ENGINE AR-COMP 10R1655 - Caterpillar

If the affected machine has less than 2000 hours, the failed boom can be weld repaired or replaced at the dealers discretion based on the commercial situation, Please communicate with local Technical Representative and EXD Product Support team.
If the boom is replaced, refer to the proration table in the Service Claim Allowance section of this Service Letter.
If the machine has more than 2000 hours, refer to the attached Rework Procedure for the boom repair. Also refer to the proration table in the Service Claim Allowance section of this Service Letter.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-2000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
2001-4000 hrs,
13-24 mo 33.0% 100.0% 0.0% 0.0% 50.0% 0.0%
4001-6000 hrs,
25-36 mo 0.0% 100.0% 0.0% 0.0% 100.0% 0.0%
This is a 6.0-hour job
Note: Do NOT place order of 3920284/">392-0284 Boom prior to communication with EXD Product Support team for the repair.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".
Refer to the Service Manual if/as necessary.
Refer to REHS1841, Special Instruction, "General Welding Procedures", and SEBD0512, Reuse And Salvage Guidelines, "Caterpillar Service Welding Guide", before proceeding through the next steps.
Rework Procedure for a Boom Crack Issue:
Refer to Image1.1.1 for the location of the issue.
Image1.1.1
1. Clean the area for inspection. Refer to REHS1841, Special Instruction, "General Welding Procedures", "Proper Cleaning for Inspection".
2. Prepare the area for welding. Refer to REHS1841, Special Instruction, "General Welding Procedures", "Preparing the Area for Welding".
3. Use the dye penetrant to inspect the entire area for possible cracks.
4. Protect the machined surfaces from sparks and weld deposits.
5. Use an air carbon arc torch in order to gouge out the crack completely. Refer to Image1.2.1.
Image1.2.1
6. Use a grinder in order to gouge a beveled angle greater than 25 degrees. Refer to Image1.3.1.
Image1.3.1
7. Use the dye penetrant to inspect the gouged area in order to ensure that the crack has been removed. Be sure to clean the prepared groove before welding.
8. Weld the gouged groove with enough penetration. Tie-in to each plate with the proper weld penetration.
9. Grind the weld toe (R3 min.) after the weld has cooled. Refer to Image1.4.1.
Image1.4.1
10. Relieve the stress in all welds by needle peening. A wire brush can be used to clean the welded area.
11. Use Caterpillar authorized paint for painting the welds.