Rework Procedure for Replacing the Electric Swivel{5060} Caterpillar

Material Handler:

MH3037 (S/N: KPM201-215)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified.

Problem

The Electric Swivel on certain MH3037 Material Handlers may seize or stick. These situations may damage the harnesses and cause a machine down situation. The failures may occur at low hours in all applications. The first sign of failure of the swivel is the machine position sensor reading incorrectly.

Solution

Replace failed Connector Gp with new 395-6590 Connector Gp . This new part has improved internal clearances that should mitigate the risk of seizing or sticking failure mode.

Required Parts

Rework Procedure

Procedure to replace the 395-5259 Swivel Gp with the 395-6590 Swivel Gp .

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Illustration 1	g03732891
Steering Wheels

1. Position the machine so that the upper frame is in line with the lower frame. Refer to Illustration 1.

2. Make certain that stabilizers are in the full down position and that cab is lowered to the ground. This action is necessary for zeroing the sensor on the new electric swivel after installation is completed.

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Illustration 2	g03731245
(A) Bottom Guard Plate (B) Right Side Rail

3. Remove the Bottom Guard Plate (A) and Right Side Rail (B) from the lower frame. This action will allow access to the electric swivel harness connector in the forward center section of the lower frame. Refer to Illustration 2.

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Illustration 3	g03731256
(C) Lower Frame Harness Connector (D) Electric Swivel Harness Connector

4. Disconnect Lower Frame Harness Connector (C) from Electric Swivel Harness Connector (D). Remove and retain the hardware holding electric swivel connector to frame so that the electric swivel connector can be removed from the frame. Refer to Illustration 3.

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Illustration 4	g03731282

5. Remove the wires from the electric swivel connector so that the harness can pass through the hydraulic swivel. Refer to Illustration 4.

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Illustration 5	g03731289
(E) Harness Assembly

6. Disconnect Harness Assembly (E) from control panel. Refer to Illustration 5.

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Illustration 6	g03731304
(F) Nut (G) Bracket

7. Remove Nut (F) and Bracket (G). Refer to Illustration 6.

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Illustration 7	g03731313
(H) Harness Connector

8. Disconnect the Harness Connector (H) to the position sensor of the electric swivel. Refer to Illustration 7.

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Illustration 8	g03731318
(J) Set Screws

9. Loosen the three Set Screws (J) on the electric swivel then unscrew the electric swivel from the nipple in the hydraulic swivel. Refer to Illustration 8.

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Illustration 9	g03731330
(K) Set Screw (L) Nipple (M) Electric Swivel (1) 005-8615 Pipe Nipple

10. Remove the four Set Screws (K) in the hydraulic swivel. Remove the Nipple (L) from the Hydraulic Swivel (M). Put blue Loctite on the threads of the new Nipple (1). Screw the new nipple into the hydraulic swivel and tighten. Put blue Loctite on the set screws and install and tighten the screws in the hydraulic swivel. Refer to Illustration 9.

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Illustration 10	g03731343
(4) Harness for 395-6590 Swivel Gp

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Illustration 11	g03731344
(K) Set Screw (M) Hydraulic Swivel

11. Feed the harness of Swivel Gp (4) through the nipple, the hydraulic swivel (M), and the hole in the bottom plate of the hydraulic swivel. Apply blue Loctite to the threads of the nipple. Screw the electric swivel onto the nipple. Apply blue Loctite to the Set Screws (K). Install and tighten the set screws in the electric swivel. Refer to Illustrations 10 and 11.

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Illustration 12	g03731351
(2) 096-4876 Nut (3) 395-6130 Plate As

12. Install the new Plate As (3) and Nut (2). Refer to Illustration 12.

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Illustration 13	g03731352

13. Install the wires of the harness from the electric swivel into the new connector. Wires are marked for pin location in the connector. Refer to Illustration 13.

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Illustration 14	g03731355
(C) Lower Frame Harness Connector (D) Electric Swivel Harness Connector

14. Install the Electric Swivel Harness Connector (D) in the bracket on the lower frame. Connect the Lower Frame Harness Connector (C) to the electric swivel harness connector and secure using hardware retained from Step 4. Refer to Illustration 14.

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Illustration 15	g03731359
(H) Harness Connector

15. Connect the electric swivel position sensor harness to the harness on the upper frame.

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Illustration 16	g03731361

16. Route the harness from the electric swivel along the frame to the control panel. Refer to Illustration 16.

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Illustration 17	g03731364
(E) Harness Assembly

17. Connect Harness Assembly (E) from the electric swivel to the control panel. Refer to Illustration 17.

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Illustration 18	g03731365
(A) Bottom Guard Plate (B) Right Side Rail

18. Reinstall the Right Side Rail (B) to the lower frame. Reinstall the Bottom Guard Plate (A) to the rails. Refer to Illustration 1.

MH3000 Zero Sensors

The sensor will have to be zeroed after the new electric swivel is installed. Use the following process to zero the sensor.

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Illustration 19	g03732897
(N) F2 Diagnostic Display

1. Select F2 Diagnostic Display (N). Refer to Illustration 19.

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Illustration 20	g03732900
(P) F2 Maintenance Display

2. Select F2 Maintenance Display (P). Refer to Illustration 20.

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Illustration 21	g03732915

3. Select F2 - Pin Code Box will be displayed.

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Illustration 22	g03732927
(R) Dial

4. Enter Maintenance Screen Code, 0000, by rotating Dial (R) to desired # and push enter in center of dial.

5. Select F2 for next.

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Illustration 23	g03732929
(S) F3 Maintenance Display 2

6. Select F3 Maintenance Display 2 (S). Refer to Illustration 23.

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Illustration 24	g03732939
(R) Dial

7. Rotate selector Dial (R) to select sensor number. Rotate Dial until display reads "1" and push the enter button in center of Selector Dial to select.

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Illustration 25	g03732944
(R) Dial

8. Rotate Dial (R) until display reads "1". Refer to Illustration 25.

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Illustration 26	g03732948
(R) Dial

9. Push enter button in center of Selector Dial (R) to select "1" – Zero Upper Lower Orientation. Refer to Illustration 26.

   Note: Section will change to green after selected

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Illustration 27	g03732961
(R) Dial

10. Push enter button in center of selector Dial (R) to zero the sensor. When enter button is pushed, "Zeroed" will be flash displayed in front of the sensor. Refer to Illustration 27.

    When zeroing the sensor the machine has to be positioned properly:

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    Table 2

    Sensor	Position
    1- Zero Upper Lower Calibration	Machine facing straight forward
    	Upper and lower in line with each other