PRODUCT SUPPORT PROGRAM FOR REPAIRING THE REAR FRAME ON CERTAIN 740 ARTICULATED TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE REAR FRAME ON CERTAIN 740 ARTICULATED TRUCKS

Usage:

REBE7863-00

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08Dec2011

J016

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE REAR FRAME ON CERTAIN 740 ARTICULATED TRUCKS
7051		PS52141

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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 "PS52141" 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

31Dec2013

PROBLEM

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The existing rear frame side rails may crack on certain 740 Articulated Trucks. The cracks may develop in, or adjacent to, the longitudinal welds which retain the two sections of the side rails. The welds run along the upper and lower surfaces of the side rails.

AFFECTED PRODUCT

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Model	Identification Number
740	B1P05414-05425

PARTS NEEDED

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No parts needed for this program

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%
0-15000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 25.0-hour job
Two claims are permitted on each frame rail on any of the affected product, up to a maximum of four claims on any particular machine. When carrying out a repair, clearly identify which part of the frame is being repaired - right hand rail upper face, left hand rail lower face - and document it in the claim story.

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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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Also refer to Special Instruction REHS1841 ? General Welding Instructions

Side Beam Structure:-

The side rails are manufactured from two x "C"-sections of steel which are welded together using the submerged arc welding process.

Repair Procedure

1. Clamp the rail to prevent it springing apart when the cracked section of weld is completely removed.
2. Grind the cracked section of weld flush with the side rail.
3. Drill a 5 mm hole 50 mm (2 inches) away from each end of the crack to prevent the crack propagating along the intact weld during the repair.
4. Grind the crack out completely by grinding a 90-degree "V"-Groove along the full length of the cracked area completely up to the 5mm holes. Check the crack has been removed using dye penetrant.
5. Re-weld the frame using the welding parameters and sequence described below.

Image1.1.1

Weld # 1 ? A keyhole, short-arc transfer "dip" weld using between 17 - 20 volts.
Weld # 2 ? A single hot pass over the dip weld using 28 volts.
Welds # 3 & 4 ? Two single, stringer, capping welds using 30 ? 32 volts.

6. Remove weld spatter and repaint area as required.