Procedure for Reinforcing Bracket As on Certain M Series Motor Graders {6158, 6159} Caterpillar


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Procedure for Reinforcing Bracket As on Certain M Series Motor Graders {6158, 6159} [M0068166]
FRAME AND BODY
FRAME GP
Procedure for Reinforcing Bracket As on Certain M Series Motor Graders {6158, 6159}
1.1. Introduction
2.1. Safety Section
3.1. Qualifications
4.1. Proper Welding Procedure on Machines and Engines with Electronic Controls
5.1. Area Preparation
6.1. Required Tools
7.1. Prepare for Rework
8.1. Reinforcing Procedure
Blade
BLADE (S/N: 7YW1-UP)
Motor Grader
12M Series 2 (S/N: F9M204-UP)
12M Series 3 (S/N: N9B1-UP)
140M Series 2 (S/N: R9M1-UP)
160M Series 2 (S/N: R9L1-UP; R9T1-UP)

Introduction

This Special Instruction contains necessary information for reinforcing 335-3029 Bracket As on Certain M Series Motor Graders.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Clean all surfaces and remove burrs from all areas where parts are to be installed. Chase all tapped holes used for mounting purposes.

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 must 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 of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by AVSpare. If used, ensure the safety of the operating personnel and others.

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

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.


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

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.


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

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.


Reference: Reuse And Salvage Guidelines, SEBD0512, "AVSpare Service Welding Guide".

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

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

Required Tools

Table 1
Quantity  Description 
Arc Welder 
178 mm (7 inch) Pneumatic Grinder 
  Assorted Sanding Pads 
237-5181 RESPIRATOR 
  Personal protective equipment 

Prepare for Rework

  1. Park the machine on a flat hard surface.

  2. Lower the bowl to the ground and support the bowl and lower the apron to the bowl floor.

  3. Place the machine transmission in Park position.

  4. Shut off the engine and place chocks in front of and behind the wheels.

  5. Place the battery disconnect switch in the OFF position.

  6. Protect any hoses, harnesses, and cylinders that are in the area of the rework from weld slag.

Reinforcing Procedure

Perform the following procedure for reinforcing the 335-3029 Bracket As:



Illustration 1g06036717
Reinforcing 335-3029 Bracket As
(1) Plate 1
(2) Plate 2
(3) Plate 3


    Illustration 2g06036105
    Plate 1
    (A) 417.5 mm (16.44 inch)
    (B) 319.5 mm (12.58 inch)
    (C) 307.5 mm (12.11 inch)
    (D) 275.5 mm (10.85 inch)
    (E) 209.5 mm (8.25 inch)
    (F) 134.5 mm (5.3 inch)
    (G) 12 mm (0.47 inch)
    (H) 230 mm (9.06 inch)
    (J) 218 mm (8.58 inch)
    (K) 108 mm (4.25 inch)
    (L) 96 mm (3.78 inch)
    (M) 98 mm (3.86 inch)
    (N) 68 mm (2.68 inch)
    (P) 80 mm (3.15 inch)
    (R) 20 mm (0.79 inch)
    (S) 50 mm (1.97 inch)
    (T) 285.5 mm (11.24 inch)
    (U) 20 mm (0.79 inch)
    (V) 429.5 mm (16.91 inch)

  1. Fabricate the plate 1 as per the dimensions in Illustration 2.


    Illustration 3g06036674
    Plate 2
    (W) 314 mm (12.36 inch)
    (Y) 232 mm (9.13 inch)
    (Z) 167 mm (6.57 inch)
    (AA) 102 mm (4.02 inch)
    (AB) 106 mm (4.17 inch)
    (AC) 12 mm (0.47 inch)
    (AF) 45 degree
    (AG) 70 mm (2.76 inch)
    (AH) 60 mm (2.36 inch)
    (AJ) 134 mm (5.28 inch)
    (AK) 108 mm (4.25 inch)
    (AL) 96 mm (3.78 inch)
    (AM) 549.2 mm (21.62 inch)
    (AN) 50 mm (1.97 inch)
    (AP) 80 mm (3.15 inch)
    (AR) 399.2 mm (15.72 inch)
    (AS) 20 mm (0.79 inch)

  2. Fabricate the plate 2 as per the dimensions in Illustration 3.


    Illustration 4g06036701
    Flat pattern of plate 3
    (AT) 97 mm (3.82 inch)
    (AU) 42 mm (1.65 inch)
    (AV) 15.2 mm (0.60 inch)
    (AW) 27 mm (1.06 inch)
    (AY) 291.2 mm (11.46 inch)
    (AZ) 271.2 mm (10.68 inch)
    (BA) 193.6 mm (7.62 inch)
    (BB) 100 mm (3.94 inch)
    (BC) 125 mm (4.92 inch)


    Illustration 5g06036713
    Formed views of plate 3
    (BD) 90 mm (3.54 inch)
    (BE) 15 degree
    (BF) 50 mm (1.97 inch)
    (BG) 186 mm (7.32 inch)
    (BH) 20 mm (0.79 inch)
    (BJ) 125 mm (4.92 inch)

  3. Fabricate the plate 3 as per the dimensions in Illustration 4, and Illustration 5.


    Illustration 6g06036735
    Installing plate 2
    (W1) 8 mm (0.31 inch) bevel-groove weld
    (W2) 8 mm (0.31 inch) fillet weld

  4. Bevel-groove weld from (AE) to (AD) with 8 mm (0.31 inch) thickness on both sides.

  5. Install the plate 2 (2) as per Illustration 6.


    Illustration 7g06036764
    Installing plate 1
    (BK) 60 mm (2.36 inch) fillet weld
    (W2) 8 mm (0.31 inch) fillet weld

  6. Install the plate 1 (1) as per Illustration 7.


    Illustration 8g06036778
    Installing plate 3
    (BL) 10 mm (0.39 inch) fillet weld
    (W2) 8 mm (0.31 inch) fillet weld
    (W3) 8 mm (0.31 inch) V-groove weld
    (W4) 20 mm (0.79 inch) bevel-groove weld

  7. Install the plate 3 (3) as per Illustration 8.

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