Product Support Program For Reworking The Rear Axle Bolted Joints On Certain 826G Compactors And 980G Custom Product Landfill Machines Caterpillar

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4648" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from Parts Stock as soon as possible.

Termination Date

Problem

The rear axle bolted joints need to be reworked on certain 826G Compactors and 9 Gosselies built 980G Custom Product Landfill Machines. In certain applications, the rear axle pinion housing to differential carrier bolted joint and/or the trunnion thrust plate to trunnion bolted joint may work loose under load.

Affected Product
Model & Identification Number

826G (7LN1-450)

980G (9CM615, 9CM735, 9CM780, 9CM1012, 9CM1039, 9CM1069, 9CM1096, 9CM1134, 9CM1177)

Parts Needed

1 - 8F5900 Seal - O-ring

16 - 5P8247 Washer

10 - 5P8248 Washer

1 - 6V6640 Sealant

16 - 1608509 Bolt (M16)

10 - 1608510 Bolt (M20)

Action Required

Affected Product

See the attached Rework Procedure.

Parts Stock

Rework all 1098941 Differential Bevel Gear Group from Parts Stock. See the attached Rework Procedure.

Service Claim Allowances

Affected Product

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

The problem and rework is confined to the rear oscillating axle only. Parts Stock rework is confined to the 1098941 Rear Differential And Bevel Gear Group - no spin only.

For the Affected Product rework, follow the complete rework procedure Steps 1 through 15. For Parts Stock rework, follow Steps 3 through 9.

For all rework, refer to the instructions in the Power Train Disassembly and Assembly Service Manual SENR1330. For parts reference, refer to the 1098939 Axle Arrangement - Oscillating and the 1098941 Differential Group - No Spin in Parts Manual SEBP2406.

1. Remove the rear axle arrangement from the machine following the instructions in the Disassembly and Assembly Service Manual.

2. Remove the drive shaft yoke and front support from the differential pinion shaft housing following the instructions in the Disassembly and Assembly Service Manual. Inspect the front support bearing sleeve and seals. Replace if damaged.

3. Place the rear axle housing assembly on wood blocks with the differential pinion facing upward. (For Parts Stock rework, place the differential and bevel gear group in a repair stand with the differential pinion facing upward.)

4. Remove and discard the sixteen 6V5686 Bolts and washers holding the differential pinion shaft housing to the bevel gear group carrier assembly.

5. Remove two bolts (180 degrees apart) that hold the seal retainer to the pinion shaft housing. Install two M10 forged eyebolts in their place. Fasten a hoist to the eyebolts.

6. Install two M16 forcing screws in the pinion shaft housing mounting flange. Loosen the pinion shaft housing from the bevel gear group carrier assembly. Remove the pinion shaft housing assembly as a unit. The weight of the housing assembly unit is 77 Kg (170 lb). Save the shim pack for reuse.

7. Remove any dirt and oil from the bevel gear group carrier assembly internal threads. Inspect the threads for damage. Repair if needed.

8. Replace the 8F5900 Seal - O-ring at the pinion shaft housing mounting flange with a new seal. Lightly lubricate the seal. Using the original shim pack previously removed, assemble the pinion shaft housing assembly to the bevel gear group carrier assembly.

9. Assemble dry, sixteen 1608509 Bolts with new 5P8247 Washers to the mounting flange. Do not lubricate the bolt threads or carrier assembly internal threads. Tighten all sixteen bolts to 105 ± 20 N·m (78 ± 15 lb ft). Check the first few bolts tightened to see if they held correct torque. Turn all sixteen bolts an additional 120 ± 10 degrees.

NOTE: The 1608509 Bolts are high strength. Do not substitute. The bolts have a pre-applied thread lock patch. If the thread lock patch was removed during shipping and handling, add a small amount of high strength 1549731 (10 ml bottle) or 1550695 (50 ml bottle) Thread Lock to the bolt threads before assembly.

10. Reposition the rear axle arrangement, same orientation as the axle sits in machine, for access to the rear trunnion bolted joint.

11. Remove the rear support from the axle trunnion following the instructions in the Disassembly and Assembly Service Manual. Inspect the rear support bearing sleeve, thrust bearings and seals. Replace if damaged.

12. Discard the ten 6V3532 bolts and washers holding the thrust plate to the trunnion. Remove any dirt and oil from the trunnion internal threads. Inspect the threads for damage. Repair if needed.

13. Assemble the rear support to the trunnion following the instructions in the Disassembly and Assembly Service Manual. Install dry, ten 1608510 Bolts and 5P8248 Washers to assemble the thrust plate to trunnion. Do not lubricate the bolt threads or trunnion internal threads. Tighten all ten bolts to 210 ± 40 N·m (155 ± 30 lb ft). Turn all ten bolts an additional 120 ± 10 degrees.

NOTE: The 1608510 Bolts are high strength. Do not substitute. The bolts have a pre-applied thread lock patch. If the thread lock patch was removed during shipping and handling, add a small amount of high strength 1549731 (10 ml bottle) or 1550695 (50 ml bottle) Thread Lock to the bolt threads before assembly.

14. Complete the assembly of the rear support following the instructions in the Disassembly and Assembly Service Manual. Apply 6V6640 sealant to the mating surfaces of the rear support and cover.

15. Following the instructions in the Disassembly and Assembly Service Manual, assemble the rear axle arrangement to the machine. Bleed the brake system, fill the axle with oil, reassemble machine guarding, reassemble the compactor wheels and test the machine.