PRODUCT SUPPORT PROGRAM FOR ULTRASONIC INSPECTION AND REWORK OF THE 451-2853 BOOM AND BEARING ASSEMBLY ON CERTAIN MH3022 AND MH3024 MATERIAL HANDLERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR ULTRASONIC INSPECTION AND REWORK OF THE 451-2853 BOOM AND BEARING ASSEMBLY ON CERTAIN MH3022 AND MH3024 MATERIAL HANDLERS [UEBE0154]

IMPLEMENTS

BOOM GP

PRODUCT SUPPORT PROGRAM FOR ULTRASONIC INSPECTION AND REWORK OF THE 451-2853 BOOM AND BEARING ASSEMBLY ON CERTAIN MH3022 AND MH3024 MATERIAL HANDLERS

UEBE0154-00

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14Jul2020

L110
L111
M610
Z800

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR ULTRASONIC INSPECTION AND REWORK OF THE 451-2853 BOOM AND BEARING ASSEMBLY ON CERTAIN MH3022 AND MH3024 MATERIAL HANDLERS
6501		PS46792

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NOTE:

AVSpare’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to AVSpare.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46792" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your AVSpare product analyst.

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TERMINATION DATE

31Jul2022

PROBLEM

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The existing 451-2853 Boom and Bearing Assembly can show cracks in the boom nose area on certain MH3022 and MH3024 Material Handlers. Certain welds in the boom nose area can have deficiencies and need to be inspected. If the existing 451-2853 Boom and Bearing Assembly shows cracks, it can lead to a complete boom nose break. Inspection and rework will avoid a boom break.

AFFECTED PRODUCT

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Model	Identification Number
MH3022	FB300164, 168, 182-188, 190, 202, 226, 233-234, 239, 248, 270, 273, 286, 299, 301, 304-305, 317, 321, 2259, 2267, 2317, 2367, 2389, 2422, 2487, 2512 FM200283, 292-294, 296, 316, 320, 322-323, 326, 336, 339-340, 343, 355-358, 370-371, 380, 382, 385, 404, 409-410, 412-413, 420, 422-423, 426, 431, 437, 440-441, 446-447, 453, 455, 457-459, 472-473, 489-490, 497, 500, 523, 527, 529
MH3024	FB700288, 307, 310, 313, 326, 340-341, 344-345, 372, 374-375, 378, 395, 409-410, 415, 435, 439, 458, 471, 474-475, 478-479, 504, 519, 521, 523, 537, 541, 543-545, 548-549, 555-556, 560, 563, 569, 580-582, 586, 588-590, 600-601, 603

PARTS NEEDED

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Qty	Part Number	Description
1	5923366	BOOM AS-BEARING (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Inspection of the longitudinal welds shown in Image1 is required.

Depending on the outcome of the inspection different action is required.

1. In case a visual inspection is already showing cracks in the area of the boom nose, please contact your Dealer TC. Create a GDSN Product Health Service Request (SR) to receive instructions if the failed part can be repaired or has to be replaced by an improved component 592-3366 Boom and Bearing Assembly. Include the Component Serial Number and attach all relevant photos to the SR prior to submitting to AVSpare.

2. In case no cracks are detected during the visual inspection, an ultrasonic inspection (UT-check) following the instruction provided in the attached CONVENTIONAL ULTRASONIC INSPECTION INSTRUCTION SHEET needs to be performed. Weld deficiencies identified in the UT-Check need to be repair welded.

If repair welding is required after Visual or Ultrasonic Inspection, refer to the attached Rework Procedure "Repair Instruction of the Boom Nose".

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 61-72 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 14.0-hour job
The labor hours stated in the Service Claim Allowance Table is applicable: a) In case of replacement of 451-2853 Boom and Bearing Assembly is required. b) Boom removal to ensure proper weld position to achieve full penetration weld quality of repair weld is required. Note: This allowance covers the required labor for stick and boom, removal and installation, as well as disassembly and assembly of the hose and tubes at the boom. Additional labor allowance for Initial Ultrasonic Inspection and Repair Weld if required. Case 1: Repair Weld of visible cracks. In case visible cracks in the boom nose area are detected and require repair weld, qualified personnel needs to perform this repair welding. If non Dealer personnel is performing the repair weld, costs only will be reimbursed if a copy of the companies invoice is attached to the claim. No labor hours for the repair weld can be claimed in addition to the outside companies invoice. If Dealer personnel is performing the repair weld, 4 Hours Labor can be claimed in addition. Case 2: Initial Ultrasonic Inspection and Repair Weld. 2 Hours Labor will be allowed for cleaning, preparation of the Initial Ultrasonic Inspection (UT-Check) and repainting the front nose area. As the UT-Check needs to be applied at the lower boom nose area generally it can be conducted in the installed position by using some kind of safe scaffolding to get access to the welds. Stick and Boom Removal are not required. If non Dealer personnel is performing the ultrasonic test, costs only will be reimbursed if a copy of the UT-Check-Companies invoice is attached to the claim. Also the UT-Check Report, following the attached CONVENTIONAL ULTRASONIC INSPECTION INSTRUCTION SHEET needs to be provided along with the claim. No labor hours for the ultrasonic test can be claimed in addition to the outside companies invoice. In case UT-Inspection shows weld deficiencies which require repair weld, qualified personnel needs to perform this repair welding. If non Dealer personnel is performing the repair weld, costs only will be reimbursed if a copy of the companies invoice is attached to the claim. No labor hours for the repair weld can be claimed in addition to the outside companies invoice. If Dealer personnel is performing the repair weld, 4 Hours Labor can be claimed in addition. After Repair Weld Ultrasonic Inspection.: All repaired welds require an Ultrasonic Inspection. If non Dealer personnel is performing the after repair ultrasonic test, costs only will be reimbursed if a copy of the UT-Check-Companies invoice is attached to the claim. Also the UT-Check Report, following the attached CONVENTIONAL ULTRASONIC INSPECTION INSTRUCTION SHEET needs to be provided along with the claim. No labor hours for the after repair ultrasonic test can be claimed in addition to the outside companies invoice. If available, a company providing UT-Check and Repair-Weld service at once should be selected to reduce machine downtime and logistics effort to a minimum.

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Repair Instruction of the Boom Nose

Image1.1.1

1. Check the existing welds for failures by visual inspection and ultrasonic check.

The longitudinal weld between the side plate and bottom plate, at boom nose area, need to be inspected.

Check for visible cracks in the welds. Refer to Image1.2.1. If no cracks are visible, perform an ultrasonic inspection (UT-check) following the instruction provided in the attached CONVENTIONAL ULTRASONIC INSPECTION INSTRUCTION SHEET.

Image1.2.1

2. Grind out the failure weld.

In the case that visible cracks or weld deficiencies are identified, grind out failure weld at the bottom plate and create weld preparation as indicated in Image1.3.1.

Image1.3.1

3. Reweld the failure areas.

Welds need to be completed as full penetration welds as specified in Image1.4.1.

Image1.4.1

4. Welding information.

Refer to Image1.5.1 for the weld symbols and requirements.

Image1.5.1

5. Welding requirements.

Welding quality is critical to the success of the repair procedure. The welds must be smooth and continuous. No undercutting is allowed. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Note: Refer to REHS1841, Special Instruction, "General Welding Procedures", and SEBD0512, Reuse And Salvage Guidelines, "AVSpare Service Welding Guide", before proceeding through the next steps.

Prepare the metal for welding according to "Preparing the Metal for Welding". Refer to the illustrations for welding symbols and specifications.

Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to repair weld the boom. Basic welding wire ESAB OK tub rod 15.00 with a 1,2mm (0,05in) diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E17T-5 with positive polarity. The welding wire must be shielded with CO? gas.

Welding of the gouged grooves requires LB-52 (AWS E7018), or an equivalent electrode. Basic welding wire ESAB OK tub rod 15.00 with a 1,2mm (0,05in) diameter can also be used.

All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300 degrees Celsius (572 degrees Fahrenheit). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16 degrees Celsius (60 degrees Fahrenheit).

Penetration characteristics may vary greatly depending on the electrode diameter, shielding gas, welding current and plate thickness. Geometry of welded joints, surface conditions and composition of the base metal and electrode also affect welds.

A root pass should be applied before each weld is finished.

For more welding information, consult the REHS1841, AVSpare Service Welding Guide.

6. Preparing the metal for welding.

Cover all finished bores and threads. Finished bores and threads must be protected from all of the following items: foreign material, gouging and paint spatters. Do not remove the covers until the boom is painted.

All grease, water, paint, rust, dirt and scale must be removed before welding. Any of these materials will discharge gas, which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove paint, rust, dirt and scale with a wire brush or by buffing or grinding. Shot blasting all work areas will also remove foreign material.

Remove any oil or grease that is on the boom with a AVSpare approved solvent.

7. Repair instruction.

Refer to Steps a through e.

a) Clean the boom. Remove all foreign material and paint from the weld areas. Refer to "Preparing the Metal for Welding" for more details.

b) No double plates are necessary.

c) Repair case of visible crack failure at boom nose. Grind out crack to its full depth by air arc gouging or grinding by following the separate repair instruction. Using a dye penetrant of magnaflux makes finding depth of crack easier. Fill this area with the appropriate weld ensuring full weld penetration. Refer to "Welding Requirements" for more details.

d) Repair case of weld deficiency identified by UT-Check at boom nose. Grind out marked rejectable indications defined by UT-Check to the full root (full plate thickness) by air arc gouging or grinding. Fill this area with the appropriate weld ensuring full weld penetration. Refer to "Welding Requirements" for more details.

e) Grind the welds to an even surface.

Note: The preferred weld position is horizontal, or if horizontal is not possible, the bottom-up-method.

8. Ultrasonic inspection of repair welds.

Do an Ultrasonic check of the repaired areas, after the rework is finished. Refer to following Standards and follow the instruction provided in the attached CONVENTIONAL ULTRASONIC INSPECTION INSTRUCTION SHEET:

ISO 5817 C Welding ISO 6520 Classification of geometric imperfections in metallic materials EN 1714 Non destructive testing of weld joints ? Ultrasonic testing of weld joints.

9. Painting and coating of the boom.

a) Shot blast all the welded areas. A wire brush or a grinder can also be used to clean the welded areas.

b) Paint all of the welds, plates in the boom nose area. Use a AVSpare authorized paint.

c) Remove all protective covers from the bores and threads once the paint has dried.

d) The bores must be free of paint and grease prior to assembly of the bearings.

e) Refer to the Operation and Maintenance Manual and Service Manual for lubrication instructions and quantities.

10. CONVENTIONAL ULTRASONIC INSPECTION INSTRUCTION SHEET: