PRODUCT SUPPORT PROGRAM FOR REPLACING THE TRANSMISSION OUTPUT TRANSFER GEAR GROUP ON CERTAIN 836G COMPACTORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TRANSMISSION OUTPUT TRANSFER GEAR GROUP ON CERTAIN 836G COMPACTORS

Usage:

REBE6460-01

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15Apr2011

(Revised 03Feb2012)

U-150

A-124

D-137

O-138

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TRANSMISSION OUTPUT TRANSFER GEAR GROUP ON CERTAIN 836G COMPACTORS
3159 3075		PS43265

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43265" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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 15Apr2011 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Apr2013

PROBLEM

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The existing output transfer gear group can have premature idler bearing failure on certain 836G Compactors. If the existing output transfer gear group fails the idler bearing it will require updating the output transfer gear group to the new idler bearing design.

AFFECTED PRODUCT

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Model	Identification Number
836G	7MZ00267-00299, 400-493, 75001-75007 BRL00270-00535, 75001-75008

PARTS NEEDED

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Qty	Part Number	Description
2	0S1594	BOLT
2	1P3705	SEAL-RECTANGULAR
1	2K4472	SEAL-O RING
1	2R6806	ADAPTER-STR
2	3D2824	SEAL-O-RING
3	3J1907	SEAL-O-RING
1	3J7354	SEAL-O-RING
2	3K0360	SEAL-O-RING
12	4J0522	SEAL-O-RING
8	4J0524	SEAL-O-RING
1	4J0527	SEAL-O-RING
1	5P2587	SEAL-O-RING
1	5P8245	WASHER-HARD
1	5P8286	SEAL-O-RING
1	6J2680	SEAL-O RING
1	6K9194	ADAPTER-ELBOW
2	6V5839	WASHER-HARD
4	6V8397	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
1	6Y6328	SHIM PACK
1	7L2181	SEAL-O RING
1	8M4443	SEAL-O RING
1	8M4986	SEAL-O RING
2	8M8157	SEAL-O-RING
2	8S8820	CLIP
1	9S1366	BOLT
1	10R4556	CORE AS (After Failure Only)
1	20R0128	CASE AS
2	0307955	ADAPTER-TEE
2	1240501	CONE-SPL TAPERED
2	1240502	CUP-SPL TAPERED
2	1334292	SEAL-LIP TYPE
2	1961185	SENSOR GP-SPD -A
1	2147568	SEAL-O-RING-STOR
1	3343888	GEAR-TRANSFER
2	3346034	BEARING AS-RLR
1	3407300	TUBE AS
1	3466619	CAGE AS.-BEARING
1	3466671	TUBE AS
1	3521571	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 8% 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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Refer to the Rework Procedure below.

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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%
0-8000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-10000 hrs, 61-100 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 40.0-hour job

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PARTS DISPOSITION

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

Return the cores as soon as possible in order to make sure parts will be available for the service letter.

Rework Procedure

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The return of the cores is very important to the success and availability of the parts for this service letter. Make sure the cores are returned as soon as possible.

Refer to RENR2183 "Disassembly and Assembly for 836G Landfill Compactor Power Train" for instruction on how to remove, disassemble, assemble, and install the power train.
Assembly of the drop box is documented in RENR6356 Disassembly and Assembly for the 836H Landfill Compactor Power Train. There are 2 version of the assembly process for the output transfer gears. Use the process for BXD1000-UP. This process documents the assembly of the case with the straight roller bearing on the idler gear.

Before/After Failure
Remove transmission from the machine following the steps in RENR2183. Separate the output transfer gear from the planetary following the procedure "Transmission from Input Transfer Gears and Output Transfer Gears ? Separate"
Output Transfer Gears - Disassemble
Follow the assembly process in RENR6356 for BXD1000-up (RENR6356)

The following steps are to provide additional support for installing the positive lube supply lines and fittings for the new bearing.

1. Install "Tee" part number 030-7955 in place of the 164-6877 Elbow callout 1 shown in image 1.1.1
2. Install "Tee" part number 030-7955 at callout 2 shown in image 1.1.1

Image1.1.1

3. Install 340-7300 Tube Assembly between the two "Tee" fittings, callouts 1 & 2
4. Install 164-6867 Connector Assembly and 6K-9194 Elbow at callout 5 as shown in Image 1.2.1
5. Install 346-6671 Tube Assembly between "Tee" fitting at callout 2 and elbow fitting at callout 5 as shown in 1.2.1
6. Additional clip and support brackets need to be installed to support the lines group. Image 1.2.1 illustrates the locations. callout 4 requires (1) 0S-1594 Bolt, (1) 6V-5839 Washer, and (1) 8S-8820 Clip. Callout 3 requires (1) 9S-1366 Bolt, (1) 5P-8245 Washer, and (1) 352-1571 Bracket Assembly. Callout 6 requires (1) 0S-1594 Bolt, (1) 6V-5839 Washer, and (1) 8S-8820 Clip.