PRODUCT SUPPORT PROGRAM FOR REWORKING THE ARM ASSEMBLY CENTER CASTING ON CERTAIN 963C TRACK LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE ARM ASSEMBLY CENTER CASTING ON CERTAIN 963C TRACK LOADERS

Usage:

REBE2709-00

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16Nov2007

U-597

A-488

D-489

O-524

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE ARM ASSEMBLY CENTER CASTING ON CERTAIN 963C TRACK LOADERS
6119		PS51396

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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 "PS51396" 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

31Jul2011

PROBLEM

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The existing arm assembly center casting can fail on certain 963C Track Loaders. The failure is typically a crack appearing on the top of the ribs which support the tilt lever. If the casting ribs fail, they have to be reworked. If the crack has reached the hollow section of the casting, the whole arm assembly has to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
963C	2DS00430, 2120, 2122-3189 BBD00332-01611, 2000-2845

PARTS NEEDED

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Qty	Part Number	Description
1	2161018	ARM &BRG AS.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 0% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the 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%
0-5000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job
This is a 3 hour job to weld repair the cracks using the rework procedure. An additional 5 hours will be allowed for replacement of the lift arm.

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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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Inspect the crack. If the crack has not reached the hollow section of the casting, try to weld repair the crack. Refer to the steps below. If the crack has reached the hollow section of the casting, or if the rib cracks again after the first attempt to repair, replace the whole arm assembly. Refer to Disassembly and Assembly Manual, RENR5233, for the liftarm disassembly and assembly procedure.

1 - Clean the surface and remove the paint. Grind the areas of the crack (at least 10 cm (3.950 inch) from the crack) up to the white metal.

2 - Remove the steel by arc-air gouging on all the length of the crack, plus an additional 5 cm (1.970 inch), up to two-thirds of the thickness. Use carbon electrode diameter 8 mm (0.315 inch) or 10 mm (0.394 inch) in order to perform a U groove see Illustration 3 (C). If casting defects appear during the gouging operation, the defects must be eliminated by arc- air gouging. Grind all of the U groove up to the white metal, in order to remove all of the carbon deposits.

3 - Fill the U groove by welding, see Illustration 3 (D). The following welding processes are preferred for this repair: Gas Metal Arc Welding (GMAW) with wire electrode diameter 1.2 mm (0.047 inch) (EN 440 G3Si or G4Si1 / AWS ER70S-6) and Shielded Metal Arc Welding (SMAW) with electrode diameter 3.2 mm (0.126 inch) to 4 mm (0.158 inch) (EN499 E432 B32 H5 / AWS E7018).
Note: If the welders ability is sufficient, It will not be necessary to disassemble the lift arm, the welding position can be vertical ascending.

Image1.1.1

4 - Clean the surface and remove the paint. Grind the areas of the crack (at least 10 cm (3.950 inch) from the crack) up to the white metal.

5 - Remove the steel by arc-air gouging on all the length of the crack, plus an additional 5 cm (1.970 inch), up to two-thirds of the thickness. Use carbon electrode diameter 8 mm (0.315 inch) or 10 mm (0.394 inch) in order to perform a U groove see Illustration 4 (E). Check that all of the crack is removed, (perform when possible dye penetrant testing). Grind all of the U groove up to the white metal, in order to remove all of the carbon deposits.

6 - Fill the U grooves by welding see Illustration 4 (F) .