Product Support Program For Installing New Drum Bearing Housings On Certain CP563 And CS563 Vibratory Compactors Caterpillar

Product Support Program For Installing New Drum Bearing Housings On Certain CP563 And CS563 Vibratory Compactors

Usage:

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Caterpillar: Confidential Yellow

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.

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4845" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use " T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use " Z" as the SIMS Description Code

NOTE: This Revised Service Letter replaces the October 23, 1992 Service Letter. Changes have been made to the Affected Product and Action Required.

Termination Date

October 31, 1994

Problem

The 077-3308 Tapered Bearing, 6R1279 Shaft Assembly, or 7X8006 Shaft Assembly on certain CP563 and CS563 Vibratory Compactors may fail.

Affected Product

Group 1
Model & Identification Number

CP563 (1YJ1-241, 1YJ243, 1YJ244, 1YJ246, 1YJ249, 1YJ253-255, 1YJ257, 1YJ258, 1YJ260, 1YJ261)

CS563 (8XF1-236, 8XF238-487)

Group 2
Model & Identification Number

CP563 (5AJ1-58, 5AJ60, 5AJ61)

CS563 (7GG1-43, 7GG45-117, 7GG119-145, 7GG148-158, 7GG168-174, 7GG176, 7GG177)

Group 3
Model & Identification Number

CP563 (1YJ263, 1YJ264, 1YJ270, 1YJ275, 1YJ277, 1YJ279, 1YJ280, 1YJ282, 1YJ284, 1YJ290)

CS563 (8XF489-536, 8XF540, 8XF543, 8XF545, 8XF550, 8XF555, 8XF578, 8XF580, 8XF582, 8XF585)

Group 4
Model & Identification Number

CS563 (7GG195)

Parts Needed

Groups 1 And 2

1 - 4C5300 Sealant

2 - 9F2247 Pipe Plug

1 - 1G7437 Shaft

4 - 1G9730 Plate

4 - 1G9738 Plate

2 - 1G9741 Retainer plate

8 - 1G9742 Seal

1 - 1G9778 Pilot ring

1 - 1G9909 Washer

1 - 1G9910 Spindle

1 - 1G9911 Washer

1 - 1G9912 Nut

4 - 4H1394 Washer

1 - 7H3171 Plug

8 - 2K4973 Nut

8 - 4L6454 Bolt

16 - 5P1075 Washer

1 - 5P2503 Cup-Roller

1 - 5P2504 Cone-Roller

8 - 8T2502 Bolt

8 - 8T4896 Washer

1 - 8T9011 Solvent

1 - 8T9014 Sealant

4 - 8T9399 Bolt

4 - 2V0936 Washer

1 - 7X8285 Gasket

1 - 9X7421 Seal

4 - 2Y5671 Washer

4 - 005787 Washer

1 - 300060 Cup

1 - 300061 Cone-Roller

4 - 773308 Tapered Bearing

1 - 773637 Seal

2 - 774684 Shaft, Shim

1 - 776630 Seal

4 - 1010002 Washer, Shim

NOTE: On CP563 1YJ1-262 and 5AJ1-56, and on CS563 8XF1- 487 and 7GG1-188, use a 1G7974 (Formerly 7X8008) (LH) Weight Shaft Assembly or 1G7976 (Formerly 6R1279) (RH) Weight Shaft Assembly, if after failure and out of specification.

On CP563 1YJ263 and Up and 5AJ 57 and Up, and on CS563 8XF488 and Up and 7GG189 and Up use 1G7977 or 1G7978 Weight Shaft Assembly. Refer to June 29, 1992 Service Magazine article, "New Weight Shafts Improve Compaction".

Use 1G9399 Bearing Housing (formerly 982233 or 1G5667), 1G9400 Bearing Housing (formerly 7X8013 or 1G5669), 1G9401 Bearing Housing (formerly 7X8014 or 1G5668) as required.

Groups 3 And 4

1 - 4C5300 Sealant

2 - 9F2247 Pipe Plug

4 - 1G9730 Plate

4 - 1G9738 Plate

2 - 1G9741 Retainer plate

8 - 1G9742 Seal

1 - 1G9778 Pilot ring

1 - 1G9909 Washer

1 - 1G9910 Spindle

1 - 1G9911 Washer

1 - 1G9912 Nut

4 - 4H1394 Washer

1 - 7H3171 Plug

8 - 2K4973 Nut

8 - 4L6454 Bolt

16 - 5P1075 Washer

1 - 5P2503 Cup-Roller

1 - 5P2504 Cone-Roller

8 - 8T2502 Bolt

8 - 8T4896 Washer

1 - 8T9011 Solvent

1 - 8T9014 Sealant

4 - 8T9399 Bolt

4 - 2V0936 Washer

1 - 7X8285 Gasket

1 - 9X7421 Seal

4 - 2Y5671 Washer

4 - 005787 Washer

1 - 300060 Cup

1 - 300061 Cone-Roller

4 - 773308 Tapered Bearing

1 - 773637 Seal

2 - 774684 Shaft, Shim

1 - 776630 Seal

4 - 1010002 Washer, Shim

Use 1G9399 Bearing Housing (formerly 982233 or 1G5667), 1G9400 Bearing Housing (formerly 7X8013 or 1G5669), 1G9401 Bearing Housing (formerly 7X8014 or 1G5668 as required.

Action Required

When performing and oil change or other maintenance, inspect the drum serial number. The drum serial number is a four-digit number located on the vibratory motor side of the machine, on the inside of the drum shell, along the weld seam. If the drum serial number is followed by a "Z1" or "Z2" no further action is required - the drum has already been updated.

A Scheduled Oil Sample (SOS) reading may be used to assist in determining the condition of the bearings. Take an oil sample from the drum of the compactor after rotating the drum to obtain a representative sample. Analyze the oil sample to identify the condition of the bearings. The following chart shows the readings based on the oil being changed every 1000 hours.

NOTE: Copper readings by themselves should not be used as an indicator of bearing condition. Copper is a result of the brass cage wearing against the outer bearing race. Copper in combination with iron, increasing to the limits listed in the chart, is an indicator of bearing wear. Silicon readings are normally a result of dirt entry or due to assembly.

Refer to Special Instruction SEHS9514, "Installation of Vibratory Bearing Housing Plate Assemblies " for the disassembly and assembly of the vibratory drum. This Special Instruction includes information for the installation of plate assemblies to improve lubrication of the drum bearings.

NOTE: Affected product in Groups 2 and 4 require the oil passage ways for the two inner drum heads (Items 2) be inspected and the gap (Item 6) between the head (Item 2) and the drum shell (Item 1) be filled with weld. After welding, the repaired areas should be cleaned and painted. Refer to the Illustrations.

NOTE: The drums should be thoroughly cleaned prior to assembly.

The following housing bore, shaft and bearing dimensions should be verified before assembly to assure correct interference and slip fits exist:

NOTE: The dimension between the two weight shafts and bearing inner race is designed to be a slip fit. Failure to have a slip fit will lead to loss of shaft end play and may cause bearing end loading and eventual failure.

NOTE: The 7X8006 Shaft between the two weight shaft assemblies should be replaced with a 1G7437 Shaft during assembly of affected product in Groups 1 and 2.

NOTE: Do not install the 1G5239 or the 9X0761 Breather into the drum support gear box during assembly. Replace the breather with a 7H3171 Plug.

NOTE: The 9X7421 Seal should be installed under the 7R3145 Magnetic Sensor in the drum support gearbox.

Refer to Special Instruction SEHS9493 "Drum Support Gearbox Modification " for installation of a new 1G9910 Spindle with a new 1G9912 Retaining Nut. Install one 9F2247 Pipe Plug into the outer face edge of the 1G9910 Spindle, and another 9F2247 Pipe Plug into the flange outer edge of the 1G9910 Spindle.

NOTE: After the drum is reworked, add the characters "Z2" after the four-digit drum serial number.

NOTE: Both weight shaft assemblies should be inspected for the weld shown in the Illustrations. The two plates should be welded continuously to minimize debris from accumulating between the plate and weight and causing possible future contamination.

Illustration 1