TERMINATION DATE

January 31, 2007

PROBLEM

Quick coupler PW2507 on 950G-962G is showing weld and structure weakness.

 

AFFECTED PRODUCT

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first

Parts

PARTS DISPOSITION

Attach. (1-Rework Procedure)

• Serial number plate (A)
• Top plate (B)
• PW2507 quick coupler (C)
• Hinge plate (D)
• Cracks at location (X)
• Cracks at location (Y)

* Parts not available through CAT ordering system.

Personal injury or death can result from sudden attachment movement.

Sudden movement of the attachment can cause injury to persons near the attachment.

To prevent injury or death, make sure that the area around the attachment is clear of personal and obstructions before servicing the attachment

1. Remove the PW2507 quick coupler from the host machine. Refer to Operation and Maintenance Manual, "Quick coupler installation and removal, Removal procedure".
2. Clean quick coupler, before repairing.
3. Place the quick coupler on a flat and level surface, and secure it against moving.


Repair cracks in top plate

WARNING

Personal injury can result from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas
 

1. Remove serial number plate and holder (A) from top plate (B).
2. Remove paint at areas to be welded before welding or flame cutting.




Illustration 2: Cracks in top plate




3. Grind away cracks in top plate (B). See illustration 2.
4. Clean the grinded surface.


WARNING

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.

Read and understand the manufacturer?s instructions and your employer?s safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society 2501 N.W. 7th Street Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from

U.S. Department of Labor.

Washington, D.C. 20210
 

5. Use AWS A5-1 or E7018 class electrode to repair the area.
6. Build up the original shape of the top plate (B).
7. Let welds cool down.
8. Remove all debris from the welds.




Illustration 3: New top plate


 
9. Create an additional top plate (B). Use material (St. 52-3, thickness 10 mm. Refer to illustration 3.




Illustration 4


 
10. Make plates(E)(2x). Use material (St.52-3, thickness 10 mm. Refer to illustration 4.




Illustration 5: Position of plates


 
11. Positions plates (B) and (E) on PW2507 quick coupler (C).
12. Tack weld plates (B) and (E) onto the coupler.
13. Weld the plates onto the coupler. Place an 8mm (0.31 inch) fillet over square groove weld with a 1.5mm (0.06 inch) penetration.
14. Weld serial plate holder onto plate (B).
15. Let the welds cool down.
16. Remove all debris from the welds.
17. Clean and repaint the repaired areas.
18. Install serial number plate.


Repair cracks in hinge plates

WARNING

Personal injury can result from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas
 

1. Remove paint at the areas to be welded before welding or flame cutting.




Illustration 6: Temporary bar

WARNING

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.

Read and understand the manufacturer?s instructions and your employer?s safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society 2501 N.W. 7th Street Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from

U.S. Department of Labor.

Washington, D.C. 20210
 

2. Tack weld temporary bar (H) onto PW2507 quick coupler (C).




Illustration 7: Cracks in hinge plates


 
3. Flame cut away cracks in hinge plates (D).
4. Clean the surface.
5. Use AWS A5-1 or E7018 class electrode to repair the area.
6. Build up the original shape of the hinge plates (D).



Illustration 8: Stiff plate


 
7. Make new stiff plates (K) (2x). Use material (St. 52-3, thickness 25mm. Refer to illustration 8.
8. Create bar (I). Dimensions: 150x25x789mm.



Illustration 9: Section B-B


 
9. Grind away parts of the hinge plates (D) at the location circled in illustration 9. Also refer to illustrations 10 and 11 for more detail.




Illustration 10



Illustration 11: Section D-D


 
10. Chamfer stiff plates (K) before installing onto the quick coupler (C). See illustration above.
11. Tack weld stiff plates (K) and bar (I) onto the quick coupler (C).
12. Weld stiff plates (K) and bar (I) onto quick coupler (C). Place an 8mm (0.31 inch) fillet over square groove weld with a 1.5mm (0.06 inch) penetration.
13. Remove all debris from the welds.
14. Remove temporary bar (H) from the quick coupler.