The Frame Needs To Be Reinforced On Certain CS573 And CS583 Compactors Equipped With An Open ROPS Caterpillar

The Frame Needs To Be Reinforced On Certain CS573 And CS583 Compactors Equipped With An Open ROPS

Usage:

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Caterpillar: Confidential Yellow

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1265" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI1265" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the April 13, 1995 Service Letter. Changes have been made to the Affected Product.

Problem

The frame may crack in the area of the support for the ROPS assembly on certain CS573 and CS583 Compactors.

Affected Product
Model & Identification Number

CS573 (8PK68, 8PK69)

CS583 (8YJ1-124, 8YJ128-130, 8YJ134, 8YJ135, 8YJ137, 8YJ138, 8YJ140-144, 8YJ148-150, 8YJ152, 8YJ154-157, 8YJ159 1EL129-132 , 1EL140-142, 1EL145, 1EL177)

Parts Needed

Dealers will need to order parts for this Program.

1 - 5E9146 Channel (use 10 cm per machine)

1 - 9G2265 Clip

2 - 5M3062 Bolt

2 - 8T4121 Washer-Hard

2 - 8T4137 Bolt

2 - 8T4896 Washer

1 - 1010811 Switch Assembly-Roller

1 - 1111516 Bracket

1 - 1111517 Bracket

1 - 1127100 Harness Assembly

4 - 1238552 Plate

Action Required

See attached rework procedure.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

NOTE: This is a 12-hour job. If the frame is cracked, additional, reasonalbe salvage labor to repair the crack may be allowed. The additional salvage labor must be explained in the claim story.

NOTE: U.S. and Canadian Dealers Only - this Program does not qualify for a Type 2 SIMS Report.

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-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

1. Remove left and right tire assemblies.

2. On the left and right sides of the machine, disconnect hydraulic hoses from clamps and move harnesses out of the way to gain access to the frame uprights.

3. On left and right front of frame upright, remove lower 153 mm (6 inches) of angle iron. Refer to Illustration 1.

4. On rear side of left frame upright, remove 5E9146 hydrasorb channel. Refer to section B-B of Illustration 1.

NOTE: Do not cut into frame upright.

5. If cracks are present, these must be ground and rewelded.

NOTE: The quality of a welding repair is dependent on the skill of the welding operator and the materials used for the repair. All welds must conform to the standards shown in AWS specifications for qualified welds (AWS D1.1-83)

a. Only low hydrogen welding is permitted. All welds must be smooth, free of gas holes or cracks, and have no undercuts or overlaps.

b. Use one of the recommended welding processes and type of electrodes that follows:

1. Shielded Metal Arc Welding (SMAW): Use a covered electrode that meets the American Welding Society Class E7018. An electrode with a core diameter of 3 mm (.012 inches) is recommended for the root (first) pass.

2. Gas Metal Arc Welding: Use a bare electrode that meets American Welding Class E7052, E7053, E7056 or E7051B.

c. All electrodes must be dry. Follow the manufacturers instructions on handling and storage to prevent moisture absorption.

NOTE: The repair surface must be clean. Remove all foreign material before welding. All slag and foreign material must be removed after each pass of multipass welds and tie ends before making a following pass or weld connection.

d. More than one weld must be used if the groove preparation is more than 5mm (0.287 inches) deep. Each pass must be cleaned and inspected before it is covered with an additional pass. Care must be used with each pass to prevent unfused areas between layers and at the deposit and base metal interface.

e. A good root (first) pass is important. Care must be used to prevent the contaminant (trapping) of slag or the formation of voids or root porosity.

f. Any defect in the root pass or following passes must be corrected before the next weld is made (in the same groove).

g. Any weld defect must be ground out, cleaned and welded again. Welding to cover a welding defect is not allowed.

h. The weld toe geometry must be free from undercut, cold laps and poor transitions after the weld deposit is ground flush with the adjacent surface.

i. After grinding the weld deposit flush with the plate surface, unfused lengths around the weld deposit perimeter can be detected by using a dye penetrant.

6. Position and tack four 123-8552 plates on the right and left upright as shown in Illustration 1A, 3 and 4. Finish weld as shown in Illustration 2, Detail J.

7. Position and weld 10 cm of 5E9146 hydrasorb channel to rear of left upright.

8. Clean, paint and reposition harnesses and hydraulic hoses. Reinstall both tires and panels.

9. Refer to Service Magazine article "New Automatic Shut Off Switch for Vibratory System Available" dated March 21, 1994. Install the 101-0811 switch assembly to the engine governor.

NOTE: Switch position should be adjusted to achieve continuity at 2100 rpm ± 50 rpm.

10. Verify vibratory system operation.

ILLUSTRATION 1