PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE ROPS ON CERTAIN CP-663E, CS-663E, AND CS-683E VIBRATORY SOIL COMPACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE ROPS ON CERTAIN CP-663E, CS-663E, AND CS-683E VIBRATORY SOIL COMPACTORS

Usage:

SEBE9031

January 10, 2005
U-14
D-13
O-14

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE ROPS ON CERTAIN CP-663E, CS-663E, AND CS-683E VIBRATORY SOIL COMPACTORS
7323		PI10344

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10344" as the Part number and "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 "PI10344" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The ROPS assembly needs to be inspected on certain CP-663E, CS-663E, and CS-683E Vibratory Soil Compactors. If water accumulation or deformation of the support tube is found the ROPS may need to be repaired or replaced. A deformed support tube may reduce the ROPS effectiveness in a rollover and may result in personal injury or death to the operator.

AFFECTED PRODUCT

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Model	Identification Number
CP-663E	ASF00201, 202, 203, 204
CP-663E	DAF00212, 214
CP-663E	AFL00301, 304, 306, 307, 314, 315
CS-663E	ASB00100, 101, 104, 109
CS-663E	AEF00302, 315, 319, 332, 343, 346, 350, 373, 374, 381, 382, 383, 395
CS-663E	DAG00343
CS-683E	AGR00307, 308, 317, 331, 334, 355, 369
CS-683E	DAD00309, 310, 311, 341, 344
CS-683E	ASG00302, 309

PARTS NEEDED

Dealers will need to order parts for this Program.

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Quantity	Part Number	Description
22 *	8T4123	WASHER-HARD
10 *	8T4131	NUT
12 *	7X2563	BOLT
1 *	2008670	ROPS AS
* No parts are required unless the ROPS fails the initial inspection.

ACTION REQUIRED

See the attached procedure.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1	0	0	0	0
NOTE: This is a 1-hour job to inspect the ROPS.
NOTE: When required, 4 hours will be allowed to replace the ROPS.
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.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999 SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE ROPS ON CERTAIN CP-663E, CS-663E, AND CS-683E VIBRATORY SOIL COMPACTORS MODELS INVOLVED - CP-663E, CS-663E, AND CS-683E VIBRATORY SOIL COMPACTORS

Dear Caterpillar Product Owner:

The ROPS assembly needs to be inspected on the products listed below. If water accumulation or deformation of the support tube is found the ROPS may need to be repaired or replaced. A deformed support tube may reduce the ROPS effectiveness in a rollover and may result in personal injury or death to the operator.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated January 10, 2005 when scheduling this service. You will not be charged for the service performed.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to January 10, 2005 Service Letter

REWORK PROCEDURE

Note: Parts will be needed only if the ROPS does not pass the inspection criteria. Common hand tools needed:

Small Steel Square

Small Steel Rule (Metric)

1. Inspect the ROPS in the two locations marked (A). Determine if there are holes present on the top of the ROPS support tube at the two locations marked (A).

2. Holes in the locations marked (A) may have been previously plugged with sealant. If sealant is present, remove the sealant from the holes in both locations (A). The sealant may have become dry and hardened.

3. If holes are not present in the locations marked (A) proceed to step 19. If holes are present in the locations marked (A), proceed to step 4.

4. Both ROPS support tubes (C) must be checked for a convex surface (curving outward) and cracks. A convex surface or cracks may exist due to water freezing in the support tube.

5. Check for a convex surface on the outer surface of the ROPS support tubes (E). Check the entire length (D) of the ROPS support tube. A convex surface greater than 1 millimeter would be the result of water freezing inside the tube.

6. Use a small square to check for convex surface on the ROPS support tube. Hold one side of the square flat against the front surface of the ROPS support tube. Hold the other side of the square against the outside surface of the ROPS support tube. Use the square to check the entire length (D) of the ROPS support tube.

7. Measure any gaps (F) that may exist between the square and the outside surface of the ROPS support tube.

Note: The ROPS support tubes have a radius at each corner. Any gaps that are measured should not be measured at the area of the radius at each corner. Do not measure on the radius at each corner. 8. The maximum gap (F) should be no more than 1 millimeter. If the gap (F) measures more than 1 millimeter the ROPS should be considered damaged. If gaps (F) measure 1 millimeter or less than the ROPS should be considered acceptable. Note: The ROPS support tubes may have a concave surface (curving inward). A concave surface (G) is acceptable and is of no concern.

9. Repeat steps 7-9 for the opposite side ROPS support tube.

10. Visually inspect the entire length (D) of the ROPS support tube (E) for any signs of cracks, cracked welds, or deformation. If any cracks, cracked welds, or deformation exist the ROPS should be considered damaged. If no cracks, cracked welds, or deformation exist the ROPS should be considered acceptable.

11. Repeat step 11 for the opposite side ROPS support tube.

12. If the ROPS is considered damaged it must be replaced. Proceed to step 18.

13. If the ROPS is considered acceptable it will not need to be replaced. Proceed to step 14.

14. Remove the two bolts (B) which connect the ROPS to the operator's platform. The bolts (B) are threaded directly into the plate on the bottom of each ROPS support tube (C). The bolts (B) are 20mm bolts. Removing the bolts will allow any water that may have accumulated in the ROPS support tubes to drain out.

Note: A significant amount of water may have accumulated in each of the ROPS support tubes. Use caution when removing the bolts (B). Prepare for a significant amount of water flow when the bolts are removed. 15. Fill the existing holes (A) with weld. Grind the weld smooth. Repeat this process for opposite side.

16. Paint the welded areas after the weld has cooled.

17. Reinstall the two bolts (B) that were removed in step 4. Tighten the two bolts to 460 +/-60 Nm (339 +/-44 Lb Ft). Proceed to step 19.

18. Replace the ROPS per disassembly and assembly manual KENR3574 if the ROPS is damaged as a result of water freezing in the support tubes.