PRODUCT IMPROVEMENT PROGRAM FOR ULTRASONIC INSPECTION OF STABILIZER CYLINDER RODS ON CERTAIN M300C and M300D SERIES WHEELED EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR ULTRASONIC INSPECTION OF STABILIZER CYLINDER RODS ON CERTAIN M300C and M300D SERIES WHEELED EXCAVATORS [REBE1422]

IMPLEMENTS

STABILIZER GP

PRODUCT IMPROVEMENT PROGRAM FOR ULTRASONIC INSPECTION OF STABILIZER CYLINDER RODS ON CERTAIN M300C and M300D SERIES WHEELED EXCAVATORS

REBE1422-00

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15Nov2006

U-741

A-708

D-694

O-722

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR ULTRASONIC INSPECTION OF STABILIZER CYLINDER RODS ON CERTAIN M300C AND M300D SERIES WHEELED EXCAVATORS
5468		PI10558

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10558" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10558" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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PROBLEM

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Due to variations in the friction welding process of the stabilizer cylinder eye to cylinder rod connection on M313C, M315C, M316C, M318C and M313D Wheel Excavators there is the possibility of a fracture of this joint.

Cracks may not be seen from the outside of the cylinder rod. Therefore the stabilizer cylinder rod friction weld needs to be ultrasonically inspected.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
M316C	H2C00521-00525, 527-529, 532-533, 535, 537, 549, 555, 577, 579-583, 585-586, 588, 591, 594, 597, 620
M318C	H2D00613, 615-620, 622-624, 626-629, 631-635, 645, 685-687, 689, 691-694, 697, 699, 704, 709-710

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*****Group 2*****
M313C	H2A00514, 516, 519-520, 524, 526, 542, 569, 571, 579, 581, 589, 612, 615
M313D	W3H00135
M315C	H2B00406-00411, 413-415, 435, 447, 451-453

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1884991	CYL GP-HYDRAULIC
*****Group 2*****
1	2249320	CYL GP-BASIC

ACTION REQUIRED

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Immediately inform the customers of the affected population to stop the machines from operation, or not to use the stabilizers under any circumstances and have them securely locked in the upward position by the lock pin (Image 1) including the lock spring (Image 2). Please also refer to the OMM.

Perform ultrasonic testing of the stabilizer cylinder rod friction weld joint. According your machine configuration two or four cylinders need to be checked.

Refer to the attached rework procedure for the inspection process requirements and for the interpretation of the results.

If a crack is detected, replace the cylinder. See corresponding D&A section.

If the ultrasonic test shows a cylinder needs to be replaced, the ultrasonic test results need to be attached to the SIMS ticket. Otherwise the claim will be rejected.

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Image1

Image2

OWNER NOTIFIAVSION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.0-hour job for Group 1
3

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.0-hour job for Group 2
3

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR ULTRASONIC INSPECTION OF STABILIZER CYLINDER RODS

MODELS INVOLVED - CERTAIN M300C AND M300D SERIES WHEELED EXCAVATORS

Dear AVSpare Product Owner:

Immediately stop your machines from operation, or do not use the stabilizers under any circumstances and have them securely locked in the upward position by the lock pin including the lock spring. Please also refer to the OMM.

The stabilizer cylinder needs to be ultrasonically inspected and potentially replaced on the products listed below. There might be cracks in the friction weld of the stabilizer cylinder rod which may cause the fracture of the cylinder rod. This may result in sudden drawback of the stabilizer foot with subsequent tilting of the machine, when the machine is in a stabilized position. If the stabilizer is in an upward position the stabilizer may drop suddenly down. Both events may result in personal injury or death. You will not be charged for the service performed.

Contact your local AVSpare dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 15Nov2006 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

AVSpare Inc.

Identification #(s)

Attached to 15Nov2006 Service Letter

Rework Procedure

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General:
The ultrasonic weld inspection needs to be performed according DIN EN 1714 ? ULTRASONIC TESTING OF WELDED JOINTS ? including its normative references.

The ultrasonic personnel needs to be qualified and trained according DIN EN 473, Grade 2, with scope for welded joints.

If DIN EN 1714 and 473 is not available or valid in your country, ultrasonic checks need to be performed and personnel qualified by your countries corresponding Standard.

Since this is a very sophisticated task to perform we strongly recommend using qualified ultrasonic personnel. We recommend the use of the company Vohtec for dealers that are located in close proximity (please see contact details below). Vohtec has special experience with this cylinder rod failure.

Vohtec
Qualit?tssicherung
Car-Zeiss-Str. 17
93431 Aalen
- Germany -
Telephone Contact:
Mr. R. Vogt, Tel.: +49 7361 912013
Mr. M. Zielinski, Tel.: +49 7361 912030

If non AVSpare personnel is performing the ultrasonic test, reimbursement of costs only if a copy of the companies invoice is attached to the claim. No labor hours for the ultrasonic test can be claimed in addition to the outside companies invoice, except if a cylinder is cracked and needs to be replaced.
Also the dealer needs to schedule to have all machines inspected in one batch, within the dealers respective marketing region.

Machine preparation:
1)Park machine on ground level
2)Lower the stabilizers to the ground (Image1.2.1)
3)Stop the engine
4)Remove the cover over the stabilzer cylinder for a better access to the cylinder (Image1.2.1) and to avoid the cover drops down accidentally during ultrasonic test.
5)Remove dirt, grease and oil from the cylinder rod surface
6)If you need better access to the friction weld area you may raise the stabilizer (Image1.2.2). Secure the stabilizer to avoid accidental drop down during test.

Image1.2.1

Image1.2.2

Test instruction:
First perform a visual inspection for surface cracks in the area identified (Image1.5.1). If a crack is found replace the cylinder.

Perform the ultrasonic test at the weld area of the cylinder eye to rod connection (Image1.5.1). You need to perform the ultrasonic test on two or four stabilizer cylinder rods, depending on your machine configuration.

Record the results.

Recommended Ultrasonic Setup:

Device: any ultrasonic device with DGS-module
Probe: MWB70-4 ; grinded to Radius 35
Frequency: 4 MHz
prf Mode: manual
prf Value: 200 Hz
Range: 100 mm
Probe Delay: 60.156 μs
Velocity: 3255 m/s
Display Delay: 0.000 μs
Amplification: 81 dB
DGS Mode: on
DGS Curve: 1.00 mm
Reference Type: backwall
Gate: A
Gate Start: 25 mm
Gate Width: 70 mm
Amplitude Correction: 2.0 dB
Transfer Correction: 3 dB

Adjustment:
(1) Distance: K2, R=25mm echo at 80% display level at 25mm sound path,
second echo at 100mm sound path through variation of probe
delay

(2) Sensitivity: with settings described by (1) -> record reference echo -> start DGS mode -> ready for testing!

(3) Verification: rod without failure -> ?part accepted? -> no echo indication
in range 100mm except for echos due to geometrical conditions
at the eye of piston rod.

rod with failure -> ?not accepted part? -> echo indications
with a height of at least 80% display level additionally to
echos due to geometrical conditions at the eye of piston rod

If vohtec personnel is performing the ultrasonic test, please use the following piston rod for calibration:
SN 188-4991
DW130/70-492RZ
20256"A"

Test Arrangement (schematic):
See Image1.5.1

Image1.5.1

Typical echo pictures without failure and with failure:

Image 1.6.1 shows a typical screen dump of "backwall echo indication" initiated by reflection of ultrasonic beam from the hole in the eye of the cylinder head.

Image 1.6.2 shows a typical screen dump of a failure indication (transversal crack) in the checked friction weld.
Please pay attention the probe position is in the same as in image 1.6.1 but the significant echo is always nearer the zero position (on x-axis) in comparison with the "backwall echo" from image 1.6.1.