PRODUCT SUPPORT PROGRAM FOR UPDATING THE ROTATING MANIFOLD AS. ON CERTAIN GLL B-SERIES LOGGING GRAPPLES Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE ROTATING MANIFOLD AS. ON CERTAIN GLL B-SERIES LOGGING GRAPPLES [REBE1962]

HYDRAULIC SYSTEM

ROTATOR GP

PRODUCT SUPPORT PROGRAM FOR UPDATING THE ROTATING MANIFOLD AS. ON CERTAIN GLL B-SERIES LOGGING GRAPPLES

REBE1962-00

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11Jun2007

U-248

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE ROTATING MANIFOLD AS. ON CERTAIN GLL B-SERIES LOGGING GRAPPLES
6307 6326		PS42427

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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 "PS42427" 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 AVSpare product analyst.

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TERMINATION DATE

30Jun2008

PROBLEM

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Certain GLL B-Series rotating Forestry Grapples are experiencing failures of the Center Rotate Manifold (270-5102). The failures are caused by hydraulic pressure build up in the small air cavities at both ends of the manifold. The pressure separates the manifold housing from the manifold spool, and loosens or damages the internal wear plate bolts (M10 x 1.5) and the external end cap bolts (M5 x .8).

Replacement rotate motors have been assembled with the incorrect hardware for mounting the pinion gear. The incorrect hardware interferes with the grapple body and may result in premature rotate motor shaft failure.

Performing this service letter adds pressure vents to both ends of the manifold to relieve pressure, and the rotate motor will be inspected for incorrect hardware.

AFFECTED PRODUCT

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Model	Identification Number
GLL52	GRD00501-00503, 520-529, 532-540
GLL55	GRH00502-00503, 507, 521, 523-524, 527, 533
GLL60	A3D00501-00506, 508-513, 521-537, 540-545, 547-558, 562-567, 569-570

PARTS NEEDED

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Qty	Part Number	Description
1	6F7316	BOLT
1	7X0517	WASHER-HARD
1	3068076	KIT-SERVICE

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-5000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-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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MANIFOLD REMOVAL FROM GLL B GRAPPLE

Refer to D & A manual RENR6658, Rotator Manifold ? Remove. Caution: manifold weighs 54 lbs (24 kg). Use lifting device or 2 people to lift manifold.

MANIFOLD DISASSEMBLY

Step one: Remove all dirt, grease and oil from manifold. This is required to prevent contamination during disassembly.

Step two: Remove qty 6 end cap bolts (2). Remove manifold end cap (3).

Image1.2.1

Step three: Remove stop plate (4) and o-ring from groove in manifold housing.

Image1.3.1

Step four: Remove nylon thrust washer (6), qty 4 wear plate bolts (5), and wear plate (7).

Image1.4.1

Step five: Remove second nylon thrust washer (8).

Image1.5.1

MANIFOLD ASSEMBLY

Step one: Wipe exposed surfaces of spool and housing clean. Do not use solvent or degreaser.

Step two: Using new parts provided in 306-8076 service kit, assemble first nylon thrust washer, wear plate, second nylon thrust washer, and qty 4 wear plate bolts. Apply a medium strength thread locker to bolts and tighten to 35 +/- 6 lb ft. Align flat faces of the hex head bolts, and place the stop plate in the center.

Step three: Assemble o-ring supplied in parts kit to groove on manifold housing. Apply a light coating of grease to hold o-ring in place.

Step four: Assemble new end cap 305-8110 and qty 6 end cap bolts supplied in kit. Assemble without grease under end cap. New bolts are 5mm longer. Ensure that old bolts are discarded and not reused. Apply a medium strength thread lock to bolts and tighten to 51 +/- 9 lb in (4.25 +/- 0.75 lb ft).

Step five: Thread pressure check valve (2) 305-8111 into 1/8-27 NPT hole in end cap (1). Tighten fitting to a torque no greater than 12 lb ft. Fitting will not thread all the way down until hex flats are flush with bottom of counter-bore. It should thread far enough that the pressure relief valve is recessed into the counter-bore and protected. Touchup paint as needed to prevent rust.

Image1.6.1

Step six: Remove 1/8-27 NPT plug (3) from manifold spool cap. Discard and replace with second check valve supplied in parts kit. Tighten fitting to a torque no greater than 12 lb ft. Fitting will not thread all the way down until hex flats are flush with O.D. of spool cap.

Image1.7.1

MANIFOLD INSTALLATION INTO GLL B GRAPPLE

Refer to D&A manual RENR6658, Rotator Manifold ? Install. Caution, manifold weighs 54 lbs (24 kg). Use lifting device or 2 people to lift manifold.

ROTATE MOTOR

Step One: Remove rotate motor. Refer to D&A manual RENR6658, Gerotor Motor - Remove

Step Two: Some rotate motors (268-2792) have been assembled with the incorrect hardware for mounting the pinion gear to the motor shaft.

The incorrect mounting hardware (1) consists of a bolt, flat washer, and split lock washer. The use of this hardware will cause interference between the gear mounting bolt and the body of the grapple. This interference may result in premature motor shaft failure.

The incorrect bolt, flat washer, and lock washer must be removed and NOT reused. The correct mounting hardware consists of Bolt 6F-7316 and Washer 7X-0517.