Rework of the Sideplates{7250, 7258} Caterpillar

Articulated Truck:

D400E Series II Ejector (S/N: APF1-UP)

Introduction

This Special Instruction contains information on identifying potential areas of cracking on the sides of the body. The Special Instruction outlines rework that is suggested in order to resolve the problem. The information in this Special Instruction can be applied to the listed machines in order to prevent the cracking.

Before performing the rework that is outlined in this Special Instruction, ensure that you understand the information that is contained in the Special Instruction.

References

Reference: Parts Manual, SEBP3025, "D400E Series II Ejector Truck".

Areas of Potential Cracking

Illustration 1	g01062043

Illustration 2	g01062042

Inspect the sideplates for cracking. Pay particular attention to the areas around the wells for the tailgate cylinders. Any cracks that are found need to be gouged out and the cracks welded. For information on welding, refer to ""Weld Specifications and Qualifications" ". Repairing any cracks in the sideplates will not eliminate the cause of the cracks. After any cracks are repaired the sideplates need to be reworked in order to strengthen the sideplates so that further cracks can be avoided. In order to rework the sideplate, refer to ""Rework of the Sideplates" ".

Rework of the Sideplates

Illustration 3	g01062044

Illustration 4	g01062045

In order to rework the sideplates, install the components that are listed in Table 1. Refer to Illustration 3 and Illustration 4. For the fabrication of the components, refer to ""Fabrication of Components for the Rework of the Sideplates" ". For the installation of the components, refer to ""Installation of Components for the Rework of the Sideplates" ".

After all the components for the rework of the sideplates have been installed, paint all the bare metal and new components.

Weld 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: OHSA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Welders must be qualified for fillet welding and groove welding. The welder must be qualified in different welding angles. The angles are vertical, horizontal, etc. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to ISO 9606 or "American National Standards Institiute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process and GMAW process. 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. Place the clamp for the ground cable as close as possible to the welding area. This 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. Do NOT use hoses as a ground point for the welder. Do NOT use the ground pole on the batteries as a ground point for the welder.

4. Protect the wiring harnesses from the weld splatter.

Prepare the Area for Welding

Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.

• Oil

• Grease

• Paint

• Dirt

If the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding process.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal. A maximum interpass temperature of 260 °C (500 °F) should be observed.

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

Weld Specifications

Low Hydrogen Electrodes for the SMAW Process

The tables that follow list the mechanical properties of welds that are deposited by low hydrogen electrodes.

Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer's specifications.

The table that follows shows setting for the welding current for the electrode diameter.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.

Flux Cored Welding Electrode for the FCAW Process

The table that follows lists the mechanical properties of welds that are deposited by the flux cored welding electrode.

The table that follows shows setting for the welding current for the flux cored welding electrode that has a diameter of 1.3 mm (.052 inch).

Note: The settings for the welding current can vary due to the position of the weld. Also, the settings for the welding current can vary with the manufacturer of the welding electrode.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The volume of the fillet weld should not exceed 8.0 mm (.315 inch).

Arc Welding Electrodes for the GMAW Process

The table that follows lists the mechanical properties of welds that are deposited by the GMAW Process.

The welding parameters will vary with the position of the weld and with different electrode manufacturers.

Weld Inspection

The weld should not have any of the conditions that follow:

• Cracks

• Porosity

• Undercut

• Incomplete Fusion

In order to verify the quality of the weld, refer to"American National Standards Institiute (ANSI)/American Welding Society (AWS) Specification D14.3" and ISO 6520.

Fabrication of Components for the Rework of the Sideplates

Fabricate the following components from either ASTM A572 grade 50 structural steel or ASTM A656 grade 50 structural steel.

Large Plate (1) and Large Plate (3)

Fabricate one large plate (1) and one large plate (3) for each ejector body that is being reworked.

Illustration 5	g01062046
Development View Large Plate (1)

Illustration 6	g01062047
Large Plate (1)

Illustration 7	g01065607
Development View Large Plate (3)

Illustration 8	g01062048
Large Plate (3)

Fabricate large plate (1) from 10 mm (0.39 inch) thick structural steel. Refer to Illustration 5, Illustration 6 and Table 8.

Fabricate large plate (3) from 10 mm (0.39 inch) thick structural steel. Refer to Illustration 7, Illustration 8 and Table 8.

Side Plate (2) and Side Plate (4)

Fabricate one small plate (2) and one small plate (4) for each ejector body that is being reworked.

Illustration 9	g01065602
Development View Small Plate (2)

Illustration 10	g01065603
Small Plate (2)

Illustration 11	g01065605
Development View Small Plate (4)

Illustration 12	g01065604
Small Plate (4)

Fabricate small plate (2) from 8 mm (0.32 inch) thick structural steel. Refer to Illustration 9, Illustration 10 and Table 9.

Fabricate small plate (4) from 8 mm (0.32 inch) thick structural steel. Refer to Illustration 11, Illustration 12 and Table 9.

Installation of Components for the Rework of the Sideplates

When you install the fabricated components to your machine, please note that you must tailor the fit of the fabricated components in order to conform to any deformation of the body that may have occurred because of use of the machine.

1. The following steps illustrated the installation procedure of large plate (1) and small plate (2) on the left side of the body. Repeat the steps for large plate (3) and small plate (4) on the right side.

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Illustration 13	g01065987

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Illustration 14	g01068199
View Z-Z Small plate (2) is shown in position.

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Illustration 15	g01065989
Small plate (2) is shown in position.

2. Cut and remove section (5) without gouging into the parent plates. Only remove material from the horizontal channel on the side of the body. Do not remove material from either the vertical channel or the side plate. Only remove enough of the region in order to ensure that small plate (2) will fit without gaps and that the small plate is aligned with the lower plates on the body. Refer to Illustration 13, Illustration 14, Illustration 15 and Table 10.
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   Table 10

   Dimensions
   A	54 mm (2.13 inch) Approximate
   B	76 mm (2.99 inch) Approximate

3. Ensure that 201-4594 Plates (6) are installed on the body.

4. Ensure that welds (7) are intact. If necessary, run new welds. Refer to Illustration 15 and Table 11. For information on welding, refer to ""Weld Specifications and Qualifications" ".
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   Table 11

   Welding Information
   C	6 mm (0.24 inch) Bevel Groove Weld

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Illustration 16	g01065990

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Illustration 17	g01068149
View Z-Z

5. Position small plate (2) to the body before welding the plate in position. Refer to Illustration 16, Illustration 17 and Table 12. For information on welding, refer to ""Weld Specifications and Qualifications" ".
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   Table 12

   Welding Information
   D	6 mm (0.24 inch) Fillet Weld
   E	6 mm (0.24 inch) Bevel Groove Weld

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Illustration 18	g01065988
View Z-Z

6. Position section (5) to the body between small plate (2) and the vertical channel before welding the section in place. Refer to Illustration 18 and Table 13. For information on welding, refer to ""Weld Specifications and Qualifications" ".
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   Table 13

   Welding Information
   F	6 mm (0.24 inch) Fillet Weld

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Illustration 19	g01067152

7. Position large plate (1) to small plate (2) and the body before welding in position. Do not start or stop any welds in region (H). Note that areas (J) are clearance for existing welds. Refer to Illustration 19 and Table 14. For information on welding, refer to ""Weld Specifications and Qualifications" ".
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   Table 14

   Welding Information
   G	6 mm (0.24 inch) Fillet Weld
   I	6 mm (0.24 inch) Bevel Groove Weld