PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SERVICE BRAKE ON CERTAIN 825K SOIL COMPACTORS AND 826K LANDFILL COMPACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SERVICE BRAKE ON CERTAIN 825K SOIL COMPACTORS AND 826K LANDFILL COMPACTORS

Usage:

TEBE2520-00

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28Jan2015

U-35

A-23

D-32

O-33

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SERVICE BRAKE ON CERTAIN 825K SOIL COMPACTORS AND 826K LANDFILL COMPACTORS
4251		PI11007

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI11007" as the Part Number and "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 "PI11007" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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PROBLEM

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The service brake assembly needs to be reworked on certain 825K and 826K Compactors. The existing service brake may result in reduced braking capability over time and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
825K	23300257, 5005 SEE00201, 204
826K	23200256-00257, 6001, 6006-6012, 6014-6015, 6017-6018, 6020, 6022 SET00300-00301

PARTS NEEDED

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Qty	Part Number	Description
48	8T0666	BOLT-HEX HEAD
2	1953722	PLATE-OUTER (Before Failure Only)
2	2010737	DISC-FRICTION (Before Failure Only)
2	3818291	PISTON (Before Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 Service Manual as necessary.

Before beginning any repairs park the machine in a safe working area on level ground. Refer to the Operation and Maintenance Manual for additional safety requirements before making any repairs.

1. The service brake group needs to be reworked. Refer to the attached Rework Procedure.

2. Inspect and replace existing friction discs according to UENR3840, Testing and Adjusting, 824K Wheel Dozer, 825K Soil Compactor and 826K Landfill Compactor Machine Systems.

3. The service brake functionality needs to be inspected and tested after the Rework Procedure is completed. Refer to the SEBU9110, Operation and Maintenance Manual, and UENR3840, Testing and Adjusting, 824K Wheel Dozer, 825K Soil Compactor and 826K Landfill Compactor Machine Systems.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 43.0-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.

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SERVICE BRAKE

MODELS INVOLVED - CERTAIN 825K SOIL COMPACTORS AND 826K LANDFILL COMPACTORS

Dear Cat Product Owner:

The service brake needs to be reworked on the products listed below. The existing service brake may result in reduced braking capability over time and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 28Jan2015 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 28Jan2015 Service Letter

Rework Procedure

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Complete for left and ride side:

1. Remove the final drive cover. Remove the final drive sun gear and axle shaft. Remove the final drive. Check piston assembly (1) part number to ensure that 381-8291 Piston Assembly is installed. If 381-8291 Piston Assembly is not installed, remove existing piston assembly and install a 381-8291 Piston Assembly.

Refer to the section below: "Disassembly of the Brake Piston" for removal of the piston assembly.

2. Remove the damper plate. The damper plate will not be reused. Inspect and replace existing friction discs according to UENR3840, Testing and Adjusting, 824K Wheel Dozer, 825K Soil Compactor and 826K Landfill Compactor Machine Systems.

3. Install a fourth 201-0737 Friction Disc and 195-3722 Outer Plate (Reference 433-3465 and 433-3466 Brake Group). Assemble the final drive assembly, tighten to a specified torque of 1000 +/- 125 N.m.

4. Assemble the axle shaft and sun gear. Assemble the final drive cover and tighten to a specified torque of 270 +/- 40 N.m.

Refer to Image1.1.1.

Image1.1.1

Disassembly of the Brake Piston:

Note: Personal injury can result from being struck by parts propelled by a released spring force.

1. Make sure to wear all necessary protective equipment.

2. Follow the recommended procedure and use all recommended tooling to in order to release the spring force.

3. Position piston assembly (2) into a suitable press.

4. Use Tooling (B), and the suitable press, in order to compress springs (13). Compress springs (13) and remove retaining pins (12) from spring guides (11). Release the pressure from the suitable press.

5. Remove springs (13) and spring guides (11) from piston assembly (2).

Refer to Images1.2.1 and 1.2.2.

Image1.2.1

Image1.2.2

6. Remove O-ring seal (14) from piston housing (15). Refer to Image1.3.1.

Image1.3.1

7. Remove piston (16) from piston housing (15). Refer to Image1.4.1.

Image1.4.1

8. Remove D-ring seal (17) from piston housing (15).

Image1.5.1

9. Remove D-ring seal (18) from piston housing (15). Refer to Image1.6.1.

Image1.6.1

Installation Procedure:

1. Install piston and piston housing (15) in the reverse order of removal.

Note: Lockpatch bolt: Material is for a single use only and assembly should be completed within 10 minutes. Further turning of the fastener after initial assembly should be avoided. For service, the internal thread should be cleaned of the adhesive remnants and a new replacement screw with thread lock procured. If situation requires reuse of fastener, clean the internal and external threads and apply Loctite 242 or Loctite 243 - Anaerobic Adhesive.