Procedure to Provide the New Inboard Ski Device on Certain Cold Planers{5645} Caterpillar

Cold Planer:

PM-200 (S/N: P1C1-UP)

PM200 (S/N: P1M1-UP)

Introduction

This Special Instruction will provide the necessary steps to install the new Inboard Ski device on certain PM-200 Cold Planer. Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts or perform any work.

Safety Section

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DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS. FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH. CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS. PROPER CARE IS YOUR RESPONSIBILITY.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

Required Parts

Installation Procedure

Illustration 1	g03256896

Attach a "Do not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer.

Machine Preparation

1. Park the machine on level ground.

2. Move the rotor control switch to the OFF position.

3. Reduce engine speed.

4. Apply the parking brake.

5. Raise the machine to the full UP position. Then install the rear leg supports. Refer to the Operation and Maintenance Manual, "Service Support (Leg Locks)"

6. Stop the engine. Turn the engine start switch key to the OFF position. Then remove the key.

7. Turn the battery disconnect switch to the OFF position. Then remove the key. Place lockout/tag out in the battery disconnect switch.

Rotor Chamber Rework

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Illustration 2	g03257540
(1) Rotor chamber location

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Illustration 3	g03257547
(2) Rotor chamber location (right) (H) Reference edge of ear tab

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Illustration 4	g03257552
(3) Rotor chamber location (left) (H) Reference edge of ear tab

1. Locate the work area on the front side of rotor chamber (1) .

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Illustration 5	g03257559
(A) 138.5 ± 3 mm (5.5 ± 0.120 inch) (H) Reference edge of ear tab (4) 282-3742 Plate

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Illustration 6	g03257656
(B) 81.9 ± 3 mm (3.25 ± 0.120 inch) (H) Reference edge of ear tab

2. Locate plate (4) location with measurement (A) and measurement (B) on rotor chamber (2) .

3. Tack weld plate (4) into place.

4. Weld plate (4) with an 8 mm (0.315 inch) fillet weld.

5. Repeat Steps 2 through 4 on the location (3) .

Anti-Slab Rework

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Illustration 7	g03258319

1. Locate the work area on the front side of antislab plate (5) .

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Illustration 8	g03258336
Right-hand side Anitslab plate (6) Antislab Plate (C) 120.6 mm (4.75 inch) (D) 70 mm (2.75 inch) (E) 158.2 mm (6.23 inch) (F) 339 mm (13.35 inch)

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Illustration 9	g03258337
Left-hand side Anitslab plate (6) Antislab Plate (C) 120.6 mm (4.75 inch) (D) 70 mm (2.75 inch) (E) 158.2 mm (6.23 inch) (F) 339 mm (13.35 inch)

2. Locate and mark the four hole locations using measurements (C), D, E and F.

3. Drill four 13.5 mm (0.5 inch) holes on the antislab plate.

4. Repeat Steps 1 through 3 on the opposite antislab plate.

Inboard Ski Mounting Procedure

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Illustration 10	g03258738

1. Mount 392-1552 Tube As (7) to the chamber plate (left and right side position) by using 8T-4196 Bolt (8) and two 7X-7729 Washer per bolt.

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Illustration 11	g03258776

2. Install 392-1555 Tube As (10) on 392-1552 Tube As (7) (left and right) by using 134-9621 Handle (11), 131-8195 Bolt (12) and 146-9410 Collar (13) .

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Illustration 12	g03260057
(14a) 392-1548 Plate (14b) 392-1549 Plate

3. Mount 392-1548 Plate (14a) to the right side antislab plate by using 8T-4186 Bolts (15), 8T-4133 Nuts (16) and 7X-7729 Washers (9) .

4. Mount 392-1549 Plate (14b) to the left side of the antislab plate by using 8T-4186 Bolts (15), 8T-4133 Nuts (16) and 7X-7729 Washers (9) .

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Illustration 13	g03260136
()

5. Mount 392-1544 Tubes (17) on to 392-1548 Plate (14a) using 162-8352 U-Bolts (18), 392-1550 Plates (19), 8T-4133 Nuts (16) and 7X-7729 Washers (9) .

6. Mount 392-1544 Tubes (17) on to 392-1549 Plate (14b) using 162-8352 U-Bolts (18), 392-1550 Plates (19), 8T-4133 Nuts (16) and 7X-7729 Washers (9) .

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Illustration 14	g03260436

7. Mount the 392-1547 Plate As (20) on to 392-1544 Tubes (17) on the right and left-hand side. Mount by using 268-3212 Bolts (21), 7X-0510 Hard Washers (22), 9S-0798 Bushings (23), 096-4876 Nuts (24) and .

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Illustration 15	g03260578

8. Lock the mount to 392-1547 Plate As (20) on to 392-1544 Tubes (17) on the right and left-hand side using 8B-1056 Clevis Pins (22) and 5P-8837 Lock Pins (26) .

Ground Clearance Adjustment (2.0m Rotor Chamber)

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Illustration 16	g03260601

1. Remove bolts (27) and washers (28) form guard (29) on the upper right side of the rotor chamber.

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Illustration 17	g03260656

2. Reassemble guard (29) by using 7X-2537 Bolts (30), 5P-4116 Hard Washers (31) and 6V-3964 Hard Washers (32). Adjust guard (29) to provide clearance larger or equal to 12 mm (0.470 inch) with the frame in order to take out sensor harness.

Ground Clearance Adjustment (2.2m Rotor Chamber)

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Illustration 18	g03260839

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Illustration 19	g03260841

1. Aging on bolts (33) on the upper right side of the rotor chamber, adjust guard (34) to provide clearance larger or equal to 12 mm (0.470 inch) with the frame in order to take out sensor harness.