Instructions for Repairing the Rollover Protection Group on Certain H Series Wheel Tractor-Scrapers{7301} Caterpillar

Wheel Tractor-Scraper:

621H (S/N: DBK1-UP; HKK1-UP; NYY1-UP; EAZ1-UP)

623H (S/N: EJD1-UP; DBF1-UP)

627H (S/N: LCT1-UP; DBW1-UP)

Introduction

ReferenceAVSpare Service Welding Guide, SEBD0512

On certain H Series Wheel Tractor-Scraper that have a 309-6560 Rollover As the FOPS plates welds may be defective. This issue will result in machine down time.

Note: If the defective weld has resulted in a crack, perform the entire rework procedure on the crack. Do not try to repair the crack.

Safety

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your AVSpare dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

Prepare the Machine For Rework

1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel. Place the transmission direction control switch in the NEUTRAL position. Engage the parking brake. Lower the bowl to the ground and lower the apron to the bowl floor. Stop the engine and put chocks in front of the wheels and behind the wheels.

2. Disconnect all power to the cab.

3. Inspect work area and machine for flammable materials or liquids and properly isolate or remove from area.

4. Cover the engine compartment with a tarp to protect the engine compartment from sparks and slag. Protect all components in the vicinity of this rework from sparks and slag.

Required Tooling

Table 1

Tooling used to Perform This Rework Procedure
	Quantity	Tool Number	Tool Name
	As Required		Sander /Buffing Wheel
	1		Hand Grinder
			Use one of the two provided WPS (MIG or stick)
			Welding Equipment 0.035" dia, ER70S filler weld wire
		4C-5843	Black Paint
		4C-4205	Primer Paint
	As Required		Personal Protective Equipment
A	If Needed (1)		Roof flattening tool
B	(2)		One 2 x 2 x 61 long angle iron
C	5	8T-5911 (2)	Weld Nut
D	5	8T-4835 (2)	Bolts
E	2	7X-2572 (3)	Bolt

( 1 )	Requires items (B), (C), (D), and (E)
( 2 )	Used to manufacture one roof flattening tool (A). Measure the distance between the cab lifting bosses to verify this length.
( 3 )	Required to install one roof flattening tool onto the cab bosses. Check to see if the bolts are installed in your cab bosses.

Table 2

Parts Required for this Rework
Item	Qty	Part Number	Part Name
1	2	464-0553	Plate

Welding Specifications and Qualifications

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel who are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to AWS D1.1 Structural welding code-steel or equivalent nationally or Internationally recognized code or standard for guidance on welder qualification testing requirements. The welders must have used the process at some time within the last six months. The welders must complete the process of certification if the welders have not used the welding processes for six months.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This procedure will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses from the welding spatter.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C (60° F).

Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6° C (60° F) requirement.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the welding spatter.

Required Tooling

The following tools are needed, and these tools are in addition to the normal supplies in the shop:

• The Welding equipment and electrodes that are shown above

Weld Inspection and Acceptance Criteria

Note: For Definition or visual examples or defect types reference ISO 6520.

Table 3

Defect Name	Remarks	Defect Limit
Cracks - Longitudinal, Transverse, Radiating, Crater, Disconnected, Branching	--	Not Permitted
Crack - Transverse	Hard Surfacing Welds Only	Permitted
Crack - Transverse	Joining Welds	Not Permitted
Surface Porosity	Maximum Diameter for a Single Pore	1 mm (0.040 inch)
	Maximum Pores in Any 300 mm (11.81 inch) Length of Weld	6
	Maximum Number of Pores in Any 50 mm (2.0 inch) of Weld Length for Welds Less Than 300 mm (11.81 inch) in Length	1
Clustered Porosity	Maximum Length of Cluster in Any Weld	3 mm (0.120 inch)
Elongated Cavities	Maximum Height or Width	3 mm (0.120 inch)
	Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
	Maximum Length in Any Weld	10% of Weld Length
Shrinkage Cavities	Maximum Diameter or Length	1 mm (0.040 inch)
Slag or Flux or Oxide Inclusions	Maximum Height or Width	1mm (0.040 inch)
	Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
	Maximum Length in Any Weld	10% of Weld Length
Puckering (Oxide Inclusion - Aluminum)	--	Not Permitted
Metallic Inclusion	--	Not Permitted
Lack of Fusion	Visual (Breaking the Surface)	Not Permitted
	Subsurface Maximum Height or Width	1mm (0.040 inch)
	Subsurface Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
	Maximum Length in Any Weld	10% of Weld Length
Lack of Penetration	Maximum Reduced Penetration	10% of Nominal Penetration Not to Exceed 1mm (0.040 inch)
	Maximum Allowed Total Length of Reduced Penetration	10% of Weld Length
Undercut	Maximum Depth Measured From Plate Surface - Any Length	0.5 mm (0.020 inch)
Excess Weld Metal - Groove Weld Reinforcement (Convexity)	Any Length	--
	Weld Face Width 20 mm (0.79 inch) or Less	2 mm (0.079 inch)
	Weld Face Width Over 20 mm (0.80 inch) But Less Than 30 mm (1.20 inch)	3 mm (0.120 inch)
	Weld Face Width 30 mm (1.20 inch) and Over	4 mm (0.160 inch)
Excess Weld Metal - Fillet Weld Convexity	Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
	Weld Toe Angles of 135 Degrees and More Are Better	--
Excess Penetration	Without Drawing Limitation	2 mm (0.080 inch) (Any Length)
	With "Melt - Thru" and "Flush" Weld Symbols	1 mm (0.040 inch) (Any Length)
	With "Melt - Thru" and "Grind Flush" Symbols	Not Permitted (After Grinding)
Overlap	Expressed as Minimum Toe Angle	90 Degrees
Fillet Weld Leg Size - Undersize	Applies to Either Weld Leg Measured Independent of the Other	--
	Maximum Undersize	1 mm (0.040 inch)
	Maximum Length of Undersize Weld	10% of Total Weld Length If At Least 10% of Total Weld Length is at Least 1 mm (0.040 inch) Over Nominal Size, Otherwise, No Undersize Length is Permitted
Fillet Weld Leg Size - Oversize	Applies to Either Weld Leg Measured Independent of the Other	--
	Maximum Oversize	+25% (max 3 mm (0.120 inch))
	Conformance to Design - Fillet Weld Leg Sizes May be Oversized (Within Defect Limitations or Beyond) Without Repair Provided the Excess Does not Interfere with Satisfactory End Use of the Component (i.e., Distortion, Fit-Up Interference, etc.) A Documented Deviation Process Shall Be Used, And Corrective Action Pursued To Eliminate Further Deviations	--
Fillet Weld - Linear Length When Specified At Less Than The Length Of The Joint	Weld Size ≤ 6.5 mm (0.256 inch)	± 6.5 mm (0.256 inch)
	Weld Size ≥ 6.5 mm (0.256 inch)	± 12.5 mm (0.492 inch)
Fillet Weld Throat Size - Undersize	Nominal Size (0.7 x Leg Size) Not Inclusive of Penetration Beyond the Weld Root	Not Permitted
	Weld Crater Only	2 mm (0.080 inch) MAX Maximum Undersized- and Not to Exceed 20% of Specified Throat
Incompletely Filled Groove Weld	Careful Consideration Needs to be Given When Plate Mismatch is Apparent	Not Permitted
	Weld Depth Must be Maintained as a Minimum	--
Root Concavity on Open Root Groove Welds	Maximum Depth measured From Plate Surface or Tube Inner Surface - Any Length	0.5 mm (0.020 inch)
Poor Restart (Tie - In)	Measured in Terms of Excess Weld Metal (Fillet Weld Convexity) or Overlap on Groove Welds, Lack of Fusion, or Insufficient Throat	--
	Excess Weld Metal on Fillet Welds, Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
	Overlap on Groove Welds, Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
	Lack of Fusion - Visual Maximum Length Per Restart	3 mm (0.120 inch)
	Insufficient Weld Throat	Not Permitted
Stray Arc Strike	--	Not Permitted Without Repair
Slag	SMAW, SAW, FCAW, GMAW, GTAW	Not Permitted
	--	Silicon Residue Permitted Unless Removal Specified by Drawing Note
Combined Discontinuities	Total Maximum Combined Length of All Imperfections in a Weld, Expressed as a Percent of Total Weld Length	15%
	(No Single Type of Imperfection Can Exceed the Limits for That Single Type of Imperfection)	--

Welder Certification and Details of Weld Test for GMAW Procedure

Welder must be qualified to meet AWS D14.3, AWS D1.1, AWS B2.1

Table 4

AVSpare Wheel Tractor-Scraper ROPS Rework Procedure GMAW, MANUFACTURERS WELDING PROCEDURE SPECIFIAVSION (WPS)
General Information:
Qualifying Manufacturer	Cat dealer
Qualifying Location	Local Customer Dealer
PQR Number / Revision	N/A
Date	6/16/2014
Joint Design:
Weld preparation detail (Sketch)	See below

Illustration 1	g03731472
(A) 35 mm (1.38 inch) (B) Doubler Strip (C) Roof (D) ROPS (E) 6 mm (0.24 inch) (F) 5 mm (0.196 inch) (G) 4 mm (0.16 inch)

Table 5

Backing material / Thickness	N/A
Details of back gouging	N/A
Joint Type / Weld Size	Lap / 5 mm
Root Opening	N/A
Required Root Penetration	N/A
Groove Angle	N/A
Filler Materials:
Filler metal classification and trade name	ER70S-6
Filler metal specification	AWS 5. 18
Electrode diameter	.9mm
Number of Electrodes	1
Electrical Characteristics:
Transfer mode (short, arc, globular, spray	Short Arc
Current ( AC, DCEP, DCEN, Pulsed	DCEP
Pulse welding details (current, frequency)	N/A
Tungsten Electrode Type / size	N/A
Preheat:
Preheat temperatures (Min. / Max.)	N/A
Inter-pass temperatures (Min. / Max.)	N/A
Other information:
Examiner or test body authorized by
WPS number / revision	WPS 01
Welders name / ID Number
Welding process	GMAW
Applicable Welding Standard	MS-4025
Programmer	N/A
Base material ( Mtl. 1 / Mtl. 2)
AVSpare material specifications	Part Number Specified
MS 4025 Group	1. 1, 1. 2, 1. 3
Material thickness	4-5 mm
Outside diameter (pipe)	N/A
Method of preparation and cleaning	Grinding or Wire Brushing
Position:
Position	2F /Horizontal
Vertical Progression	N/A
Shielding
Shielding gas composition / flow rate	75% Ar / 25 %CO2 / 21L / Min
Gas Cup size	19mm ID
Flux	N/A
Electrode-flux specification (class)	N/A
Back shielding particulars	N/A
Technique
Stringer or weave bead	Push/Stringer
Oscillation (amp., freq., dwell time)	N/A
Multiple or single pass per side	Single
Electrode Spacing (longit., lat., angle)	N/A
Contact tube to work distance	15 - 25 mm
Manual, Semi-automatic, or Automatic	Semi-auto
Torch Angle	10-20 Degrees
Inter-pass cleaning	Grinding or Wire Brushing
Post Weld Heat Treat. / Aging
Time, temperature, method	N/A

Table 6

Welding Details
Pass	GMAW	Filler Metal Class / Size	WFS (m/min	Volt	Amps.	Travel Speed (mm/s	Heat Input (KJ/mm	Shielding gas
All	GMAW	ER70S-6 0.9 mm (0.035 inch)	436-533 (485IPM 12-12.7	21.6-26.4 (24)	190-200	15-20 IPM 6.3-8.4	N/A	35-40

Welder Certification and Details of Weld Test for SMAW Procedure

Welder must be qualified to meet AWS D14.3, AWS D1.1, AWS B2.1

Table 7

AVSpare Wheel Tractor-Scraper ROPS Rework Procedure SMAW. MANUFACTURERS WELDING PROCEDURE SPECIFIAVSION (WPS)
General Information
Qualifying Manufacturer	Cat dealer
Qualifying Location	Local Customer Dealer
PQR Number / Revision	N/A
Date	6/16/14
Joint Design
Weld preparation detail (Sketch)	See below

Illustration 2	g03731472
(A) 35 mm (1.38 inch) (B) Doubler Strip (C) Roof (D) ROPS (E) 6 mm (0.24 inch) (F) 5 mm (0.196 inch) (G) 4 mm (0.16 inch)

Table 8

Backing material	N/A
Details of back gouging	N/A
Joint Type / Weld Size	Lap joint / 5mm
Root opening	N/A
Required root	N/A
Groove angle	N/A
Filler Materials
Filler metal classification and trade name	ER70S-6
Filler metal specification	AWS 5. 18
Electrode diameter	3.2 mm (0.125 inch) or 2.4 mm (0.095 inch)
Number of Electrodes	1
Electrical Characteristics:
Transfer Mode (short arc globular, spray.	N/A
Current ( AC, DCEP, DCEN, Pulsed	DCEP
Pulse welding details (current, frequency)	N/A
Tungsten electrode type / size	N/A
Preheat:
Preheat temperatures (Min. / Max.)	N/A
Inter-pass temperatures (Min. / Max)	N/A
Other information:
Examiner or test body authorized by
WPS number / revision	WPS 01
Welders name / ID Number
Welding process	SMAW
Applicable Welding Standard	MS-4025
Programmer
Base Material (Mtl. 1 / Mtl. 2)
AVSpare material specifications	Specified Part Number
MS 4025 Group	1. 1, 1. 2, 1. 3
Material thickness	4-5 mm
Method of preparation and cleaning	Grinding or Wire Brushing
Position
Position	2F /Horizontal
Vertical Progression	N/A
Shielding
Shielding gas composition / flow rate	N/A
Gas cup size	N/A
Flux	N/A
Electrode- flux specification (class)	Low Hydrogen
Back shielding particulars	N/A
Technique
Stringer or weave bead	Drag/Stringer/weave
Oscillation (amp., freq., dwell time)	N/A
Multiple or single pass per side	Single
Electrode spacing (longit., lat., angle)	N/A
Contact tube to work distance	5 - 10 mm
Manual, Semi-automatic, or Automatic	Manual
Torch Angle	5-10 Degrees
Inter-pass cleaning	Grinding or Wire Brushing
Post-weld heat Treatment. / Aging
Time, temperature, method	Preheat to 70° (F) if the base metal is below 32° (F)

Table 9

Welding Details
Pass	Process	Filler Metal Class / Size	WFS (m/min	Volt	Amps.	Travel Speed (mm/s	Heat Input (KJ/mm	Shielding gas
All	SMAW	ER7018 3.18 mm (0.125 inch)	N/A	N/A	112-138 (125)	12-15 IPM 6-6.3	N/A	N/A

Proper Protective Equipment

• Weld helmet

• Grinding shields

• Gloves

• Hearing protection

• Safety-toed footwear, etc.

• Suitable fire extinguisher

• Suitable ladder and fall protection

Instructions for the Fabrication of the Dealer Fabricated Roof Flattening Tool (If Required)

Illustration 3	g03744400
(B) Angle iron (C) Weld nuts (F) 1549.4 mm (61 inch) (G) 25.4 mm (1 inch) (H) 25.4 mm (1 inch) (J) 50.8 mm (2 inch) (K) 50.8 mm (2 inch) (L) 6.4 mm (0.25 inch) (M) 22.2 mm (0.88 inch) (N) 279.4 mm (11 inch) (P) 469.9 mm (18.5 inch) (R) 660.4 mm (26 inch) (S) 850.9 mm (33.5 inch) (T) 1041.4 mm (41 inch) (U) 19 mm (0.75 inch) (V) 25.4 mm (1 inch)

1. Cut one 2 x 2 x 0.25 inch angle iron (B) to a length of 1549.4 mm (61 inch) as shown.

2. Drill two 25.4 mm (1 inch) diameter holes (P) as shown.

3. Drill five 19 mm (0.75 inch) diameter holes (N) as shown.

4. Weld five 1/2-13 weld nuts (C) onto angle (B) as shown.

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Illustration 4	g03744732

5. Install five 1/2-13 x 2.0 in bolts (D) into each weld nut as shown.

Removal Procedure for the Affected Cab Components

1. Remove the rear nonmetallic roof cover.

2. Open the window to facilitate headliner removal.

3. Remove the headliner from the cab per the following instructions.

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Illustration 5	g03723161

4. Remove and retain six washers and six M6 torx head screws from back lower rear panel located behind the seat.

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Illustration 6	g03795462
(A) Cover (B) Cover (C) Cover (D) Cover (E) Cover

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Illustration 7	g03723182
View of cover (B)

5. Remove and retain four washers and four M6 torx head screws from cover (B) and then remove the cover.

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Illustration 8	g03723201
View of cover (C)

6. Remove and retain three washers and three M6 torx head screws. Remove M6 torx head screws and coat hanger. Remove cover (C) .

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Illustration 9	g03723227
View of duct connector behind cover (D)

7. Separate cover (C) from duct work as shown above.

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Illustration 10	g03727140
View of cover (D)

8. Remove and retain one louver on the window side of cover (D) .

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Illustration 11	g03723235
View of cover (D)

9. Remove and retain two washers and two M6 torx head screws. Remove one washer, and one M6 torx head screw from the louver cavity of cover (D) .

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Illustration 12	g03723276
View of RH rear post "C"

10. Remove and retain cover (D) by separating cover (D) from the duct work.

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Illustration 13	g03723287
View of handrail

11. Remove and retain two washers and two M12 hex head bolts. Then remove the third grab handle floor bolt that is located beneath the slit in floor mat.

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Illustration 14	g03729386
View of ladder release

12. Remove and retain two washers and two M6 torx head screws. The ladder release can be laid onto bottom plenum. Do not remove the ladder release entirely from cab.

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Illustration 15	g03723359
View of cover (A)

13. Remove and retain six washers and six M6 torx head screws from cover (A) .

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Illustration 16	g03723360
View of cover (E)

14. Open RH side window then remove and retain four washers and four M6 torx head screws. Remove cover (E) .

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Illustration 17	g03723362
View of mirror

15. Remove and retain two washers and two M8 hex head bolts to remove and the mirror. Retain the mirror and the hardware.

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Illustration 18	g03723383
View of the radio (If equipped)

16. Remove and retain radio (H) if equipped.

17. Remove two M6 torx screw (F) from HVAC control panel. Pull the HVAC control panel out until connector (J) is exposed. Disconnect connector (J) and remove the HVAC control panel.

18. Remove six washers and six M6 torx head screws at (G) to remove the plate. Retain all parts.

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Illustration 19	g03723384
View of dome lamps

19. Pull the dome lamps from headliner. Disconnect, remove and retain the dome lamps from the harness.

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Illustration 20	g03723385
View of head liner

20. Remove and retain seven washers and seven M6 torx head screws from the head liner.

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Illustration 21	g03728643
View of "Before and After" the headliner removal

21. Use a putty knife to separate headliner and ROPS radio plate structure, then drop headliner. Remove the headliner from cab.

    Note: To minimize risk of a fall, use care when transferring the headliner through the doorway. Remember that the grab bar near the doorway has been removed.

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Illustration 22	g03723652
View of the harness at the top right side of the cab

22. Loosen and lower the RH electrical harness by clipping six zip ties. Pull the harness away from ROPS tube and allow the harness to droop freely.

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Illustration 23	g03723651
View of the Product Link radio

23. Remove and retain four M6 bolts from Product Link radio and allow the radio to hang from the connector.

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Illustration 24	g03723649
View of the harness at the top left rear side of the cab

24. Loosen and lower the left harness by removing two M10 Bolts and four zip ties from the harness. Allow the left-hand harness to hang away from ROPS.

Paint Removal

Illustration 25	g03723745

Using a sander/buffing wheel, remove paint in areas to be welded.

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Illustration 26	g03723758
View looking down on the left side of the cab roof (A) ROPS roll form tube (1) Plate (B) Roof cover boss

1. Place plate (1) flat on the roof to mark the weld locations for a continuous 5 mm (0.2 inch) fillet weld around the complete perimeter of the plate. Locate plate (1) left-to-right by butting the outboard edge against the ROPS roll formed tube. Locate plate (1) fore/aft by centering the circular cutout on the roof cover boss (B) .

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Illustration 27	g03723780
(C) Width of area where paint is to be removed.

2. Remove the paint from the roof and the ROPS. Remove the paint from the roof 76 mm (3.00 inch) away from the valley.

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Illustration 28	g03723803

3. Remove paint.

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Illustration 29	g03723804

4. Remove paint from the boss weld face.

5. Repeat this procedure on the other side.

Preparation for Welding

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Illustration 30	g03723957

1. Check both sides of the cab roof for raised welds. Grind flush the roof weld (If required). Use the loose plate (1) as a protective shield for the ROPS tube as shown if this grinding step is required. Do not grind into the parent material of the ROPS

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Illustration 31	g03723956

2. If the existing weld between the roof sheet and the ROPS roll formed tube is raised above the roof, then grind the existing weld flush. Grinding the weld will prevent interference with the repair plates. Plate (1) is laying against the ROPS to prevent the grinder from damaging the ROPS. If the weld is flush, then ignore this step.

Weld The Plates

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Illustration 32	g03724480
View of the completed welds as seen from above.

1. MIG Weld (GMAW) or Stick Weld (SMAW) plate (1) using 5 mm (0.2 inch) continuous welds. Weld per the appropriate attached Weld Procedure Specification (WPS) using the following information.

2. Set and test the welding equipment parameters in accordance with the selected WPS for either a MIG (GMAW) or a stick (SMAW). Then test weld on scrap metal prior to welding on the cab. Thoroughly clean weld area to remove contaminants.

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Illustration 33	g03724453
Ground cable attached to a bolt in the front lifting lug.

3. Ground the welding machine lead to the cab as closely as practical to the weld to be added. Connect the ground to one of the large bolt heads near the front of the cab roof.

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Illustration 34	g03724169
View looking down on the right side of the cab roof. (A) ROPS roll form tube (1) Plate (B) Roof cover boss

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Illustration 35	g03724168
View looking down on the left side of the cab roof. (A) ROPS roll form tube (1) Plate (B) Roof cover boss

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Illustration 36	g03723962
(A) ROPS roll form tube (1) Plate

4. Place plate (1) flat on the roof. Locate plate (1) left-to-right by butting the outboard edge against the ROPS roll formed tube. Locate plate (1) fore/aft by centering the circular cutout on roof cover boss (B) .

   Note: Plate (1) must be flush to the roof and butted against the roll formed tube.

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Illustration 37	g03724385

5. The maximum allowable gap between plate (1) and the roof is 1 mm (0.04 inch). For gaps that are greater than 1 mm (0.04 inch), flattening the roof is required. If the proper gap is held with the roof in a neutral state, then proceed to Step 8.

6. When the gap between plate (1) and the roof is greater than 1 mm (0.04 inch), then manufacture roof flattening tool (A) .

7. Manufacture roof flattening tool as shown in this Special Instruction, "Dealer Fabricated Roof Flattening Tool (If Required)" and locate roof flattening tool (A) on the roof bosses. Install and tighten two bolts (E). Tighten bolts (D) as necessary to flatten plate (1) against the roof. Maintain the maximum 1 mm (0.04 inch) gap between new plate (1) and the roof.

8. Tack weld plate (1) in place while the flattening tool is applying force as shown in the next step.

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Illustration 38	g03724456
View of the top of the cab. As seen from the front.

9. Tack plate (1) in place using tack welds 6 to 8 inches on center.

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Illustration 39	g03728876
(1) Plate (2) Groove spot weld (3) Roof (4) ROPS tube

10. Fill any depression if necessary on the weld between ROPS tube (4) and existing roof (3). Perform this procedure at each end of plate (1). Use a groove spot weld (2). This Weld is Not a Tack Weld.

Weld Option Number One (Study Option One and Option Two Prior to Performing the Finish Weld)

Use option one if roof boss is too close to ROPS roll formed tube, limiting GMAW nozzle access.

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Illustration 40	g03724549

1. Make the first 5 mm (0.2 inch) weld from (D) to (E) in one continuous bead.

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Illustration 41	g03724551

2. Make the second 5 mm (0.2 inch) fillet weld from (F) to (G) in one continuous bead and tie the second weld in to the first bead.

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Illustration 42	g03724556

3. Check to verify that the tie in is complete.

4. Continue welding plate (1) all around.

5. When welding on left side is completed and weld area has cooled below 38° C (100° F), visually inspect the weld. Inspect the weld for conformance to visual acceptance per the weld criteria provided.

6. Repeat plate (1) welding procedure for the right-hand side.

Welding Option #2

Use if boss location allows GMAW nozzle access for continuous weld sequence.

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Illustration 43	g03724717

1. Start weld at (H) to (J) making one continuous weld.

2. Continue welding plate (1) all around.

3. When welding on left side is completed and weld area has cooled below 38° C (100° F), visually inspect the weld. Inspect the weld for conformance to visual acceptance per the weld criteria provided.

4. Clean the welds using the buffing wheels. After the welds are cleaned then thoroughly clean up the dust.

5. Repeat plate (1) welding procedure for the right-hand side.

Images of the Completed Welds

Illustration 44	g03725306

Clean and Paint

Illustration 45	g03725355

1. Clean the area to be painted using sanding and buffing wheels. Remove all rust, weld slag/silicon islands or oxides.

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Illustration 46	g03725369
Apply primer coat

2. Coat the area using 4C-4205 Primer Paint ensuring adequate coverage.

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Illustration 47	g03725370
Apply finish coat

3. Coat the area's with top coat 4C-5843 Black Paint ensuring adequate coverage.

Reassembly

Use all retained parts from the disassembly procedure to perform the assembly procedure. Reverse the procedure to reassemble the machine.