PRODUCT SUPPORT PROGRAM FOR REWORKING THE 218-2197 STICK ON CERTAIN 330C HYDRAULIC EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 218-2197 STICK ON CERTAIN 330C HYDRAULIC EXCAVATORS [REBE2000]

IMPLEMENTS

STICK GP

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 218-2197 STICK ON CERTAIN 330C HYDRAULIC EXCAVATORS

REBE2000-00

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15May2007

O-174

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 218-2197 STICK ON CERTAIN 330C HYDRAULIC EXCAVATORS
6502		PS51295

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51295" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31May2009

PROBLEM

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Cracks can appear at three specific weld locations (see Image 1)of the stick 218-2197 on certain 330C Hydraulic Excavators. If a crack is not propagating out of the welds, follow the rework procedure attached. If a crack is propagating out of the weld into a plate, please take pictures and contact Product Support Service Engineer Christian M?hle(email: Muhle_Christian@cat.com, phone: +32 71 25 2559) for further instructions.

AFFECTED PRODUCT

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Model	Identification Number
330C	CAP00857, 907, 956, 1005, 1060, 1123, 1210, 1270-1271, 1275, 1279, 1283, 1287, 1320, 1419, 1423, 1502, 1507, 1574, 1593, 1636, 1638, 1641, 1855, 1878, 1909, 1911, 1979, 2180, 2197 CGZ00320-00321, 373, 457, 619, 760, 933 JCD00273, 277, 280, 286-287, 290, 292-297, 299, 301-302, 304-305, 307-309, 311, 313-316, 318-320, 324, 326-327, 329-332, 335, 337-339, 341-343, 350-352, 354, 356, 364
330CL	JNK00192-00193, 199, 206, 217, 224, 227-228, 234, 240, 249, 251-252, 262-264, 268, 273, 278, 291, 313-314, 320, 331, 337, 345, 348, 352

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Please refer to the attached Rework Procedure.

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Image1

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%
0-6000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 49-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 36.0-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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General recommendations:

Equipment required: Power source able to supply 500 Amps or more with DC current for welding. This source should also be able to gouge with 500 Amps or more.
Polarity: DCEP (direct current electrode positive) = reverse polarity.
Shielding gas : C02 or mixed gas ARGON/ CO2 (80/20)
It is recommended that this rework be done at room temperature without any air blow.
Parts have to be clean of oil, moisture, grease, paint or any other contaminants in the weld joint prior to welding. Weld shall be free of weld spatter or slag that pose assembly or contamination problems.
Welder should be properly qualified to weld with Gas Metal Arc Welding (GMAW ? MIG/MAG).
All welding should be done in FLAT position. If vertical position is the only possibility the welding has to be done in the vertical up position and not in the vertical down position. Welder MUST be qualified for the specific position.
Filler metal (?1.2, ?1.4 or ?1.6mm) must correspond to following standards: AWS A5. 18 ER 70 S-6, DIN 8559 SG3 or EN 440 G4Si1.
Wires certified in AVS Belgium: SAF OERLIKON CARBOFIL SG3 / ESAB OK AUTROD 12.64 / PITTINI PITARC G9 / THYSSEN K56.
If shielded metal arc welding (SMAW - stick) is the only available option use basic electrode ESAB OK 48.00 ?3.25 mm or any electrode corresponding to standard: AWS A5.1- E7018 or EN ISO 2560-A E 42 4 B 42 H5.
Mask all parts prior gouging.

REFERENCES:

AWS D14.3 - Specification for Welding Earthmoving and Construction Equipment
AWS D1.1 ? Structural Welding Code - Steel

POCEDURE:

Remove Bucket, Bucket cylinder, Linkage, Lines from the stick
Remove the stick from machine.
Turn the stick in order to gouge and weld in FLAT position
FOR WELDING AVOID ALWAYS EXCESSIVE TEMPERATURE BETWEEN PASSES (250 ? C MAX) .

REWORK AT LOAVSION 1:

Cut transversally the top plate by following the dimensions on the drawing (1008 mm, on H. See Image 1.2.1)
Gouge off the weld connecting the top plates (on G - See Image 1.2.1) and remove the backup strip.
Gouge the weld connecting the side plate and the top plate between F and J (See Image 1.2.1). Do that on right and left side plates.
Remove the part of the top plate between G and H.

Image1.2.1

Inspect the weld quality between the last side plates (See Image 1.3.1). Check inside of the stick that the backup strip is correctly positioned with no gap (See Image 1.3.2).

If the weld is OK go to the REWORK AT LOAVSION 2, otherwise continue to follow the present procedure.

Gouge that weld. Remove the backup strip under the weld.
Fix a new backup strip onto the same location and reweld the butt by avoiding the gaps. Tack inside chamfer. Those weld points MUST be fully remelted.
Grind the new weld such that the surface gets completely flat. Do not decrease the weld size under 11 mm. (See Image 1.3.3)

Image1.3.1

Image1.3.2

Image1.3.3

Fix the new baffle (item 1 - See Images 1.4.1 and 1.4.3) and weld around it at the right location according to the drawing. See the Table (Image 1.4.4) to get the material equivalence of the steel to use for the Baffle.
Fix the new backup strips onto the top plates on G and H (detail A in Image 1.4.2). Tack inside chamfer. Those weld points MUST be fully remelted.

Image1.4.1

Image1.4.2

Image1.4.3

Image1.4.4

Weld a new top plate (Item 3 - See Images 1.5.1 and 1.5.2).
See the Table (Image 1.4.4) to get the material equivalence of the steel to use for the top plate. The longitudinal welds must be continuous and free of starts and stops. For the transverse weld, reweld butt joint at both ends of plate after gouging (4 mm mini from back side of beveled plates or use flux-tab before welding (instead of gouging). Also grind plate edge flat and chamfer 0.5 to 3 mm for the both corners.
LET COOL SLOWLY USING HEATED COVER.

Image1.5.1

Image1.5.2

REWORK AT LOAVSION 2:

Gouge the weld from K to L (See Image 1.6.1)
Check if there is a chamfer on the edge of the side plate where you have just gouged a weld.
If there is no chamfer, chamfer that side plate following the geometry indicated by section A-A.(See Image 1.6.2)
Always weld in flat position.
Preheat at 200?C. control interpass temperature (min 150?C, max 250?C).
Reweld that butt (section W-W - See Image 1.6.3).
Grind the new weld in order to get a flat surface. Do not decrease the weld size under 14 mm. The transition where the grinding stops must be smooth to avoid a sharp edge.
Do the same rework procedure at location 2 for the other side of the stick.
LET COOL SLOWLY USING HEATED COVER .

Image1.6.1

Image1.6.2

Image1.6.3

REWORK AT LOAVSION 3:

If the lug is the OLD design (See Image 1.7.1), follow the procedure.
If that lug design has been already improved go not further and stop the rework procedure here.

FOR WELDING AVOID ALWAYS EXCESSIVE TEMPERATURE BETWEEN PASSES (250 ? C MAX).
Manufacture 2 extra lug parts (See Image 1.7.2). See the Table (Image 1.4.4) to get the material equivalence of the steel to use for the lugs.

Image1.7.1

Image1.7.2

To weld that part with the original lug from A to E (See Image 1.8.1). Start with a first pass and gouge 4 mm mini from back side of the joint to remove inclusions,?
Keep on welding the next passes. It is very important to alternate the passes in the same sequence as the one indicated by the sketch below (See Image 1.8.2).
Grind this weld so that the surface is completely flat along it.
Weld on E (See Images 1.8.1, 1.8.2 and 1.9.4). It is very important to follow the procedure indicated by the sketch.

Image1.8.1

Image1.8.2

Start with the welds at the end of lugs (transversal weld - See Images 1.9.1 to 1.9.3). Do not make weld to maintain the melted metal, only grind afterwards.
Make the longitudinal weld starting from the end E of the transversal weld to B (See Image 1.9.4). Weld must be continuous and free of start and stop.
Weld transversally on A (See Image 1.9.4)

Image1.9.1

Image1.9.2

Image1.9.3

Grind the welds that you have just made on E so that the surface of the lug end gets smooth. Weld ends require grinding or tig-treatment (See Image 1.10.1).
Grind the weld on A so that you get 3 flat surfaces that are shaped continuously with the original lug.
LET COOL SLOWLY USING HEATED COVER .
Do the same procedure at location 3 for the other lug.