The Rear Axle Brakes Need To Be Relocated To The Front Axle On Certain 834B And 836 Compactors Caterpillar

The Rear Axle Brakes Need To Be Relocated To The Front Axle On Certain 834B And 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 "PI3978" 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 "PI3978" 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

October 31, 1997

Termination Date

April 30, 1998

Problem

The rear axle brakes need to be relocated to the front axle on certain 834B and 836 Compactors. Moving the brakes to the front axle will provide improved brake line protection in a landfill environment.

Affected Product
Model & Identification Number

834B (92Z453)

836 (3RL1-111)

Parts Needed

1 - 1422279 Brake Group - Front

Action Required

See the attached procedure.

Owner Notification

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

Service Claim Allowances

NOTE: This is a 52-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter 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

1. Place machine on level surface, install articulation safety link, properly raise and support machine with jack stands, and remove all four wheels.

2. Remove all brake lines, guarding, and the junction block from the rear axle.

3. Remove the hose assembly from the rear axle to brake control manifold and install the 9S4188 Plug and 4K1388 Seal into port.

4. Remove the final drives with brakes from rear axle and the final drives without brakes from front axle. Reinstall the final drives with brakes on the front axle. Reinstall the final drives without brakes on the rear axle. Use new 1H8278 Seals.

5. Remove brake bleeder, adapter, tube, and hardware from final drives. Remove guard plate that bleeder mounted to and replace with new 1425047 Plate Assembly, using new 5P1075 Washer and 0S1594 Bolt (tighten to 47 N·m). Replace bleeder, adapter tube and hardware with new parts: 9F2167 Screw, 1V7443 Adapter, 4R5844 Washer, 5B3254 Nut (tighten to 70 N·m), 1V7439 Tube Assembly, 3J7354 Seal, and 3J7352 Connector.

6. Remove brake line below tube and hardware from final drives. Replace with new parts: 6V8639 Connector, 3K0360 Seal, 8E5375 Tube Assembly, 6V8398 Seal, 6V9169 Nut (tighten to 370 N·m), 8T4123 Washer, 8E5147 Plate Assembly, 5D1753 Washer, 9M1974 Washer, 0344160 Bolt (tighten to 25 N·m), and 6V8988 Elbow.

7. Remove existing right and left hand triangular guards and replace with new 1425998 and 1425999 Guard Assemblies using new 5P1076 Washer and 8T4835 Bolt (tighten to 105 N·m).

8. Install new 1V8074 Junction Block to front axle using new 2V7964 Plate and new 8T4896 Washer, 4L6459 Bolt, and 6V8801 Nut (tighten to 47 N·m).

9. Install new 6V8639 Connectors into junction block using new 3K0360 Seals.

10. Install new 8E5366 and 8E5369 Brake Line Tubes using new 6V8398 Seals.

11. Position 4B0418 and 1B3057 P-clips on tubes. See Section G-G and section A-A as an installation guide.

12. Install new 1425044 and 1425048 Right and Left Hand Plate Assemblies using 5P1075 Washer, 4L9337 Bolt (tighten to 47 N·m). Use care to assure bolts retain the 4B0418 P-clips under the plate assembly.

13. Install 1434608 Plate Assembly using 8T4896 Washer and 4L6454 Bolt (tighten to 47 N·m). Use care to assure bolt retains 1B3057 P-clip under plate assembly.

14. Install 1425043 Plate Assembly to existing guard plate and new 1425044 and 1425048 Plate Assemblies using 5P1075 Washer and 4L6454 Bolt (tighten to 47 N·m).

15. Install new 1425045 and 1425046 Right And Left Hand Plate Assemblies to cover new 1425044, 1425048, and 1434608 Plate Assemblies using 5P1075 Washer and 4L6454 Bolt (tighten to 47 N·m).

16. Remove existing shipping link storage brackets from top of front frame hitch plate and grind smooth.

17. Weld on new 1435976 Plate (6 mm fillet weld, low hydrogen process) to front frame top hitch plate as shown in Illustration 2.

NOTE: This step is not required if you are implementing PS8904.

18. Weld on 5K1586 Tapped Bar (5 mm fillet weld, both sides, low hydrogen process) to top of rear frame hitch plate as shown in Detail F.

19. Install 2V2175 Manifold using 8T4896 Washer and 7X0290 Bolt (tighten to 47 N·m).

20. Remove existing tube assembly from brake control manifold and install new 1267986 Hose Assembly with new 4J0520 Seal, 4J5267 Seal, 1P4576 Flange, 1P4577 Flange, 8T4896 Washer, 5S7382 Bolt, and 9B7237 Bolt (tighten both bolts to 47 N·m). Restrain hose to transmission using 2V7963 Angle Assembly, 4S4455 P-Clip, 8T4896 Washer, and 5M3062 Bolt, and 9B7237 Bolt (tighten both bolts to 47 N·m) as shown in Section B-B.

21. Route new 1267987 Hose Assembly through trolley using new 6V1874 Grommet. Install hose using new 4J5267 Seals, 1P4576 Flange, 8T4896 Washer, 5S7382 Bolt and 9B7237 Bolt (tighten both bolts to 47 N·m).

22. Replace fluid and bleed brakes.

23. After completing all rework activities, reinstall the steel wheels and 6V7742 Nuts. (Tighten nuts to 570 N·m).

24. Test and adjust the brake system using the SENR2612 Service Manual.

Illustration 1