PRODUCT SUPPORT PROGRAM FOR REWORKING THE LOWER ELEVATOR IDLER BEARINGS ON CERTAIN 613C WHEEL TRACTOR-SCRAPERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE LOWER ELEVATOR IDLER BEARINGS ON CERTAIN 613C WHEEL TRACTOR-SCRAPERS

Usage:

REBE2344-00

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25Sep2007

U-480

D-384

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE LOWER ELEVATOR IDLER BEARINGS ON CERTAIN 613C WHEEL TRACTOR-SCRAPERS
6241		PS42520

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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 "PS42520" 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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TERMINATION DATE

30Sep2009

PROBLEM

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The existing elevator idlers can fail on certain 613C Wheel Tractor-Scrapers. If the existing idler bearings fail they can seize the lower idler assembly and inhibit the elevator function.

AFFECTED PRODUCT

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Model	Identification Number
613C II	8LJ02500-03376

PARTS NEEDED

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Qty	Part Number	Description
2	3J9133	BEARING-SLEEVE
1	8I1098	SHAFT (IF NEEDED)
4	8J8258	WASHER-HARDENED
4	9J0113	WASHER
2	3098819	BEARING

ACTION REQUIRED

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The bearings in the lower idler assemblies of the elevator will be replaced to increase the service life of the idler assemblies on each side of the elevator. The elevator chains will be broken and the bottom of the elevator will be reworked one side at a time.

Refer to the attached Rework Procedure.

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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%
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 8.0-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.

Rework Procedure

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1) Place blocking underneath the scraper bowl to elevate the lower portion of the elevator to an accessible position.

2) Loosen both elevator chains by adjusting the top elevator idlers. Remove an elevator flight if needed to provide space to break the elevator chains apart. The chains and flight group may have to be tied down to the elevator frame to prevent it from sliding off of the elevator frame once the chains are broken.

Note: Be sure the elevator is secured in the bowl while performing the next rework steps. This can be done by leaving one lower elevator arm connected to the frame at all times to prevent the upper elevator arms from loosely pivoting the elevator forward in the scraper bowl.

3) Disassemble the lower elevator assembly on one side by unbolting a lower elevator support arm from the hub on the frame. Remove the hub and lower elevator idler assembly from the elevator roller shaft.

Image1.1.1

Image1.1.2

4) Inspect the 8I1098 Shaft (E) along the surface the idlers ride. If the bearing surface is damaged or excessively worn, the shaft will need to be replaced.

Remove the two internal bearing sleeves that are pressed in the roller assembly.

5) Replace the 3J-9133 Bearing-Sleeve (B) with a new one in each of the lower elevator idlers.

Replace the 9J-0112 Bearing-Sleeve with a new 309-8819 Bearing (C) in each of the lower elevator idlers.

6) The elevator assembly can now be reassembled. Swab the lip seal surfaces of the frame with the roller lubricating grease. Install the lip seals back into the elevator frame?s lower tube assembly. Make sure that the lip seals on both sides of the roller are positioned so that they face the roller with their openings toward each roller. Refer to the illustration above. Install the elevator roller assembly back onto the roller shaft.

7) Adjust the roller shims so that 3mm of total endplay exists for the roller along the shaft by adding or removing shims. Use 8J8258 Washer Hardened (A) and 9J0113 Washers (D) as needed.

8) When installing the (6) bolts at the end of the roller shaft, use blue thread compound and torque the bolts in a sequence as many cycles as required until full torque value is achieved.

9) Use 5P0960 GREASE-A3M or comparable grease for lubricating the rollers. Lubricate the elevator idlers until grease moves past the lip seals. The idler should rotate freely. Rotate it to help distribute the grease internally and reapply grease as needed.

10) Perform steps 3-9 to the other side of the elevator assembly.

11) Remove the screw and brass plug located in the middle of the lower elevator frame tube and reinstall it using blue thread lock. Do not tighten it enough to where it presses against the roller shaft.

12) Finish by reconnecting the chains, adjusting the chain tension, and installing the elevator assembly into the scraper bowl.