Product Support Program For Repairing The Dump Body Ducktail On Certain D400E Articulated Trucks Caterpillar

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 "PS4595" 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.

Termination Date

Problem

The dump body on certain D400E 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

D400E (2YR1-1015)

Parts Needed

Fabricated, see the attached procedure.

Action Required

See the attached procedure.

Service Claim Allowances

NOTE: This is a 12-hour job including the time required to fabricate the parts. A maximum of $75.00 U.S. will be allowed for materials to fabricate the parts.

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 rear channel in the ducktail area on D400E Articulated Trucks. 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. C (60. 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. C (-20. F)

These are low hydrogen electrodes and must be stored in an electrode oven at 121. C (250. 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. C (0. 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 D400E ARTICULATED TRUCKS

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

NOTE: All dimensions are in millimeters.

1. 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 under slung 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.

2. Clean the body of oil, grease, paint, and dirt in the dump body rear channel ducktail area.

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

4. 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.

5. 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.

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

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

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

9. 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.

10. Refer to Illustration #1 for part locations.

11. Assemble & tack Item 1, See (Illustration #2)

12. Assemble, Tack Item 2, See (Illustration #3)

13. Assemble & Tack Item 3, See (Illustration #4)

14. Assemble & Tack Item # 4, See (Illustration #5)

15. See Illustration 1 for weld sizes.

Illustration 1 - Location of Parts

Illustration 2 - Item #1 - Reference #1534829

Illustration 2 - Item #3 - Reference #1534699

Illustration 4 - Item #3 - Reference #1541596

Illustration 5 - Item #4 - Reference #1541595