Product Support Program For Repairing The Dump Body Ducktail On Certain D350E Articulated Trucks Caterpillar

Product Support Program For Repairing The Dump Body Ducktail On Certain D350E Articulated Trucks

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Caterpillar: Confidential Yellow

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.

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4574" 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: This Revised Service Letter replaces the August 19, 1998 Service Letter. Changes have been made to the Rework Procedure.

Termination Date

August 31, 1999

Problem

The dump body on certain D350E Articulated Trucks may be susceptible to cracking in the ducktail area. Reinforcement of the ducktail area will increase the service life of the body.

Affected Product
Model & Identification Number

D350E (9LR1-599)

Parts Needed

Fabricated, see the attached procedure.

Action Required

See the attached procedure.

Service Claim Allowances

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

This procedure is written to cover the inspection and field repair of the dump body rear channel in the ducktail area on D350E articulated truck. This procedure will improve the life of this area of the dump body.

WELDING PROCEDURE

Read and understand the manufacturer's instructions and your employer's Safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and general area. Wear correct eye, ear, and body protection. Do not touch live electrical parts. See American National Standard Z49.1 "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CRF 1910, available from U.S. Dept. of Labor, Washington, D.C. 20408.

NOTE: Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OSHA limits. All repair welding operators must be qualified for groove and fillet welding, as outlined the current ANSI/AWS D14.3, or Caterpillar Manufacturing Practices MC1000-105. The qualification will be for the SMAW (Shielded Metal Arc Welding) process in the vertical welding positions. The welding operator must also have used this welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications. The alternate process for this repair could be FCAW (Flux Cored Arc Welding). The area to be welded and the surrounding area must be at a minimum temperature of 16 degrees C (60 degrees F) before and during welding.

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

500 MPa (72 KSI) Tensile Strength

420 MPa (60 KSI) Yield Strength

22% elongation in 50 mm (2 in)

27 J (20 ft lb) Notch Toughness at -29 degrees C (-20 degrees F)

These are low hydrogen electrodes and must be stored in an electrode oven at 121 degrees C (250 degrees F) when not in use. If the electrodes get damp, scrap or recondition them to the manufacturer's specifications.The following chart relates to the electrodes diameter and approximate current settings for welding:

Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed two times the electrode diameter. As an alternate process the FCAW process may be used with E71T-1 (ANSI/A5.20) welding electrode and the manufacturer's specified shielding gas(es). The weld deposited by these electrodes will have the following minimum mechanical properties:

500 MPa (72 KSI) Tensile Strength

420 MPa (60 KSI) Yield Strength

22% elongation in 50 mm (2 in)

27 J (20 ft lb) Notch Toughness at -18 degrees C (0 degrees F)

NOTE: This type of electrode has limitations if it is used to carry larger weld pass volumes in the flat welding position. Due to the fast freezing characteristics of this electrodes slag system, there is a chance of trapping evolving gases in the weld melt. Precaution should be taken by controlling weld pass size. Welding parameters will vary due to weld position and manufacturer of the welding electrode. For 1.30 mm (.052 in) diameter electrode typical welding parameters should be:

Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed 8.0 mm (.031 in) fillet volume. Clean the frame of oil, grease, paint, and dirt in the area to be welded. Attach the welding ground cable directly to the area to be welded. Protect all machined surfaces from sparks or splatter produced by the welding, chipping, and/or grinding operations. The welds shall be free from cracks, porosity, undercut, and incomplete fusion. All weld quality shall conform to ANSI/AWS D14.3.

REPAIR OF DUMP BODY REAR CHANNEL DUCKTAIL
D350E ARTICULATED TRUCKS

Material is ASTM A656 Gr. 50 or A572 Gr. 50.

NOTE: All dimensions are in millimeters.

1. If your truck is equipped with the underslung tailgate option, go to Step 33 and preform Steps 33 thru 37.

2. The dump body does not have to be removed from the chassis to perform the welding operations, but it may be done to avoid out of position welding. If you have an underslung or scissor tailgate it may need to be removed, at least partially, to perform the welding operations. Make sure to adequately support the tailgate if it is partially removed for the welding operations.

3. Clean the body of oil, grease, paint, and dirt in the dump body rear channel ducktail area. If your truck is equipped with a scissor tailgate, remove the support brackets with rubber pads from the dump body.

4. Visually inspect and note all cracks in the rear channel ducktail area. (use magniflux or dye penetrant as required)

5. Attach the welding ground cable directly to the body. Protect all machined surfaces from sparks or spatter produced by the welding, chipping, and/or grinding operations. If ambient temperature is below 16 degrees C (60 degrees F), preheat as specified prior to cutting, carbon arc gouging, and/or welding.

6. If you find cracking of the weld metal or base metals, preheat as specified and remove the cracked material by carbon arc gouging to a depth necessary to eliminate the cracks.

7. Taper the ends of the arc gouged area to allow for smooth transition to existing sound weld and/or base material.

8. Remove all debris in and around the carbon arc gouged area by chipping and grinding smooth.

9. Visually inspect the carbon arc gouged area for cracks, undercut, and porosity.

10. Preheat as specified and reweld the prepared area. Weld repair area shall be free from cracks, porosity, undercut, and incomplete fusion. All weld quality shall conform to ANSI/AWS D14.3.

11. Assemble & tack Item 1, (Illustration 2). For tacking position and "X" dimension from the end of the body see Illustrations.

12. Assemble & tack Item 2, (Illustration 3) to existing 14mm base plate. Air arc under side to allow for 100% weld. See Illustration 22.

13. Assemble & Tack Item 4, (Illustration 5), 502mm from the rear end of Items 2. See Illustration 24. Cut Items 4 if necessary to maintain 502mm dimension. See Illustration 21.

14. Assemble & Tack Item 7, (Illustration 8). For tacking position See Illustration 19. Trim Item 7 as necessary to allow Item 6 to set in 10mm from the edge of Items 2. See Illustration 24.

15. Assemble & tack Item 3, (Illustration 4), backing strip to Items 5. For tacking position See Illustration 22.

16. Assemble & Tack Item 5, (Illustration 6), trim to fit. Leave enough root opening to allow for 10mm penetration. For tacking position see Illustration 22.

NOTE: Do not remove the material inside the dash lines if your truck is not equipped with a tailgate.

17. Assemble & Tack Item 6, (Illustration 7). Trim the bottom edge to allow for enough root opening for complete penetration on the weld joint between parts 5 & 6. For tacking position see Illustration 22.

18. Burn out rear outer corners of scow and grind smooth prior to fitting Item 8. See Illustration 18.

19. Assemble & Tack Item 8, (Illustration 9). For tacking position see Illustration 19.

20. Assemble & Tack Item 9, (Illustration 10). For tacking position see Illustration 19.

21. Assemble & tack Item 10, (Illustration 11). For tacking position and "X" dimension from the end of the body. See Illustration 23.

22. Assemble, Tack & Weld Item 11, (Illustration 12) to existing 14mm base plate. Air arc under side to allow for 100% weld. See Illustration 23.

23. Assemble & Tack Item 12, (Illustration 13) 502mm from the rear end of Items 11. See Illustration 24. Cut Items 12 if necessary to maintain 502mm dimension. See Illustration 21.

24. Assemble & Tack Item 7, (Illustration 8). See Illustration 19. Trim Item 7 as necessary to allow Items 6 & 14 to set in 10mm from the edge of Item 11. See Illustration 24

25. Assemble & tack Item 3, (Illustration 4) backing strip to Item 13. See Illustration 23.

26. Assemble & Tack Item 13, (Illustration 14). Trim to fit. Leave enough root opening to allow for 10mm penetration See Illustration 23.

NOTE: Do not remove the material inside the dash lines if your truck not equipped with a tailgate

27. Assemble & Tack Item 14, (Illustration 15). Trim the bottom edge to allow for enough root opening for complete penetration on the weld joint between parts 13 & 14. See Illustration 23.

28. Burn out rear outer corners of scow and grind smooth prior to fitting Item 9. See Illustration 18.

29. Assemble & Tack Item 15, (Illustration 16). See Illustration 19.

30. Assemble & Tack Item 16, (Illustration 17). See Illustration 19.

31. See Illustrations 19, 20, 21, 22, & 23 for weld sizes, where to weld & NO WELD areas.

32. After all cracks have been repaired or if there is no visible cracking in the specified areas and surrounding material, preheat as specified and weld complete as shown in Illustrations 19, 21, 22, & 23.

Underslung & Scissor Tailgate Modification

33. Provide adequate support for the tailgate to prevent injury.

34. If you have an underslung tailgate attachment, you will need to remove material from parts 156-7982, 1557221, 1567983, & 1583045 shown in Illustrations 25, 26, 27, & 28 This is to provide the additional clearance needed for the pivot bosses of the tailgate.

35. If you have an underslung tailgate attachment, you will need to remove material from the tailgate arms as shown in Illustration 29. This is to provide the additional clearance needed due to the dump body modifications.

36. If you have a scissor type tailgate, additional modifications are necessary. The left and right support bracket assembly will have to be removed prior to the assembly and welding of the reinforcement plates and modify fit onto the dump body modifications See Illustration 30.

37. Go to Step 2 and preform Steps 2 thru 32.

Illustration 1 - Parts listing