Procedure for Reinforcing the Mounting Area of the Steering Cylinder on the Rear Frame{7051} Caterpillar


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Procedure for Reinforcing the Mounting Area of the Steering Cylinder on the Rear Frame{7051} [REHS1644]
FRAME AND BODY
FRAME GP
Procedure for Reinforcing the Mounting Area of the Steering Cylinder on the Rear Frame{7051}
1.1. Introduction
2.1. Machine Preparation
3.1. Procedure
Wheel Loaders:
994 (S/N: 9YF1-UP)
994D (S/N: 3TZ1-UP)

Introduction

This Special Instruction provides the necessary information that is required to install the 160-6725 Frame Field Rework Gp on the machines that are listed above. The installed 160-6725 Frame Field Rework Gp will increase the strength of the frame and the service life of the frame.

The procedure will be used for the removal of certain plates and gussets on the frame. The procedure will be used to install reinforcing plates and gussets on the frame.

Do not perform any procedure that is outlined in this publication, until you understand the information that is contained in this document. Do not order parts until you understand the information that is contained in this document.

The Special Instruction is available through the normal literature distribution system. The publication can be found on the AVSpare Service Information System (SIS).

Machine Preparation

  1. Move the machine to a smooth hard level surface that is away from operating machines and away from personnel.

  1. Install blocks on the front and the rear of the front tires.

  1. Install the steering frame lock.

  1. Raise the rear of the machine off the ground no more than a few inches. Block up the rear of the machine.

    Reference: For information on raising the machine and blocking the machine, refer to the Disassembly and Assembly, "Tires and Rims".

  1. Remove the drive shaft from the rear axle.

    Reference: Refer to the Disassembly and Assembly, "Drive Shaft (Rear Axle)".

  1. Loosen the eight bolts that hold the front trunnion to the frame enough to allow the axle assembly to tilt forward.

  1. Remove the 12 bolts and the retainer for the front trunnion.

  1. Remove the front trunnion. The approximate weight is 360 kg (795 lb).

Procedure

Note: Remove only the plates that are specified in the welding procedure. Failure to follow the procedure may result in the misalignment of the machined surface of the front trunnion.

------ WARNING! ------

Personal injury can result from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas.

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------ WARNING! ------

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

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 cause death.

Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.

U.S. Department of Labor
Washington, D.C. 20210
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NOTICE

Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.


Table 1
160-6725 Frame Field Rework Gp Parts Lists    
Item     Qty     Part Number     Description    
1     1     228-8424     Plate (Right hand side)    
2     1     160-6695     Plate    
3     2     160-6696     Plate    
4     2     160-6697     Plate    
5     1     228-8425     Plate (Right hand side)    
6     2     160-6699     Plate    
7     1     160-6701     Plate (Left hand side)    
8     1     228-8423     Plate (Left hand side)    
9     1     228-8422     Plate (Left hand side)    



    Illustration 1g00991371

  1. Use an air carbon arc to remove the two 8X-8064 Gussets and the one 8X-8065 Plate from the inside of the frame.

  1. Inspect the area for cracks and repair, if necessary.

  1. Grind the area smooth.

  1. Clean the area thoroughly before you weld any parts to the frame.

  1. Use the following welding process in order to weld all the parts onto the frame.

    • Gas metal arc welding

    • Electrode diameter 1.3 mm (.05 inch)




    Illustration 2g00991433

    (1) 228-8424 Plate . (2) 160-6695 Plate . (3) 160-6696 Plate . (4) 160-6697 Plate .




    Illustration 3g00991769

  1. Locate 228-8424 Plate (1) below the 8X-1308 Plate . Tack 228-8424 Plate (1) in place. Use a wire feed speed of 6.3. Refer to illustration 2 for the location of plate (1).

  1. Finish welding 228-8424 Plate (1) to the 8X-1308 Plate . Use a 16 mm (.6 inch) bevel weld with a wire feed speed of 11.4. Refer to illustration 3.

  1. Finish welding 228-8424 Plate (1) to the engine end of the frame. Use a 12 mm (.5 inch) fillet weld with a wire feed speed of 11.4. Refer to illustration 3.

  1. Tack 160-6695 Plate (2), 160-6696 Plate (3) and 160-6697 Plate (4) to 228-8424 Plate (1) and the 8X-1308 Plate . Use a wire feed speed of 11.4. Refer to illustration 2 for the location of the plates.

  1. Finish welding in two places 160-6697 Plate (4) to 160-6695 Plate (2) and 160-6696 Plate (3). Use a 16 mm (.6 inch) bevel weld with a wire feed speed of 11.4. Refer to illustration 3.

  1. Finish welding 160-6695 Plate (4) to 228-8424 Plate (1). Use a 12 mm (.5 inch) fillet weld with a wire feed speed of 11.4. Refer to illustration 3.

  1. Finish welding 160-6695 Plate (2) and 160-6696 Plate (3) to 228-8424 Plate (1). Use a 12 mm (.5 inch) fillet weld with a wire feed speed of 11.4. Refer to illustration 3.

  1. Finish welding in two places 160-6695 Plate and 160-6696 Plate to the 8X-1308 Plate . Use a 16 mm (.6 inch) bevel weld with a wire feed speed of 11.4. Refer to illustration 3.



    Illustration 4g00991534

  1. Use an air carbon arc to remove the following 8X-1309 Plate and 8X-7316 Gussets from the inside of the frame.

  1. Inspect the area for cracks and repair, if necessary.

  1. Grind the area smooth.

  1. Clean the area thoroughly before you weld any parts to the frame.



    Illustration 5g00991788



    Illustration 6g00991817

  1. Tack 228-8425 Plate (5) and 160-6699 Plate (6) to the 8X-1308 Plate , the 117-9980 Plate and the frame rail. Use a wire feed speed of 11.4. Refer to the illustration 5 for the location of the plates.

  1. Finish welding the 228-8425 Plate (5) to the frame rail. Use a 20 mm (.8 inch) bevel weld with a wire feed speed of 11.4. Refer to illustration 6.

  1. Finish welding the 228-8425 Plate (5) to the 8X-1308 Plate . Use a 25 mm (1 inch) bevel weld with a wire feed speed of 11.4. Refer to illustration 6.

  1. Finish welding the 160-6699 Plate (6) to the frame rail and the 8X-1308 Plate . Use a 10 mm (.4 inch) fillet weld with a wire feed speed of 11.4. Refer to illustration 6.

  1. Finish welding the 160-6699 Plate (6) to the 228-8425 Plate (5). Use a 8 mm (.3 inch) fillet weld with a wire feed speed of 11.4. Refer to illustration 6.

  1. Finish welding the 228-8425 Plate (5) to the 117-9980 Plate . Use a 12 mm (.5 inch) fillet weld with a wire feed speed of 11.4. Refer to illustration 6.

  1. Add a 12 mm (.5 inch) fillet weld with a wire feed speed of 11.4 to the top and the bottom of the 8X-3560 Support . Refer to illustration 6.

  1. Finish welding the front and the back of the trunnion mounting 8X-1308 Plate . Use a 10 mm (.4 inch) fillet weld with a wire feed speed of 11.4. Refer to illustration 6.

  1. Inspect all of the welds and repair, if necessary.

Repeat Steps 1 to 26 for the left side of the frame. Substitute the following parts.

  • 160-6701 Plate for 160-6695 Plate

  • 228-8422 Plate for 228-8424 Plate

  • 228-8423 Plate for 228-8425 Plate

Install the front trunnion.

Note: When you install the front trunnion, care must be taken in order to get the trunnion into the correct position. The new plates may cause a tight fit.

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