The Frame And Wheels May Need To Be Reworked To Prevent Wear Due To Trapped Debris On Certain 836 Compactors Caterpillar

The Frame And Wheels May Need To Be Reworked To Prevent Wear Due To Trapped Debris On Certain 836 Compactors

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Caterpillar: Confidential Yellow

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 must be administered as soon as possible. When reporting the repair, use "PI3774" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3774" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Completion Date

January 31, 1996

Termination Date

July 31, 1996

Problem

Debris may become trapped between the wheels and frame assemblies causing increased loading at the wheel face and premature wear of the wheel side plates on certain 836 Compactors.

Affected Product
Model & Identification Number

836 (3RL26-75)

Parts Needed

Dealers will need to order parts for this Program.

Wheel Rework

32 - 1169269 Bar

Engine Frame Rework

2 - 1219239 Plate

Non-Engine Frame Rework

Not Applicable

Action Required

See the attached procedure.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

Wheel Rework

NOTE: This is an 8-hour job.

Engine Frame Rework

NOTE: This is a 16-hour job.

Non-Engine Frame Rework

NOTE: This is a 16-hour job.

NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

Parts Disposition

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

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

This Program involves three separate reworks:

1. Wheel Rework

2. Engine-Frame Rework

3. Non-Engine Frame Rework

Each rework has two major sections - an inspection to determine the need for the rework, and the actual procedures to accomplish the rework. All three of the reworks also involve removing and installing the wheels. Once an inspection has been made and it is determined that a particular rework needs to be performed, refer to the Wheel Removal section to remove the wheels. After performing all the reworks needed, refer to Wheel Installation section to install the wheels back on the machine.

Wheel Removal

1. Place two hydraulic jacks under the machine as defined in the "Disassembly and Assembly" guide. The estimated weight at the axle is 23650 Kg (52030 lbs.) when equipped with a Caterpillar dozer and Caterpillar wheels.

NOTE: Work on only one axle at a time.

2. Lift machine until the wheels are off the ground.

3. Put blocks under the axle housing to help secure the machine while on the jack stands.

4. Attach a chain or slings around the wheel and secure it to a hoist. The estimated weight of the wheel is 2800 Kg (6370 lbs.).

5. Remove the nuts and washers that hold the 1014330 Wheel Assembly to the axle assembly.

6. Lift the wheel assembly off the studs and remove it from the axle.

7. Fasten the wheel to a stationary support to prevent the wheel assembly from moving.

Wheel Installation

1. Attach a chain or slings around the wheel and secure it to a hoist. The estimated weight of the wheel is 2800 Kg (6370 lbs.).

2. Lift the compactor wheel onto the studs.

3. Install the nuts and washers that hold the 1014330 Wheel Assembly to the axle assembly and tighten to a torque of 475 ± 50 N·m (350 ± 35 lb. ft.).

4. Remove the blocks from under the axle housing.

5. Lower the machine and remove the jacks.

Wheel Rework

NOTE: This rework procedure provides details for adding wiper bars to the inside face of Caterpillar wheels needed to prevent debris build up between the wheel's inner side plate and the frame. Inspection guidelines and repair procedures are provided for wheels that exhibit wear due to the debris trapped between the wheel and the frame. These procedures must be performed on all four wheels of 836 Compactors equipped with 1014330 Wheel Assemblies. This Program does NOT apply to non-Caterpillar, after-market wheels.

Inspection

1. Measure the distance from the outer edge of the wheel's inner wrapper plate to the vertical side wall face of the wheel at three separate locations.

NOTE: The distance between measurements should be equally spaced around the circumference of the wheel's inner wrapper plate.

2. If the dimension is 14 mm or larger, perform Procedure D.

3. If the dimension is 11 mm to 14 mm, perform Procedure C, then perform Procedure D.

4. If the dimension is 7 mm to 11 mm, perform Procedure B, then perform Procedure D.

5. If the dimension is less than 7 mm, perform Procedure A, then perform Procedure D.

Wheel Rework

Procedure A

1. Cut end of inner wrapper flush with the inner side wall face of the wheel.

2. Cut a ring to the following dimensions.

a. Outer diameter is 830 ± 2 mm (32.67 ± .08 in.).

b. Inner diameter is 770 ± 2 mm (30.31 ± .08 in.).

c. Plate thickness is 16 mm (.625 in.)

NOTE: The ring may be made in 3 equal length segments.

3. Add a 10 ± 2 mm (.39 ± .08 in.) chamfer to the exposed corner of the inner wrapper plate.

4. Tack the ring (or ring segments) to the edge of the inner wrapper plate. The ring segments must cover the complete circumference of the inner wrapper.

5. Fill the "V" groove between the ring and the inside diameter of the inner wrapper with weld until flush with the inner diameter of the wrapper plate.

6. Add a 12 mm (.5 in.) fillet weld to the outer diameter of the ring and the side face plate of the wheel.

7. Go to Procedure D.

NOTE: The wiper bars added in Procedure D will need to have the length shortened to 393 ± 2 mm (15.47 ± .08 in.) to provide proper clearance with the added ring support.

Procedure B

1. Form a 10 mm (.375 in.) diameter steel rod to match curve of the inner wrapper plate. The inner diameter is 778 ± 2 mm (30.63 ± .08 in.).

2. Tack the formed rod to the edge of the inner wrapper plate. The rod must cover the complete circumference of the inner wrapper.

3. Fill the "J" groove between the formed rod and the inside diameter of the inner wrapper with weld until flush with the inner diameter of the wrapper plate.

4. Fill the J groove between the formed rod and the side plate. Next, build the existing weld up to a 12 mm (.50 in.) fillet weld.

5. Go to Procedure D.

Procedure C

1. Build up the edge of the inner wrapper with weld material until the edge is 16 ± 2 mm from the inner face of the wheel assembly.

2. Go to Procedure D.

Procedure D

1. Locate eight 1169269 Bars on the inner side wall face of the 1014330 Wheel Assembly. The bars must be positioned radially (running from the inner wrapper plate to the outer wrapper plate) and equally spaced (typically 45° spacing) as shown in Illustration 1.

NOTE: 836 S/N 3RL40-75 were shipped with an interim wheel assembly that has one wiper bar fastened to the inner face. These machines require only seven 1169269 Bars to be added instead of the eight bars stated in Step #1.)

2. Weld with an 8 mm (.31 in.) fillet weld with 1.5 mm (.06 in.) penetration along both long edges of the 1169269 Bars.

3. Fill the gaps between the two ends of the bar and the inner and outer wrapper plates with a 16 mm butt weld.

4. Mount the wheel to the axle.

Placement Of The Wheel Wiper Bars
Illustration 1

Engine-End Frame Rework

NOTE: This rework procedure provides details for removing the rear axle guards from 1014315 Engine End Frame on the 836 Compactor to minimize the debris build up between the wheel's inner side plate and the frame.

Inspection

1. Look between rear Wheel Assembly and Engine Frame Assembly.

2. If the frame has a welded guard assembly that closes the gap between the Engine End Frame and the inner edge of the Wheel then, this rework is required.

3. Remove the wheels as described in the Wheel Removal section.

Engine-End Frame Rework

1. Refer to Illustration 2 to the cut the following plates:

1026575 Plate, from left side of Frame Assembly

1014325 Plate, from right side of Frame Assembly

1014320 Plate, from both sides of Frame Assembly

1014324 Plate, from both sides of Frame Assembly

1014323 Plate, from both sides of Frame Assembly

2. Trim the following plates:

1014321 Plate, on both sides of Frame Assembly (Illustration 3)

1014322 Plate, on both sides of Frame Assembly (Illustration 4)

3. Add a 1219239 Plate to both sides of Frame Assembly (Illustration 5)

4. Install the wheels as described in the Wheel Installation section.

Remove Plates As Shown
Illustration 2

View A-A Before Guard Removal
Illustration 3

View B-B Before Guard Removal
Illustration 4

Illustration 5

Non-Engine Frame Rework

NOTE: This rework procedure provides details for removing the front axle guards from 1013544 Non-Engine End Frame of the 836 Compactor to minimize the debris build up between the wheel's inner side plate and the frame. This rework should be performed on all Affected Product except those with Custom Option 2Q3991.

Inspection

1. Look between the front wheel assembly and non-engine frame assembly.

2. If the frame has a welded guard assembly that closes the gap between the engine end frame and the inner edge of the wheel, perform this rework. Removal of these guards is subject to customer approval.

3. If there is evidence of accelerated wear on the side wall of the wheel or the edge of the inner diameter wrapper plate, this rework should be applied.

4. Remove the wheels as described in the Wheel Removal section.

5. Install the wheels as described in the Wheel Installation section.

Non-Engine Frame Rework

1. Refer to Illustration 6 and cut:

1008238 Plate, from both sides of Frame Assembly

1008232 Plate, from both sides of Frame Assembly

1008230 Bar, from both sides of Frame Assembly

5P2355 Gusset, from both sides of Frame Assembly

NOTE: Some dealers have left 1008232 Plate, the flat vertical plate attached to both sides of the frame assembly, to function as a wheel cleaner. Removal of this plate is optional.

2. Remove the 1008235 Guard Assembly (left-hand guard assembly) and the 1008233 Guard Assembly (right-hand guard assembly) from the 2Q2864 Front Guard Group as shown in Illustration 7.