STEM-TRAVEL 1163620 - Caterpillar

TERMINATION DATE
31Jul2014
PROBLEM
The existing pedestal frame welds may be undersized on certain 797F Off-Highway Trucks. If the existing weld is undersized, it can crack and cause unplanned downtime. Cracks have been found in the first six months of operation.
AFFECTED PRODUCT
Model Identification Number
797F LAJ00273-00352
797F XQ WSP00101-00114
PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
Refer to the attached Rework Procedure. Refer to REHS0744 for complete welding instructions.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-14000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job
An additional 1 hour per side is allowed if repairing after failure for crack excavation. Note in the service claim which side the crack was found on.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
This procedure is for the repair of the 3 front pedestal welds on the 797 Off-Highway Truck. For complete repair insctruction, see REHS0744
1.The front pedestals should be checked on the left outside and the right outside (see Image 1.1.1).
2.The size of the welds should also be checked, using a fillet weld gage. The proper size fillet gage should be used corresponding to the weld size call out in Image 1.1.2 plus the distance of the gap (See Note 2).
3.If there is a defect then it must be cut out using Air Carbon Arc gouging or a grinder.
4.Once the defective weld has been cut out, the welder should measure the gap between the plate and the front rail. If the gap is 2 mm or under or can be closed to 2 mm or under with a clamp then the welder should apply the appropriate fillet weld according to Image 1.1.2. If the gap cannot be closed to less than 2 mm, the fillet weld leg size must be increased by the distance of the gap (see Note 2).
5.If there is not a defect, but the weld is undersized then the welder should add weld passes until the size measures the call outs in Image 1.1.2. If there is a gap of more than 2 mm, the fillet weld leg size must be increased by the distance of the gap (see Note 2).
6.The stops and starts on the welds need to be feathered and ground smooth when all welding is finished. (Blend Profile)
Note 1: The welder should note the no weld locations as specified on Image 1.1.2.
Note 2: For example, with a 4mm gap and a 12mm fillet weld, the required weld size becomes a 16mm fillet weld.
Image1.1.1
Image1.1.2