SUBJECT: SuperStackers. Front Undercarriage Replacement.

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On SuperStackers impacted by this service bulletin, there is a possibility that the front undercarriage could be compromised. KPI-JCI is requiring replacement of the front undercarriage on these units.

Inspect the front undercarriage for unusual wear, deformation, or raising and lowering irregulaties. If these conditions exist, or if binding, gouging, or popping occurs, discontinue use and contact KPI.

Note: Before completing this procedure, please consider the tools you have available as well as the site where service will be done. You will be removing all pins from the front undercarriage and lowering it to the ground (from the travel position).

It’s important that adequate lifting devices are available for this procedure. See Weights section for more information.

Make sure this procedure is done safely and properly.

SuperStacker Front Undercarriage Assembly - Cylinder guards have been removed. SuperStacker is in the fully raised position for clarity.

Front Undercarriage

Cylinders - one on each side

Lift Tubes

Note: Red circles indicate ar-eas where material buildup may be causing unusual gouging, popping, and binding of the lift tubes when raising or lower-ing the SuperStacker. Inspect and clean material buildup from these areas.

Weight at this end • 1000 lbs (old)• 1200 lbs (new)

Service BulletinSerial Numbers 412551-414315*

(*only 36150 and 30150 units in this serial number range are affected)

March 10, 2015rev. 1 April 16, 2015

SB 053 1503 MTL SST

Tools/Equipment Needed

• Front Undercarriage Replacement Kit (see order sheet)

• Rags and bucket for cleaning hydraulic oil• Wheel chocks• Standard set of wrenches• Lifting device (forklift, loader, service truck

crane - capable of lifting 3000 lbs.)• Portable lifting device or come-along• Lifting chains• Prybar• Soft mallet hammer• Line-up bar• Drill and 7/16” drill bit

Weights• Lift Tubes - 1000 lbs.• Front Undercarriage - 1400 lbs.• Cylinder Guards - 60 lbs.• Cylinders - 350 lbs. (total weight)

Note: The updated front undercarriage assembly will increase the travel axle weight by approximately 550 lbs.

Use the following procedure to remove the front undercarriage.

1. Make sure extended frame is retracted.

2. Raise SuperStacker high enough to place 6 x 8 wood blocks (included with the kit) between the gull wing axle and the main frame. Wood blocks should be pushed all the way out to the chord angles. Refer to the picture for clarity.

The 8” part of the block should be placed horizontal on the gull wing axle support.

3. Lower conveyor down onto wood blocks. Hold down the control for one minute after contact with blocks.

4. Either use wheel chocks to block the travel tires or lower the gull wing until it just con-tacts the ground but does not raise the main frame.

5. Lockout/tagout all power to the SuperStacker.

6. Unbolt and remove mudfl ap brackets (if installed) from SuperStacker.

7. Unbolt and remove the cylinder guards.

8. With a 7/16” wrench, loosen the plug two turns. Wait for pressure to be relieved.

Do not remove the plug completely. Oil will spill from the cylinders - use a rag to keep area clean and a bucket to catch excess oil.

After pressure has been relieved, retight-ten the plug.

CAUTIONFluid may be under pressure. Be careful when loosening cylinder plug. Make sure you are wearing proper hand and eye pro-tection.

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SB 053 1503 MTL SST March 10, 2015

SB 053 1503 MTL SST March 10, 2015

9. Use the service truck crane or other por-table lifting device to attach lifting chains to the cross angles on the main frame. Lower lifting hook and attach to lifting eye on the cylinder.

10. Unbolt and remove the pin connecting the cylinder to the front undercarriage. A pry-bar and hammer may be needed to help remove the pin.

Note: Only remove the upper pin from each cylinder.

11. Carefully lower cylinder to the ground.

12. Disconnect lifting device from cylinder and repeat steps 9-12 for the other cylinder.

13. Position lifting device to support the upper end of the front undercarriage. The weight at this end is 1000 lbs.

• If you have a forklift or loader, position the forklift under the front undercarriage on one side.

• If you have a service truck crane, use lifting chains capable of lifting 3000 lbs and attach to the lifting eye on the left side of the front undercarriage.

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14. If you are using lifting chains to support the upper end of the front undercarriage, make sure they are tight and tensioned so that it will suspend the assembly securely when all pins have been removed.

15. Unbolt and remove pins connecting the upper end of the front undercarriage to the main frame.

16. Slowly lower front undercarriage to the ground.

17. Install a come-along to the center cross-member on the lower end of the front undercarriage to support the lift tubes.

18. Unbolt and remove pins connecting the lift tubes to the gull wing axle.

19. Move the existing front undercarriage out of the way.

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SB 053 1503 MTL SST March 10, 2015

SB 053 1503 MTL SST March 10, 2015

New Front Undercarriage InstallationWhen installing the new front undercarriage, make sure the front undercarriage is balanced when lifting, transporting, and installing. Refer to the picture below for the front undercarriage’s center of gravity. Use the following guidelines when lifting the new front undercarriage to prevent any damage:

• Lift by outer main tube members only• Keep assembly horizontal, otherwise the

inner lift tubes could slide out• Be careful not to damage any members

welded on the top and bottom of the main outer tube

When installing the new front undercarriage, install pins in this order:

• Lift tube pins• Front Undercarriage pins• Cylinder pins

When connecting the new front undercarriage to the main frame, the weight of the new front undercarriage is 1200 lbs. at each pin location.

When installing the new front undercarriage, reuse the lift tube pins and pins that connect the front undercarriage to the main frame. New washers and bolts are included with the kit.

New pins with new bolts and washers are included in the kit for the cylinders.

Line-up bars will help line up the pin holes.

Note: You may either need to loosen the plug at the end of the cylinder to collapse it to help when installing the cylinders to the new front undercarriage, or you may use a come-along to help line up the cylinders to the front undercarriage.

20. Remove lockout/tagout.

21. Raise the SuperStacker so that you can remove the wood blocks from the Gull Wing support.

22. Lower SuperStacker onto the Gull Wing support.

23. Cycle the front undercarriage cylinders up and down to verify everything is operating properly.

24. Match drill new 7/16” bolt holes in the cylin-der guards. Refer to the drawing included with this bulletin for location of new bolt holes.

25. Bolt cylinder guards to the front undercar-riage. See drawing for bolt orientation.

26. Reinstall mud fl ap brackets.

27. Grease cylinder pins with 5 pumps of grease for each cylinder.

28. Destroy the old front undercarriage after procedure is complete.

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Please send to:

Name:

Address:

City: State: Zip:

Attn:

Serial Number:

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Check the boxes below and return to KPI-JCI.

Order one kit per SuperStacker

Send ______ Front Undercarriage Replacement kit 36150 (p/n 373474)

Parts and 10 hours total labor will be covered under KPI-JCI warranty.

Please order immediately and complete as soon as possible.

KPI-JCI700 W 21st. St.Yankton, SD 570781-800-532-9311Fax: 1-605-665-9348Email: warranty@kolbergpioneer.com

Send ______ Front Undercarriage Replacement Kit 30150 (p/n 373483)

SB 053 1503 MTL SST March 10, 2015