PRODUCT SUPPORT PROGRAM FOR REWORKING THE FENDER ASSEMBLIES ON CERTAIN 621G, 623G, AND 627G WHEEL TRACTOR SCRAPERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FENDER ASSEMBLIES ON CERTAIN 621G, 623G, AND 627G WHEEL TRACTOR SCRAPERS

Usage:

REBE2511-00

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26Sep2007

U-485

A-397

D-388

O-417

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE FENDER ASSEMBLIES ON CERTAIN 621G, 623G, AND 627G WHEEL TRACTOR SCRAPERS
7252		PS51361

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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 "PS51361" 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 Caterpillar product analyst.

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TERMINATION DATE

30Sep2009

PROBLEM

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The existing tractor fender assemblies may crack on certain 621G, 623G and 627G Wheel Tractor Scrapers. If the existing Fender Assembly cracks it can lead to further damage to the Fender.

AFFECTED PRODUCT

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Model	Identification Number
621G	CEN00300-00430 DBB00200-00340, 342-343, 345-350
623G	CES00450-00563 DBC00150-00271
627G	CEX00400-00602 DBD00250-00417, 419-423

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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See attached rework procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-4000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 8.0-hour job
A failure constitutes a visible crack found on either tractor fender in one or multiple location(s) and/or improper weld seam(s) on underside of fender as specified in the attached rework procedure in images 1.1.1, 1.1.2, and 1.2.1. The 8.0 hour total repair allowance is based on 4.0 hour repair time per fender.

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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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Tractor fender weld cracking rework procedure for 621G, 623G and 627G Wheel Tractor Scrapers

Image1.1.1

Image1.1.2

Inspect both tractor fenders for any cracking at weld seams of corners as shown in illustrations 1.1.1 and 1.1.2.

Image1.2.1

If any cracks are found, follow procedures below for repair. If no cracks are found, inspect weld seams on underside surface of fenders for proper weld joint. Illustration 1.2.1 shows correct and incorrect weld joint(s). Repair as necessary.

Repair procedure for RH tractor fender:

Image1.3.1

1. Attach a suitable lifting device to the Right Hand Fender in the location indicated in illustration 1.3.1. A 138-7573 Link Bracket (service tool) is available to use as a bolt-on lifting eye.

Image1.4.1

REAR VIEW OF BREATHERS (IF EQUIPPED)

Image1.5.1

TOP VIEW OF BREATHERS(IF EQUIPPED)
2. Remove (2) 6G-0078 Breather housings (Transmission) (IF EQUIPPED). Illustrations 1.4.1 and 1.5.1

Image1.6.1

3. Remove (5) 4L-6454 Bolts and 8T-4897 Washers. See illustration 1.6.1

Image1.7.1

4. Use a socket and long extension to loosen (2) 3K-6060 Locknuts. Note: Locknuts will not need to be removed, only loosened. See illustration 1.7.1

Image1.8.1

5. Remove (3) 7X-0347 Bolts, 7X-0515 Washers, and 3K-2889 Locknuts. See illustration 1.8.1

Image1.9.1

6. Remove bolt, nut, and washers that attach RH fender to rear of hydraulic tank shown in illustration 1.9.1.

7. Remove Fender (RH).

Image1.11.1

8. Add back-up strips to underside of RH fender outer edge shown in illustration 1.11.1. See following procedure for weld repair of crack(s) and addition of back-up strips.

This procedure consists of crack removal/joint preparation, welding, final surface finishing and inspection.

PRELIMINARY

Required Tools and Material: Adequate welding equipment and welding electrode (see below), rotary power tools to include a 7" or 9" inch surface grinder with 36 grit and 100 grit soft grinding discs or equivalent, a "pencil" grinder with drum sander or large diameter rotary file. For faster joint preparation use the air-carbon arc gouging process with a suggested 1/8" diameter (3mm) electrode, or if not available a 3mm thick edge grinding disc mounted on a "pencil" grinder will suffice. Also required is an adequate length of 3mm (0.125") x 16 mm (0.625") mild steel, strip stock to be used for back-up strip material. SAE1008, or comparable easily formed mild steel is recommended.

Cleaning/Preparation/Fit-up/Tacking: All weld joints and surfaces to be welded must be clean (no slag, mill scale, paint, rust, grease, etc.) prior to welding. Paint should be removed 75mm (3") on either side of the crack. Remove entire crack by air-carbon arc gouging or edge grinding. Gouge/grind 12 mm past end of crack. If there is a back-up strip below the cracked weld remove it as well. Remove gouging slag. Cut and form new back-up strip from 3mm x 16mm strip stock and trial fit. The back-up strip is to provide backing for the entire gouged/ground out weld repair joint. Re-form as needed, allowing the back-up strip end to hang below the fender edge approximately 6mm. Align the outer fender surfaces even with each other and tack weld the back-up strip into place. To allow full penetration, the minimum weld joint root opening is 5 mm. Tight fit up is very important to avoid burn through during finish welding. Make every effort to minimize joint size, thus reducing residual stresses and distortion.

Welding: Weld the repair joint from the bottom upwards. The number of weld passes will depend on the width of the weld joint. Start welding on the projecting end of the back-up strip. Slag and inspect for low areas, repair as needed. Grind high spots with course grit soft pad. Do not grind out base metal. Finish blending with fine grit soft pad. Grind protruding end of the back-up strip flush with fender edge and carefully blend. No sharp edges permitted.

Prime and paint as needed.

Image1.13.1

View of reworked RH fender with new backing strips in place. Illustration 1.13.1

9. Reinstall Right Hand Fender. Reattach all removed hardware from previous steps. Torque all bolts to the standard torque that is found in Specifications, SENR3130, "Torque Specifications for All Caterpillar Products."

Repair procedure for LH tractor fender:

Image1.15.1

10. Attach a suitable lifting device to the Left Hand Fender in the location indicated in illustration 1.15.1. A 138-7573 Link Bracket (service tool) is available to use as a bolt-on lifting eye.

Image1.16.1

Image1.16.2

11. Remove the 101-4480 Baffle and 237-7697 Strip shown in illustration 1.16.1, and 101-3160 Baffle shown in illustration 1.16.2.

Image1.17.1

12. Remove (6) 8T-2501 Bolts and 8T-4896 Washers shown in illustration 1.17.1.

Image1.18.1

13. To gain additional clearance for fender removal, remove (2) 5M-3062 Bolts, (2) 8T-4896 Washers, and (1) 237-7696 Plate shown in illustration 1.18.1.

Image1.19.1

14. Remove (3) 7X-0347 Bolts, 7X-0515 Washers, and 3K-2889 Locknuts shown in illustration 1.19.1.

15. Remove Fender (LH).

Image1.21.1

16. Add back-up strips to underside of LH fender outer edge shown in illustration 1.21.1. See following procedure for weld repair of crack(s) and back-up strip addition.

Image1.22.1

NOTE: Removal of angle bracket optional. See illustration 1.22.1 for location of bracket.

This procedure consists of crack removal/joint preparation, welding, final surface finishing and inspection.

PRELIMINARY

Required Tools and Material: Adequate welding equipment and welding electrode (see below), rotary power tools to include a 7" or 9" inch surface grinder with 36 grit and 100 grit soft grinding discs or equivalent, a "pencil" grinder with drum sander or large diameter rotary file. For faster joint preparation use the air-carbon arc gouging process with a suggested 1/8" diameter (3mm) electrode, or if not available a 3mm thick edge grinding disc mounted on a "pencil" grinder will suffice. Also required is an adequate length of 3mm (0.125") x 16 mm (0.625") mild steel, strip stock to be used for back-up strip material. SAE1008, or comparable easily formed mild steel is recommended.

Cleaning/Preparation/Fit-up/Tacking: All weld joints and surfaces to be welded must be clean (no slag, mill scale, paint, rust, grease, etc.) prior to welding. Paint should be removed 75mm (3") on either side of the crack. Remove entire crack by air-carbon arc gouging or edge grinding. Gouge/grind 12 mm past end of crack. If there is a back-up strip below the cracked weld remove it as well. Remove gouging slag. Cut and form new back-up strip from 3mm x 16mm strip stock and trial fit. The back-up strip is to provide backing for the entire gouged/ground out weld repair joint. Re-form as needed, allowing the back-up strip end to hang below the fender edge approximately 6mm. Back-up strip will need to be installed behind the angle bracket if it is not removed. If angle bracket is removed, the ends of the bracket that were welded will need to be dressed for re-use. Grind smooth any weld, slag, etc. from each end. Align the outer fender surfaces even with each other and tack weld the back-up strip into place. To allow full penetration, the minimum weld joint root opening is 5 mm. Tight fit up is very important to avoid burn through during finish welding. Make every effort to minimize joint size, thus reducing residual stresses and distortion.

Welding: Weld the repair joint from the bottom upwards. The number of weld passes will depend on the width of the weld joint. Start welding on the projecting end of the back-up strip. Slag and inspect for low areas, repair as needed. Re-install angle bracket in its original location with 5mm fillet welds at each end.Grind high spots with course grit soft pad. Do not grind out base metal. Finish blending with fine grit soft pad. Grind protruding end of the back-up strip flush with fender edge and carefully blend. No sharp edges permitted.

Prime and paint as needed.

Image1.24.1

17. Reattach with 5mm fillet welds if bracket was removed. See illustration 1.24.1

Image1.25.1

View of reworked LH fender with backing strips in place - front most corners. Illustration 1.25.1

Image1.26.1

View of reworked LH fender with backing strips in place ? rearmost corners. Illustration 1.26.1

18. Reinstall Fender (LH). Reattach all removed hardware from previous steps. Torque all bolts to the standard torque that is found in Specifications, SENR3130, "Torque Specifications for All Caterpillar Products".