COLLECTOR 9S3219 - Caterpillar

Problem
In some operating conditions the sides of the tractor frame on certain D25D, D30D, D40D, D350D, and D400D Articulated Trucks may crack in the area where the suspension frame pivot boss is welded into the frame rail.
Affected Product
Model & Identification Number
D25D 1HK1-268, 271-278, 292, 300, 307-312
D30D 3AJ1-220, 223-224, 229, 233-236, 238-254, 258, 272-285, 290-299, 301; 1PK1-35
D40D 2JJ1-88
D350D 9RF1-358, 373, 374, 376, 379-385, 391-392, 394-399, 410-414, 420-422, 425, 429, 435-436
D400D 8TF1-432, 434-487, 496-552, 556-570; 4EJ1-20
Parts Needed
2 - 1D4629 Cap Screw2 - 2U8929 WasherAction Required
See the attached procedure.
Service Claim Allowances
This is a 32-hour job to fabricate and install the plates. A maximum of $100.00 U.S. will be allowed for material to fabricate the plates.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Follow procedures in the Service Manual as required. Relieve drive line torque wind up and support the tractor frame on suitable stands to permit removal of the front wheels and the front axle/suspension frame assembly.
Plug all open hose and pipe ends.Use AWS A5-1-81:E7018 electrodes or equivalent for all welds.
1. Fabricate two reinforcing plates using the dimensions given in Illustration 2. Use 10 mm (.375") thick structural steel plate with a minimum tensile strength of 490 mPa (71000 psi) and a minimum yield strength of 355 mPa (51500 psi).2. Clean the affected area thoroughly (see Illustration 1). Remove all paint and inspect for damage. Any cracks must be detected and repaired before the reinforcing plates are installed. 3. Vee out any cracks found and fully weld as shown in Illustration 3. Grind weld overfill flush as shown.4. Grind the existing pivot boss welds as shown in Illustration 4 to permit flush fitting of the reinforcing plates.5. Tack weld the reinforcing plates in position as shown in Illustration 5.6. Fully weld the reinforcing plates in position as shown in Illustration 6. Apply the welds strictly in the sequence and direction shown.a) Welds (3) and (4) continue into existing steer bracket welds for 50 mm.b) Weld (5) must be continuous with no stop-starts. c) Weld (6) should completely fill the areas between the reinforcing plate and the existing weld.7. Clean and paint the repair area as required.8. Install all components previously removed. During assembly, install washers (7) and bolts (8) in place of the former parts as shown in Illustration 7.9. Bleed the brakes as described in the Service Manual and check that all systems are leak free and operating correctly.
Illustration 1 - Crack Location
Illustration 2 - Reinforcing Plate
Illustration 3 - Preparation
Illustration 4 - Preparation
Illustration 5 - Reinforcing Plate Tack Welds
Illustration 6 - Weld Detail
Illustration 7 - Location of Washer & Bolt