PRODUCT SUPPORT PROGRAM FOR IMPROVING THE FRONT FRAME BOTTOM PLATE WELDS ON CERTAIN 16M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR IMPROVING THE FRONT FRAME BOTTOM PLATE WELDS ON CERTAIN 16M MOTOR GRADERS

Usage:

TEBE2903-00

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06Apr2015

U-150

A-103

D-122

O-122

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Before/After	PRODUCT SUPPORT PROGRAM FOR IMPROVING THE FRONT FRAME BOTTOM PLATE WELDS ON CERTAIN 16M MOTOR GRADERS
7050 7051		PS44688

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must 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 "PS44688" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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TERMINATION DATE

30Apr2017

PROBLEM

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The existing front frame bottom reinforcement plate welds on certain 16M Motor Graders may not have been properly dressed at the factory. If not properly finished, the fatigue life of these welds may be reduced.

AFFECTED PRODUCT

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Model	Identification Number
16M	R9H00942-00955, 957, 961, 967-969, 973, 979-980

PARTS NEEDED

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Qty	Part Number	Description
18	7K1181	STRAP-CABLE
4	9R3761	BOSS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the Service Manual if/as necessary and see the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-16000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
16001-24000 hrs, 73-96 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 7.5-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Inspection and Repair

Remove the blade lift accumulators; refer to Disassembly and Assembly, KENR6018, Accumulator (Blade Cushion) - Remove and Install. Disconnect and remove any lights and wiring in the vicinity of the front frame bottom reinforcement plate. Disconnect electrical harness from the pin puller. Disconnect and remove the main fall sensor (if equipped). Tie all electrical harnesses and hydraulic lines adjacent to the front frame bottom reinforcement plate up and out of the way.

Remove the four bosses shown in Illustration 6. Remove the paint from the welds at the ends of the reinforcement plate as shown.

Image1.1.1

Using a weld gauge, measure the size of the welds at both ends of the bottom reinforcement plate, the bottom reinforcement plate welds adjacent to where the four bosses were removed, and the bottom reinforcement plate welds in the area under the centershift plate. Reference Illustration 7 for proper weld sizing and locations. Add weld material to any locations that do not meet minimum weld sizing requirements.

(B) 1060 mm (41.73 inch)
(C) 1010 mm (39.76 inch)
(D) 450 mm (17.72 inch)
(E) 500 mm (19.69 inch)
(F) 825 mm (32.48 inch)
(G) 875 mm (34.45 inch)
(H) 75 mm (2.95 inch)
(W1) 14 mm (0.55 inch) fillet weld
(W2) 5 mm (0.20 inch) fillet weld

Image1.2.1

Mechanically blend the weld transitions adjacent to the bosses. The weld transition should be smooth and continuous without any abrupt changes in weld size, pits, gouges, holes, or other defects.

Mechanically blend the weld start/stops under the centershift plate. The weld should have a uniform appearance without any abrupt changes in weld size, pits, gouges, holes, or other defects.

Replace the bosses using new parts (1). Reference Illustration 8 for boss locations and proper weld sizing.

(1) Boss
(L) 40 +/- 5 mm (1.57 +/- 0.20 inch)
(M) 316 +/- 5 mm (12.44 +/- 0.20 inch)
(N) 477.5 mm +/- 5 mm (18.799 inch +/- 0.20 inch)
(P) 852 mm +/- 5 mm (33.54 inch +/- 0.20 inch)
(R) 1032.5 mm +/- 5 mm (40.649 inch +/- 0.20 inch)
(W3) 3 mm (0.12 inch) fillet weld

Image1.3.1

Refer to Special Instruction, REHS8792, "Repair Procedure for the 16M Motor Grader Front Frame and Centershift Bracket" for instructions on applying a TIG dressing to the ends of the bottom reinforcement plate. Reference "TIG Dressing Procedure" section, steps 1-10. The TIG dressing must be re-applied to the ends of the bottom reinforcement plate regardless if any other rework was done or not. When applying the TIG dressing note the start and stop locations to ensure the TIG dressing is the proper length. Start/stop the TIG dressing in the center of the fillet weld and advance the TIG dressing to the toe of the weld with the bottom frame plate. When terminating the TIG dressing, advance the TIG dressing into the center of the fillet weld. Reference Illustration 9 for details.

Image1.4.1

After final inspection of all welds and TIG dressing locations, paint the frame as required for corrosion protection. Reference Special Instruction, REHS8792, section "Weld Quality Criteria, Table 4" to evaluate all welds. Reassembly all electronic and hydraulic components as required. Use Cable Straps (2) as required to restrain harnesses. Refer to Disassembly and Assembly, KENR6018.