PRODUCT SUPPORT PROGRAM FOR CHECKING AND REWORKING THE MACHINE INTERFACE MOUNTING FRAMES ON CERTAIN PC203, PC204, PC205, PC206 AND PC210 COLD PLANERS AND SW60 WHEEL SAWS Caterpillar

PRODUCT SUPPORT PROGRAM FOR CHECKING AND REWORKING THE MACHINE INTERFACE MOUNTING FRAMES ON CERTAIN PC203, PC204, PC205, PC206 AND PC210 COLD PLANERS AND SW60 WHEEL SAWS [REBE3445]

FRAME AND BODY

FRAME GP

PRODUCT SUPPORT PROGRAM FOR CHECKING AND REWORKING THE MACHINE INTERFACE MOUNTING FRAMES ON CERTAIN PC203, PC204, PC205, PC206 AND PC210 COLD PLANERS AND SW60 WHEEL SAWS

REBE3445-00

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05Mar2008

U-112

A-91

D-86

O-98

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR CHECKING AND REWORKING THE MACHINE INTERFACE MOUNTING FRAMES ON CERTAIN PC203, PC204, PC205, PC206 AND PC210 COLD PLANERS AND SW60 WHEEL SAWS
6634 6712		PS42637

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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 "PS42637" 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

31Mar2010

PROBLEM

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The existing 219-5390 Mounting Frame can be out of dimension on certain PC203, PC204, PC205, PC206 and PC210 Cold Planers and SW60 Wheel Saws. If the existing 219-5390 Mounting Frame has incorrect dimensions it could allow the planer or wheel saw to be loose on the SSL/MTL carriage and potentially fall off. The listed serial numbers need to be checked dimensionally and if incorrect reworked.

AFFECTED PRODUCT

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Model	Identification Number
PC203	PCB00191-00193
PC204	RDG00356-00366
PC205	RBG00450-00456, 460, 462, 464
PC206	DDG00598-00604, 606-607
PC210	GDR00343, 347-348, 350-351, 353-359, 361, 363
SW45	WWS00299

PARTS NEEDED

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No parts needed for this program

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%
0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.5-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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First you need to establish the interface dimension ?B? as shown below in Detail B. (Image 1.1.1 & 1.1.2)
It is also important that the LH and RH sides (as viewed from the normal driving position) are both measured, as there may be some variation from side to side.
STEP 1:
Establish dimension ?B? as shown in Detail ?B?. Please note, this dimension is critical and should be measured as accurately as possible, because it will impact the final fit up to the SSL. (See detail ?B? and ?C?)

Image1.1.1

Image1.1.2

To establish dimension ?B?, measure from the underside of the top mount plate on the interface as shown in Detail ?C? (point ?Z?) down to point ?X?. Record dimension ?B?. Check LH and RH dimensions they may vary.
See Image 1.2.1 to help with checking the dimmension.

Image1.2.1

If dimension ?B? is equal to, or less than 424mm, no rework is required.

If dimension ?B? is greater than 424mm, refer to table 1 (Image 1.4.1) for plate thickness to be used for rework.
Plate dimensions, (see illustration 1.4.2) length 250 mm (10"), Width 40 mm (1.5"), Plate Thickness: To be determined from table 1.
Use Mild Steel plate, SAE1020 or Grade 43A.
In order to ensure correct fit with the host SSL interface, it is vital that the correct thickness Mild Steel plate is welded to the individual sides, and that the assigned tolerances below are adhered to.

Image1.4.1

Image1.4.2

Steps to weld plates into place.
1. Grind the paint of areas to be welded and mark points to drill holes. (Image 1.5.1)
2. Drill 2 holes in the upper plate as shown below to increase the weld area available so the plate is not just welded along the front edge. (Image 1.5.2)
3. Clamp the correct thickness plate on the underside of the top interface plate, ensuring it is tight to the top and rear plates, as shown in Image 1.5.3.

Image1.5.1

Image1.5.2

Image1.5.3

4. Tack weld at 2/3 points along the front edge. Use some protection around the area during the welding process.
5. Having tacked both plates, refit the Planer or Wheel Saw to the SSL/MTL to ensure correct fit up with the coupler as explained in the next step below.
6. Check fit between coupler and work tool, see Image 1.6.1 to ensure that:
A. Locking pins engage correctly: - make sure levers are moved fully to the engaged position and visually check both coupler pins are extended out of the holes in the Work Tool mounting bracket. (See SSL OMM Work Tool Coupler Operation)
Make sure there is positive contact between the Work Tool and the angled side of coupler pin.
B. There is contact between SSL and Work Tool as shown.
(This is the normal contact area for all Work Tools)
C. There is clearance between SSL and Work Tool as shown.
(This is how all SSL/MTL Work Tools should fit, if fit up described above is not achieved re-check dimension ?B?)

Image1.6.1

7. If the fitup described above is OK then complete the welds in the 2 holes and along the front edge using the appropriate weld settings for the plate thickness being used. See Image 1.7.1.
8. Check on the underside of plate to ensure no excess weld is showing and dress as required.
7. Finally clean and paint all reworked areas.