PRODUCT SUPPORT PROGRAM FOR REPLACING THE WEAR BARS IN THE 4Z6938 LINER GROUP OF CERTAIN MSD LL BODIES USED ON 793 OFF-HIGHWAY TRUCKS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING THE WEAR BARS IN THE 4Z6938 LINER GROUP OF CERTAIN MSD LL BODIES USED ON 793 OFF-HIGHWAY TRUCKS

Usage:

SEBE8819

June 14, 2004
U-188
A-130
D-145


 
before or
after failure

PRODUCT SUPPORT PROGRAM FOR REPLACING THE WEAR BARS IN THE 4Z6938 LINER GROUP OF CERTAIN MSD LL BODIES USED ON 793 OFF-HIGHWAY TRUCKS

7258
PS41628
NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41628" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

Termination Date

June 30, 2006

PROBLEM

Three of the wear bar part numbers in the 4Z6938 Liner Group of certain 4Z6980 MSD II Body And Canopy Assemblies were made from the wrong material. These Bodies are used on 793 Off-Highway Trucks. The wear bars can be replaced if abnormal wear is detected.

AFFECTED PRODUCT

Model Identification Number
4Z6980

MSD II Body
& Canopy As

AHM720-752, 753-755, 780-783, 788-790, 800-805, 821-823

PARTS NEEDED

Quantity
Part Number
Description
4 2537694 BAR
1 2537695 BAR
2 2537696 BAR
NOTE: The parts will not be set up in the parts system. They are to be ordered on a Misc. MSO to Decatur.

Dealer sales people will need to submit a Misc. MSO to order the 2537694, 2537695, and 2537696 Bars. Facility will be 13 for Decatur plant and Source Facility is 89A.

ACTION REQUIRED

Refer to the attached procedure and replace the 253-7694, 253-7695, and 253-7696 Bars in the 4Z6938 Liner Group of the 4Z6980 MSD II Body And Canopy Assemblies.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts
Labor Hrs
Parts
Labor Hrs
Parts
Labor Hrs
0-15,000 Hours

0-12 Months

100 %
12
0
0
0
0
NOTE: This is a 12-hour job.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

REWORK PROCEDURE

Remove the existing bars, clean, and grind for the new bars.

Assemble/Position the new bars. Tack and weld as shown in the following instructions and illustration.

NOTE: This material is sensitive to hydrogen induced cracking. Cleanliness of material (Weld joint) and consumables are of utmost importance. Air carbon arc gouging may be used if it is the preferred maintenance method for crack removal. The gouged area must be cleaned by grinding to remove both the carbon deposit and slag. Inspection should follow gouging to ensure complete crack removal.

WELDING ELECTRODES

Proper preparation of the weld area must be conducted prior to any weld repair. Clean the area to be welded with a grinder. All paint, rust, oil, scale, slag, dirt, moisture, etc. must be completely removed. Any dye penetrant must also be removed with the appropriate cleaner. After the crack is completely removed, prepared and cleaned it may be weld repaired by one of the two following options:

OPTION 1

Preheat the weld groove and 3" in each direction from the weld centerline to 350 degrees F (176 degrees C). The maximum interpass temperature should not exceed 450 degrees F (250 degrees C). Weld the prepared groove with either the SMAW or FCAW electrode as specified below.

Electrode /Characteristics

The SMAW process may be used with E7018 (ANSI/AWS A5.1) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:
 

TENSILE STRENGTH 480 MPa (70 KSI)
YIELD STRENGTH 400 MPa (58 KSI)
ELONGATION 22%
IMPACT TOUGHNESS 20 FT LBF @-20F (27J @-18C)
NOTE: These are low hydrogen electrodes and must be stored in an electrode oven at 120 degrees C (250 degrees F) when not in use. If the electrodes get damp, scrap or recondition to manufacturer's specifications.
 
The following chart relates to the electrode diameter and approximate current settings for welding:
 
DIAMETER AMPS
3.2MM (0.125") 1/8" 70-140
4.0MM (0.156") 5/32" 110-180
4.8MM (0.166") 3/16" 190-270

Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass weave width shall not exceed two times the electrode diameter.

OPTION 2

As an alternative process the FCAW process may be used with E71T-1 H8 (ANSI/AWS A5.20) welding electrode and the manufacturers specified shielding gas (es). The weld deposited by these electrodes will have the following mechanical properties:

NOTE: Only use flux-cored electrodes that have been properly stored in moisture resistant packages that are undamaged or which have been placed in a drying oven maintained at 250 degrees F (120 degrees C).
TENSILE STRENGTH 480 MPa (70 KSI)
YIELD STRENGTH 400 MPa (58 KSI)
ELONGATION 22%
IMPACT TOUGHNESS 20 FT LBF @-20F (27J @-18C)

Welding parameters will vary due to weld position and manufacturer of the welding electrode. For 1.3mm (0.052 inch) diameter electrode typical welding parameters should be:
 

WIRE FEED SPEED VOLTAGE APPOX. AMPERAGE
MIN 200 IMP 24 210
OPT 275 IMP 28 250
MAX 325 IPM 29 300

Use the direct current electrode positive (DC reverse polarity) setting and remove the slag after every pass.

Illustration 1 - Welding Bars In Position

Illustration 2 - Alternate Position of Wear Bars
If Front of Rock Box is Worn Down Under 1/2 inch.

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