Usage:
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 "PS4712" 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.
Termination Date
November 30, 1999Problem
Cracks may develop in the side plates of certain 5130 Excavator Swing Frames. Any crack that has developed must be repaired and reinforcing plates must be added.
The need for this program will depend upon application and hours. The repair is fairly extensive and the value of the reinforcement must be weighed against the downtime required for the repair. If the repair is made it should be combined with other major overhauls, repairs, etc.
Affected Product
Model & Identification Number
5130 (5ZL22-124 7TJ7
Parts Needed
Dealers will need to order parts for this Program.
- 1 - 1626873 Service Group
NOTE: The service group includes all the necessary paltes for this program.
Action Required
See the attached procedure.
Service Claim Allowances
NOTE: This is a 150-hour job.
NOTE: A receipt must be kept in the machine history folder for outside expenses if any are incurred. These expenses must be explained it the claim story.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.
- (1-Rework Procedure)
Rework Procedure
Repair Procedure for Swing Frame
SCOPE:
This procedure covers the manual repair welding of the crack in the side plate of a 5130 Swing Frame, if necessary, and the adding of reinforcing plates on the side of the Swing Frame. This procedure will be used for air carbon arc removal of the defect, should any exist, joint preparation prior to welding, weld repair of the crack, and the welding of reinforcing plates. If you have cracks other than those addressed below, please contact your Caterpillar Product Support Personnel for LHEX.
MODULE REMOVAL:
Start by removing the counterweight, the Right Hand Enclosure, and the Left Hand Enclosure in the reverse order of Special Instruction Assembly Procedure for Hydraulic Excavator 5130 SEHS9721-01.
Use personal protective equipment when performing the following procedure/s. Fluid Spillage Containment Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collet the fluids with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates.
At operating temperature, the hydraulic oil system is hot and under pressure. Hot/pressurized oil can cause injury, release the pressure in the implement hydraulic circuits before any hydraulic lines or components are removed or disconnected.
FILLER MATERIALS:
Filler material for welding:
- Lincoln Electric OS 71M (Outer Shield)
- Lincoln Electric E7018-LH70 (Coated Electrode)
PREHEAT INSTRUCTIONS:
Weld area shall be preheated to a minimum of 70 degrees F.
NOTE: When 'blending' and/or 'grinding' are called out, grind in an undercut of 0.5mm - 1.5mm max to the weld toe.
NOTE: Prior to welding, the surface to be welded shall be clean and free of foreign materials (oxides, oil, grease, dirt, slag, paint)
NOTE: Starts and stops should be at top center of plates. Avoid stops and starts on radius of plates if possible.
NOTE: If any cracks are present, repair per steps 1 - 8. If no cracks exist, start at step number 9.
WELDING INSTRUCTIONS:
1. Using an air carbon arc rod, remove the fillet weld (1) from the top of the swing frame mounting block that may interfere with repair of the crack as shown in Illustration 1, Detail A.
2. Using an air carbon arc rod, remove the crack creating a bevel groove (2) with an angle of approximately 45 degree, half way through the plate as shown in Illustration 2, Section AA
3. Weld the bevel groove (2), cleaning each pass to insure there are no inclusions and the weld is sound as shown in Illustration 3, Section AA
4. Using an air carbon arc rod, remove the crack from the opposite side of the plate, creating a bevel groove (3) with an angle of approximately 45 degrees. Air arc deep enough to insure fusion with the first weld (2) as shown in Illustration 4, Section AA.
5. Weld the bevel groove (3), cleaning each pass to insure there are no inclusions and the weld is sound as shown in Illustration 5, Section AA.
6. Using a grinder, grind the welds on both sides of the swing frame plate smooth, removing all weld toes. See Note 1.
7. Re-weld the 25mm fillet (4), mounting block to swing frame side plate as shown in Illustration 6.
8. Using a grinder blend the 25mm fillet weld completely, removing the toes of the weld. See Note 1.
INSPECTION:
Inspect welds when complete to ensure no weld defects are present.
9. Locate and tack one 161-9772 reinforcing plate (5) to right sides of swing frame. Allow 25mm between edge of 161-9772 plate and mounting block as shown in Illustration 7.
10. Finish weld 20 X 35mm fillet (6) reinforcing plate 161-9722 to side plate. Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-ins to remove craters before welding additional layers. Fillet should tie in to existing 25mm fillet on mounting block as shown in Illustration 8.
11. Finish weld 20 mm vee groove (7) reinforcing plate 161-9722 to mounting block. Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-ins to remove craters before welding additional layers. Vee groove should tie in to existing 20 X 35mm fillet as shown in Illustration 9.
12. Grind surface of 20mm groove (8) weld to allow for proper fit-up of 161-9723 plate. Grind end of 20 X 35mm fillet to blend weld toes as shown in Illustration 10.
13. Locate and tack one 161-9723 reinforcing plate (9) to right sides of swing frame on top of 161-9722 plate. Allow 25mm between edge of plate and top of mounting block as shown in Illustration 11.
14. Finish weld 20 X 35mm fillet (10) reinforcing plate 161-9723 to 161-9722 plate. Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-ins to remove craters before welding additional layers. Fillet should tie in existing 25mm fillet on mounting block as shown in Illustration 12.
15. Finish weld 20mm bevel groove and 12 X 25 mm (10), reinforcing plate 161-9723 to mounting block. Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-in to existing 20 X 35mm fillet as shown in Illustration 13.
16. Grind ends of 20 X 35 mm fillet (12) to blend weld toes as shown in Illustration 14. See Note 1.
17. Locate and tack 161-9724, 162-6864, and 162-6866 reinforcing plates to left sides of swing frame (13). Allow 25 mm between edge of 161-9724 and 162-6864 plate and top of mounting block. 162-6866 plate should be located to provide a smooth transition from 162-6864 to 162-6866 plate as shown in Illustration 15.
18. Finish weld 25 X 35mm fillet reinforcing plate 161-9724 to side plate (14). Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-ins to remove craters before welding additional layers. Fillet should tie in to existing 25mm fillet on mounting block as shown in Illustration 16.
19. Finish weld 25mm vee groove (15), reinforcing plate 161-9724 to mounting block. Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-ins to remove craters before welding additional layers. Vee groove should tie in to existing 20 X 35mm fillet as shown in Illustration 17.
20. Finish weld 25mm vee groove (16), reinforcing plate 162-6864 to 162-6866 plate, vertical up, flush with the ends of the plate as shown in Illustration 18.
21. Finish weld 25 X 35mm fillet (17) reinforcing plate 162-6864 and 162-6866 to side plate. Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-ins to remove craters before welding additional layers. Fillet should tie in to existing 25mm fillet on mounting block as shown in Illustration 19.
22. Finish weld 25mm vee groove (18), reinforcing plate 162-6864 to mounting block and gusset. Some vertical up welding is required. Avoid starts and stops on radius if possible. If stops are necessary, grind tie-ins to remove craters before welding additional layers. Vee groove should tie in to existing 25 X 35mm fillet as shown in Illustration 20.
24. Finish weld 12mm fillet (19), 162-6866 plate to gusset, vertical up as shown in Illustration 21.
25. Grind ends of welds (20) to blend weld toes as shown in Illustration 21.
MODULE INSTALLATION:
Finish by installing the counterweight, the Right Hand Enclosure, and the Left Hand Enclosure as in Special Instruction Assembly Procedure for Hydraulic Excavator 5130 SEHS9721-01.
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