PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SUPPORT PLATE ON CERTAIN SW60 WHEEL SAWS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SUPPORT PLATE ON CERTAIN SW60 WHEEL SAWS

Usage:



REBE5994-00

03May2010


U-154
A-121
O-142

 
Priority
  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SUPPORT PLATE ON CERTAIN SW60 WHEEL SAWS

6712
PI31740
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31740" 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 "PI31740" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.


COMPLETION DATE

TERMINATION DATE

30Nov2010 31May2011

PROBLEM

The 2278128/">227-8128 Support Plate needs to be replaced on certain SW60 Wheel Saws. The existing support plate can fail. This in turn may result in complete failure of the main frame structure, if not replaced as soon as possible.

AFFECTED PRODUCT

Model Identification Number
SW60  WLS00302-00344

PARTS NEEDED

Qty

Part Number Description
1 1H6227 SEAL-O RING
1 0689932 RING-RETAINING
1 0950928 RING-RETAINING
1 2278126 BEARING (After Failure Only)
1 2278128 PLATE-SUPPORT
1 2278129 SEAL-SHAFT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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

Refer to the attached Rework Procedure.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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

 NOTE: This is a 6.0-hour job


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SUPPORT PLATE

MODELS INVOLVED - SW60 Wheel Saws

Dear Caterpillar Product Owner:


The support plate needs to be replaced on the products listed below. The existing support plate can fail at the weld between the plate and shaft. If the support plate fails and it is not replaced, the main frame may start to fail at the motor attachment points. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 03May2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.



Caterpillar Inc.

Identification #(s)



Attached to 03May2010 Service Letter


Rework Procedure


 
Removal.

Refer to your machines service manual as needed/required during this procedure.

Some of this rework procedure is performed with the wheel saw attached to the skid steer loader, use safety struts where possible. The weight of the complete wheel saw is around 1200 Kg (2640 Lbs) be sure any lifting equipment you use is able to lift this weight.
 
1. With the wheel saw attached to the skid steer loader, fully side shift the wheel to the right hand side. Position with the wheel on the ground under a lifting crane capable of the maximum weight. Lower the depth control guides down to the minimum depth setting (Image 1.2.1).
Image1.2.1
 
2. Loosen the top retaining nut for the RH side of the depth control cylinder (Image 1.3.1).
Image1.3.1
 
3. Remove the circlip retaining the bottom end of the RH side of the depth control cylinder and pull the cylinder of the pin (Images 1.4.1 and 1.4.2).

NOTE: It may be helpful to remove the side deflector plate for better access.
Image1.4.1
Image1.4.2
 
4. Remove the plate connecting the 2 adjuster frames at the rear, 6 bolts in total (Image 1.5.1). Remove the plate connecting the 2 adjuster frames at the front (Image 1.5.2).
Image1.5.1
Image1.5.2
 
5. Enter the skid steer loader and work the auxiliary lines to raise the depth control guides. This will retract the RH cylinder assembly in item 3 and raise the depth control frame on the LH side.
 
6. Completely remove the top retaining nut for the RH side depth control cylinder and then using cable ties secure the cylinder out of the way.
 
7. Remove the top bolt on the RH depth control frame as illustrated and fit a lifting eye with M12 thread. Attach lifting device to the eye and take the weight (Image 1.8.1).
Image1.8.1
 
8. Remove the 5 bolts retaining the RH flat guide plate for the depth control frame (Image 1.9.1). This RH frame should be free to lift clear, remove and store flat.
Image1.9.1
 
9. Remove the 5 nuts that secure the motor studs to the wheel (Image 1.10.1).
Image1.10.1
 
10. Remove the 4 bolts that secure the bearing housing to the RH side main frame (Image 1.11.1).
Image1.11.1
 
11. Make sure that both of the park stand legs are lowered to the ground and that the park stand legs and the wheel are all in contact with the ground (Image 1.12.1).
Image1.12.1
 
12. Connect 3 lifting chains to the wheel saw lifting points as illustrated, 2 on the rear frame and 1 on the upper main frame at the front. Take the weight with the crane (Image 1.13.1). Disconnect all of the hydraulic lines from the skid steer loader and remove the wheel saw from the skid steer loader coupler.
Image1.13.1
 
13. With the wheel saw supported by the crane carefully lower it down onto the RH side but be sure to use wooden blocks or appropriate supports to allow it to sit in a secure flat position (Image 1.14.1).
Image1.14.1
 
14. Remove the nut retaining the top of the LH side depth control cylinder (Image 1.15.1).
Image1.15.1
 
15. With the nut removed push down the LH side depth control frame complete with the cylinder still attached at the lower end.
 
16. Remove the bolts that secure the hydraulic motor (Image 1.17.1). Remove 2 bolts opposite each other from the motor cover plate and attach 2 lifting eyes with M16 threads (Image 1.17.2).
Image1.17.1
Image1.17.2
 
17. Using the lifting equipment carefully lift the motor and place to one side with some protection under the studs. The hoses can be left connected to the motor (Image 1.18.1).
Image1.18.1
 
18. Remove 2 teeth at 180 degree intervals on the wheel (Image 1.19.1).
Image1.19.1
 
19. Attach 2 lifting link eyes to these 2 teeth holders and lift the wheel carefully inside the main frame. Maneuver the wheel out of the frame and then turn it over to access the bearing and support plate (Image 1.20.1 and 1.20.2).
Image1.20.1
Image1.20.2
 
20. Remove the ring of bolts securing the support plate to the wheel (Image 1.20.2). Lift the support plate and bearing housing to a clean bench area. Remove the circlip securing the bearing cover (Image 1.21.1).
Image1.21.1
 
21. Remove the grease nipple and insert a M10 X 1 bolt, screwing in this bolt will push out the cover (Image 1.22.1).
Image1.22.1
 
22. With the cover removed you can now access and remove the circlip and spacer ring in the bearing housing (Images 1.23.1 and 1.23.2).
Image1.23.1
Image1.23.2
 
23. Using a puller remove the bearing support off of the shaft of the support plate being careful not to damage the housing seal on the underside (Image 1.24.1).
Image1.24.1
 
Installation.

Before completing the installation of the new support plate, check that the bearing and seal in the housing are in good condition. If any doubt, replace both the bearing and seal.
 
1. With the new support plate cleaned and prepared on the bench, fit the bearing housing to the support plate using a tube over the shaft down onto the inner bearing race. Either use a press or soft hammer to seat the bearing fully (Image 1.26.1).
Image1.26.1
 
2. Insert the spacer ring and fit the new circlip. If necessary, add some additional grease trough the grease point on the side of the housing (Images 1.27.1 and 1.27.2).
Image1.27.1
Image1.27.2
 
3. Fit a new O-ring to the bearing cover and fit the cover to the housing using a new circlip. Install the grease nipple removed earlier (Image 1.28.1).
Image1.28.1
 
4. With the support plate and bearing housing fully assembled, it is ready to install back onto the wheel using the original M14 bolts. These need to be tightened in a diagonal pattern to a torque of 110 Nm +/- 10 Nm (Image 1.29.1).
Image1.29.1
 
5. Lift the wheel as before with the lifting equipment and first turn the wheel over. Swing the wheel carefully back into position in the main frame sitting it centrally to allow access to fix the motor in place. Note that at this stage you need to make sure the bearing housings flat edge (as indicated by red line on Image 1.30.1) sits on the plate inside the main frame.
Image1.30.1
 
6. Lift the motor with the lifting equipment and move into position over the wheel making sure the studs align through the wheel holes. Align the motor fixing holes with the frame and install the M22 bolts. Tighten the bolts down in 2 stages using a crossing pattern to a torque of 446 Nm +/- 40 Nm (Images 1.31.1 and 1.31.2).
Image1.31.1
Image1.31.2
 
7. Remove the 2 lifting eyes from the motor and re-fit the 2 M16 bolts. Tighten the bolts to a torque of 210 Nm +/- 21 Nm. Slide the LH depth control frame up so that the upper end of the cylinder can be fixed to the main frame (Image 1.32.1).
Image1.32.1
 
8. Connect 3 lifting chains to the wheel saw lifting points as illustrated, 2 on the rear frame and 1 on the upper main frame at the front. Carefully raise the wheel saw back up to its upright position to stand on the wheel and rear support stands (Image 1.33.1).
Image1.33.1
 
9. Install the 4 bolts and nuts to secure the bearing housing to the frame and tighten to a torque of 240 Nm +/- 20 Nm (Image 1.34.1). Ensure the bearing housing sits on the support bar and up against the inside of the frame.
Image1.34.1
 
10. Using Loctite 270 fit the nuts onto the motor studs (Image 1.35.1). In a crossing pattern and over 3 stages of torque, tighten these nuts to a torque of 860 Nm. These nuts can be accessed through a hole in the main frame (Image 1.35.2). To help ease of access to these nuts, it will help if you lift the wheel slightly clear of the ground to allow you to rotate the wheel into a better position.
Image1.35.1
Image1.35.2
 
11. Re-attach the wheel saw back onto the skid steer loader and remove the lifting chains. Position the wheel saw in the working horizontal position (Image 1.36.1).
Image1.36.1
 
12. Lift into place the RH side depth control frame and fit the RH flat guide plate for the depth control frame (Image 1.37.1).
Image1.37.1
 
13. Fit the depth control cylinder to the lower point first and secure with the circlip. Raise the depth control frame to allow the upper end of the cylinder to be fixed to the main frame (Images 1.38.1 and 1.38.2).
Image1.38.1
Image1.38.2
 
14. Fit the front and rear depth control frame connecting plates (Images 1.39.1 and 1.39.2).
Image1.39.1
Image1.39.2
 
15. If either deflector plates were removed, install the deflector plates (Image 1.40.1).
Image1.40.1
 
Reconnect all hydraulic lines to the skid steer loader and test.
 
 

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