INSULATION 3727587 - Caterpillar

March 17, 2000
(Revised September 2001)
U-92
A-73
AU-55
H-28
O-79
beforeor
after failure PRODUCT SUPPORT PROGRAMFOR REPAIRING THE RADIATOR TOP TANK FILLER NECK TUBE ON 938G, 950G, 962GWHEEL LOADERS AND IT38G AND IT62G INTEGRATED TOOLCARRIERS
1353 PS40124
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS40124"as the Part number and "7755" as the Group Number. If adminstered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If adminstered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe March 17, 2000 (Revised April 2000) Service Letter. Changes have beenmade to the Affected Product.TERMINATION DATE
March 31, 2002PROBLEM
The top radiator tank filler neck solderjoint may fail on certain 938G, 950G and 962G Wheel Loaders and IT38G andIT62G Integrated Toolcarriers. The failure is due to material flexing.A replacement neck assembly stiffens the top tank and moves the solderjoint out of the flexing plane.AFFECTED PRODUCT
Model Identification Number938G 4YS1-1996
6WS1-3097
9HS1-809950G 4BS1-616
2JS1-1664
3JW1-2014
8JW1-406
5FW1-2278962G 5AS1-315
3BS1-873
4PW1-410
6EW1-408
7BW1-851IT38G 7BS1-929
1CW1-505IT62G AKP1-509
6PS1-462PARTS NEEDED
1 - 1513015 Neck AssemblyACTION REQUIRED
See that attached Rework Procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-6000 / 0 - 36 Mo 100% 1.5 0 0 0 0
6001-Up / 37-Up mo 100% 0 0 0 1.5
This is a 1.5-hour job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)
Rework Procedure
Stop the engine and lower the implements to theground.
Turn the start key to the 'OFF' position and disconnectkey to the 'Disconnect' position.
This repair may be accomplished on the machinewithout draining and removing the tank, if care is used to avoid contactingthe brass parts with the weld rod. Use 3-mm (1/8-inch) diameter E-6013electrode with the welder set on 100 to 115 amps. Try the setting on scrapparts before welding the actual repair to check your equipment and electrodes.
Mark the orientation of the old overflow tubeon the tank.
Heat the area of the tank around the filler neckwith a 'neutral' flame and remove old brass filler neck.
Clean area of filler neck with wire brush andremove paint and any corrosion.
Center pre-soldered filler neck assembly overthe hole in the surge tank with the overflow tubes pointing in the samedirection as previously. Weld the filler neck steel base to the top ofthe surge tank using the above procedure and applying a 3 mm (1/8inch)filet weld. Use extra care in avoiding contacting the brass parts withthe electrode. Do not disturb the presoldered neck until everything hascooled.
Weld may be air tested to assure a lead free assemblyapplying 69 kPa (10 psa) air pressure and an aerated soap/water solutionto the weld. Bubbles will appear at leaks.