13. Weld fabricated plates (B) to the top side of mounting plate (V) for both sides as per dimensions shown in Illustration 6.

    Note: The axle can also be used as a template to mount the mounting plates on the axle mounts.

    Note: The weight of the new axle weighs a minimum of 470 kg (1036 lb).

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Illustration 7	g03645400
(1) 315-1260 Drive Axle Gp (2) 9X-2475 Bolt (3) 8T-4123 Washer (4) 8T-4131 Nut

14. Position the new drive axle group (1) under the frame. Secure drive axle group (1) mounts using eight bolts (2), eight washers (3), and eight nuts (4) .

15. Tighten bolts (2) in a crisscross pattern to 460 ± 60 N·m (339 ± 44 lb ft).

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Illustration 8	g03645401
(5) 095-0924 Retaining Ring

16. Install retaining ring (5) to the axle pinion shaft groove.

Note: The final drive planetary group (6) needs to be oriented with the magnetic drain plug facing downward.

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Illustration 9	g03645402
(1) 315-1260 Drive Axle Gp (6) 203-4692 Final Drive Planetary Gp (7) 5H-6734 O-Ring Seal (8) 8S-4734 Bolt (9) 7X-0510 Hard Washer

17. Install final drive planetary group (6) to drive axle group (1) with new O-ring seal (7).

18. Secure final drive planetary group (6) to drive axle group (1) using six bolts (8) and six hard washers (9). Before assembly, apply blue Loctite 242 to the threads of the bolts (8). Tighten bolts (8) to a standard torque.

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Illustration 10	g03645404
(10) 7J-6285 O-Ring Seal

19. Install axle propel motor (A) that was saved in Step 5 with new O-ring seal (10) .

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Illustration 11	g03645405

20. Remove filler plug (Y) of center axle housing fill with 14.5 L (3.8 US gal) of 2P-9869 Oil (SAE30) and 0.5 L (0.13 US gal) of 185-0783 Oil (Additive). Tighten filler plug (Y) to 80 ± 15 N·m (59 ± 11 lb ft).

    Note: The Axle lubricant also provides lubricant to the 203-4692 Final Drive Planetary Gp through the axle housing.

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Illustration 12	g03645407

21. Fill 229-5051 Final Drive Planetary Gp (Z) with 1.75 L (0.5 US gal) of 2P-9869 Oil (SAE30). Tighten filler plugs to 60 ± 12 N·m (44 ± 9 lb ft).

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Illustration 13	g03645409
(11) 203-4741 Wheel (12) 077-3895 Valve Stem Cap (13) 077-3906 Valve Stem Nut (14) 077-4192 Valve (15) 201-1919 Nut (16) 8T-5439 Hard Washer

22. Install tires with two wheels (11), two valve stem caps (12), two valve stem nuts (13), two valves (14), 20 nuts (15), and 20 hard washers (16). Refer to Operation and Maintenance Manual, KEBU7569, "Tire Inflation Pressure Adjustment" for tire pressure and liquid ballast.

23. Raise the machine with a suitable lifting device and remove the stands.