CYL HSG-LH 1055353 - Caterpillar

ACTION REQUIRED
If the crack is not propagating out of the welds as shown in the below picture, apply the attached rework procedure.
If the crack is propagating out of the weld into the plate, please take pictures. Submit this information to the Dealer Solution Network (DSN) through your Technical Communicator in order to obtain the information that is necessary to complete any repairs, making sure to reference this service letter program number in the Service Request.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-5000 hrs,
25-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 6.0-hour job
A maximum of $300.00 U.S. will be allowed for materials and labor to fabricate the plates listed in the parts needed section.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Place the machine on flat, level ground.
2. Activate the implements to position the fore boom to ensure that the reworked area in on a horizontal plan - See Image 1.1.1.
Image1.1.1
3. Release the hydraulic circuit pressure from the hydraulic circuit. Refer to Testing and Adjusting Manual, RENR5509, "Hydraulic System Pressure - Release".
4. Remove the key which starts the machine, secure the cab, and disconnect all power and ground leads from the batteries in order to avoid possible damage to the electronic components.
5. Remove the fore boom cylinder.
6. Protect finish bores and surfaces from spatter when welding.
7. Remove the cracked area by arc air method or grinding (grind the gouged area if arc air method is used to remove slag or carbon pickup).
8. Use dye penetrant to make sure that the crack is completely removed, or the repair could fail.
9. Reweld the gouged/ground area.
10. Manufacture 2 reinforcement plates according to Image 1.2.1.
Image1.2.1
11. Hold the first reinforcement plate and tack weld on the end of the plate (location 1). Check the alignment with the existing plate using a level.
Make the second tack weld on the other end of the plate (location 2). Recheck the alignment.
Make additional tack welds to hold the reinforcement plate in position before the final welds are made (locations 3,4,5,6).
Image1.3.1
12. Weld from point A to point B on both sides (10 mm bevel joint - see Image 1.4.1). Build the deposit up equally on each side of the joint to allow contractive forces to balance each other and prevent distorsion. Grind this weld so that the surface is flush with the ear.
13. Weld from point B to point C on both sides (8 mm fillet weld) - See Image 1.4.1.
14. Weld on point A - See detail A of Image 1.4.1.
15. Weld on point C - See detail B of Image 1.4.1.
16. Grind toes of the welds on point A and point C to get a smooth transition profile.
17. Repeat steps 6 to 13 for the second reinforcement plate.
18. Paint the repaired area.
19. Reassemble the fore boom cylinder.
20. Reconnect the power and ground leads from the batteries.
Image1.4.1