Installation of New Handrails{7150, 7253, 7256, 7319} Caterpillar

Articulated Truck:

735 (S/N: AWR1-UP; B1N1-UP)

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: AZZ1-UP; B1R1-UP)

Introduction

This Special Instruction contains the installation procedure for the 323-5803 Handrail Assembly (Left), 323-5804 Handrail Assembly (Right), 289-4719 Handhold Assembly (Left) and 289-4720 Handhold Assembly (Right) that are part of the improved handrails on the listed machines.

Before performing the installation procedure that is detailed in this Special Instruction, ensure that you understand the information that is contained in the Special Instruction.

References

ReferenceDisassembly and Assembly, RENR5140, "735, 740 and 740 EJECTOR Articulated Trucks Machine Systems", "Fender - Remove and Install".

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

Required Parts and Suggested Tooling

Required Parts

Table 1 lists all the parts that are required in order to rework the handrails on both sides of the machine. Parts that are specific to the left side of the machine or the right side of the machine will be identified Left or Right.

Refer to Table 2 in order to decide if the mirrors should be replaced or if the mirrors should be retained.

Suggested Tooling

The following tooling or suitable equivalents will be required for the rework. Refer to ""Rework Procedure" " in order to evaluate the required tooling. Ensure that the tooling or suitable equivalents are available before conducting the installation of the new handrails.

• Lifting equipment

• Grinding equipment

• Welding equipment

• 25.4 mm (1 inch) Metal drill

• 4C-4205 Primer Paint

• 4C-4200 Paint (High Gloss Yellow)

Rework Procedure

The following information details the steps that are required to rework one of the handrails on the machine. The procedure is identical for both sides except in identified steps.

Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the hydraulic system.

Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts as replacement.

Start By

1. Remove the fenders from the machine. Refer to ""References" ".

2. Remove the following components and retain the following components with all the bolts, nuts, washers, etc:
   • Sound suppression panels

   • The accumulator for the front suspension cylinder and associated components (if equipped)

   • Automatic lubrication pump (if equipped)

   • Tread plates

   • Fender guards

   • Main rear view mirrors and auxiliary rear view mirrors. Also, remove the support for the mirrors and retain the parts that mounted the bracket to the handrail.

Removal of the Old Handrails

Show/hide table



Illustration 1	g01326998

1. Use suitable lifting equipment or a second person in order to support the weight of former handrail (1) .

2. Remove bolts (2), bolts (4), bolts (6), washers (3) and washers (5) that secure former handrail (1) to the fender. Retain washers (3) for later use.

Show/hide table



Illustration 2	g01326999

3. Remove bolts (7) and washers (8) that secure former handrail (1) to the fender. Retain the bolts and washers for later use.

4. Remove former handrail (1) and discard the handrail.

Remove the Front Section

Show/hide table



Illustration 3	g01327000

1. If 289-4729 Fender Assembly (Front Right Side) (9) does not include bracket (10) then use a suitable grinder in order to remove the bracket from the fender assembly on the right side fender. Ensure that you remove as little of the parent material from the bracket as possible. Retain the bracket for later use.

Show/hide table



Illustration 4	g01332536

2. Use a suitable grinder in order to remove fender assembly (9) from the front of the fender. Ensure that you remove as little of the parent material from the fender as possible. Discard the fender assembly.

   Note: Do not use any form of flame cutting in order to remove the front section. The application of excessive heat to the fender may distort the fender.

Show/hide table



Illustration 5	g01327001

3. Clean the area of the former weld and dress the area of the former weld.

Install a new Fender Assembly

Show/hide table



Illustration 6	g01327008

1. Install new fender assembly (12) with tread plate (11) to the fender. Use the original bolts and washers in order to position the new fender assembly in relation to the fender.

   Note: There are separate fender assemblies (12) for the left side fender and the right side fender. Ensure that the correct fender assembly is installed to the appropriate fender. Refer to Table 1.

2. Tack weld the new fender assembly onto the fender. Allow the welds to cool and check the alignment of the new fender assembly with the tread plate and the fender.

3. Remove tread plate (11) .

Show/hide table



Illustration 7	g01327009

4. Fully weld fender assembly (12) to the fender. Refer to Illustration 7 and Table 3.

   Note: For more information about welding, refer to Special Instruction, REHS1841, "General Welding Procedures" and ""Weld Specifications and Qualifications" ".

   Show/hide table

   Table 3

   Welding Dimensions for Fender Assembly (11)
   A	3 mm (0.12 inch) Fillet Weld

Show/hide table



Illustration 8	g01327002

5. For fender assembly (12) on the right side fender, fillet weld bracket (10) to the front of the fender assembly. For (S/N: AWR1-588), 740 (S/N: AXM1-1182) and 740 EJECTOR (S/N: AZZ1-327), drill hole (D) if the hole is not already machined into the fender assembly. Refer to Illustration 8 and Table 4.

   Note: For more information about welding, refer to Special Instruction, REHS1841, "General Welding Procedures" and ""Weld Specifications and Qualifications" ".

   Show/hide table

   Table 4

   Additional Welding and Machining Dimensions for Fender Assembly (11)
   B	105 mm (4.15 inch)
   C	3 mm (0.12 inch) Fillet Weld
   D (1)	10 mm (0.4 inch) Hole
   E (1)	180 mm (7.10 inch)
   F (1)	30 mm (1.18 inch)

   Show/hide table

   ( 1 )

   This only applies to 735 (S/N: AWR1-588), 740 (S/N: AXM1-1182) and 740 EJECTOR (S/N: AZZ1-327).

Show/hide table



Illustration 9	g01327004
The suspension cylinder is shown in position in order to verify that the cutout requires elongating. Remove the suspension cylinder from the area before altering the cutout.

Show/hide table



Illustration 10	g01327007
The suspension cylinder is shown in position in order to verify that the cutout allows sufficient access for the hose and bolts that fit onto the end of the suspension cylinder.

6. For 735 (S/N: AWR1-588), 740 (S/N: AXM1-1182) and 740 EJECTOR (S/N: AZZ1-327) on the fender for the right side of the machine elongate the cutout in the side of fender assembly (12) in order to accommodate the hose for the suspension accumulator. Verify that the cutout needs altering by positioning a suspension accumulator to the fender. Ensure that the suspension accumulator is not left in position when any machining is performed. Refer to Illustration 9 and Table 5. Once the cutout is made verify that there is a clear route of the hose to the accumulator and that the bolt holes for the hose flange are accessible. Refer to Illustration 10.
   Show/hide table

   Table 5

   Additional Dimensions for the Cutout in fender assembly (11)  (1)
   G	30 mm (1.18 inch)
   H	40 mm (1.58 inch)

   Show/hide table

   ( 1 )

   This only applies to 735 (S/N: AWR1-588), 740 (S/N: AXM1-1182) and 740 EJECTOR (S/N: AZZ1-327).

7. Paint fender assembly (12) and any bare metal on the fender with 4C-4205 Primer Paint and Caterpillar 4C-4200 Paint (High Gloss Yellow) .

Installation of the New Handrails

Show/hide table



Illustration 11	g01330244

1. Use a suitable cutting tool to remove a 4 mm (0.16 inch) wide section of the channel on the inside of the fender. Remove sufficient material from the channel in order to accommodate plate (13). The plate will strengthen the fender in the area of the main mounting point for the handrail.

Show/hide table



Illustration 12	g01330243

2. Fully weld plate (13) in the plate's position with a fillet weld. Refer to Illustration 12 and Table 6.
   Show/hide table

   Table 6

   Welding Dimensions for Plate (13)
   J	3 mm (0.12 inch) Fillet Weld

Show/hide table



Illustration 13	g01327010

3. Use the center of the existing bolt hole in order to drill hole (K). Refer to Illustration 13 and Table 7.
   Show/hide table

   Table 7

   Dimensions
   K	25.4 mm (1.00 inch) Hole

Show/hide table



Illustration 14	g01330245

Show/hide table



Illustration 15	g01330246

4. Install boss (14) so that the chamfered end of the boss is flush with the outside face of the fender. Fillet weld the boss into position. When the weld is cold, use a suitable tool in order to grind the weld on the outside face of the fender flush. Refer to Illustration 14, Illustration 15 and Table 8.
   Show/hide table

   Table 8

   Welding Dimensions for Boss (14)
   L	3 mm (0.12 inch) Fillet Weld

5. Paint plate (13), boss (14) and any bare metal on the fender with 4C-4205 Primer Paint and Caterpillar 4C-4200 Paint (High Gloss Yellow) .

Show/hide table



Illustration 16	g01330247

6. Position handrail (15) to the fender. Secure the handrail to the fender with bolts (16), washers (17), bolts (18) and 8T-4223 Hard Washers (3). Do not tighten the bolts at this Step.

Show/hide table



Illustration 17	g01330249

7. Position handrail (19) to the fender. Secure the handrail to the fender with 8T-4196 Bolts (7) and 7X-7729 Washers (8) . Do not tighten the bolts at this Step.

   Note: For machines with welded steps, the mounting holes in handrail (v) must be increased to 13 mm (0.52 inch).

Show/hide table



Illustration 18	g01330255

8. Connect handrail (15) to handrail (19) with grommet (20), clip (21), clip (22), bolt (23), locknut (24) and washers (25) .

9. Tighten bolts (7), bolts (16) and bolts (18) that were left loose in Step 6 and Step 7.

End By

1. Reinstall the following components with the bolts, nuts, washers, etc that were retained:
   • Sound suppression panels

   • The accumulator for the front suspension cylinder and associated components (if equipped)

2. Install new fender cover (26) to the fender.

Show/hide table



Illustration 19	g01331443

Show/hide table



Illustration 20	g01333459

3. Install conical bumper (28) with nut (29) and washer (30) onto new tread plate (27) for the left hand fender.

4. Install new tread plate (27) for the left hand fender.

Show/hide table



Illustration 21	g01332067

5. Install former tread plate (32) for the right hand fender. If an automatic lubrication system is installed then first modify the former tread plate. Modify the tread plate by installing bosses (31). Center the bosses on the existing holes. Refer to Illustration 21 and Table 9.
   Show/hide table

   Table 9

   Dimensions for Bosses (31)
   M	3 mm (0.12 inch) Fillet Weld

6. Reinstall the automatic lubrication pump (if equipped). Replace two of the former mounting bolts and washers with bolts (33) and washers (34) for use at the locations of the bosses (31) .

Show/hide table



Illustration 22	g01331448

Show/hide table



Illustration 23	g01331449
Typical example for both the top and the bottom of support (44)

7. Install new supports (35) for the mirror to the handrails. Install main mirrors (37) and auxiliary mirrors (36) to the handrails. Use the parts that were retained earlier in order to mount the supports.

   Note: At each mounting for supports (35), use 8T-4194 Bolt (38), 8T-4223 Hard Washers (39), 108-7638 Spacer (40), four 4W-8926 Washers (41) and 8T-4244 Nut (42). Washers (41) are concave in shape. Arrange the washers so that a pair of washers are opposite to the other pair of washers in order to form a simple spring.

   Perform the following additional steps if you are installing heated mirrors:

   Show/hide table
   
   

   Illustration 24	g01334903
   Typical example for both sides of the machine

   1. Secure wires (44) to support (35) with cable straps (43) .
   Show/hide table
   
   

   Illustration 25	g01334904
   Typical example for both sides of the machine

   2. Run wires (44) through nylon tubing (45). Route the wires into the fender and position the nylon tubing to the side of handrail (15). Secure the tube to the handrail with clips (46), bolts (47) and washers (48) .
   Show/hide table
   
   

   Illustration 26	g01335199

   3. For the left hand side fender, secure nylon tubing (45) to the bottom of handrail (15) with clip (46), bolt (47) and washer (48). Secure wires (44) to fender assembly (12) with cable strap (43) .

   4. For the left hand side fender, install receptacle kit (49) and receptacle kit (50) to the ends of wires (44). Refer to Table 10 for the positions of the different wires.
      Show/hide table

      Table 10

      Mirror	Wire	Pin Number
      Main	Brown	1
      Main	Blue	2
      Auxiliary	Brown	3
      Auxiliary	Blue	4

   Show/hide table
   
   

   Illustration 27	g01334931
   Right hand side of the machine and above the hydraulic tank

   5. For the right hand side fender, secure nylon tubing (45) to the bottom of handrail (15) with clip (46), bolt (47) and washer (48). Secure wires (44) to fender assembly (12) with cable strap (43) .

   6. For the right hand side fender, install receptacle kit (49) and receptacle kit (50) to the ends of wires (44). Refer to Table 11 for the positions of the different wires.
      Show/hide table

      Table 11

      Mirror	Wire	Pin Number
      Main	Brown	1
      Main	Blue	2
      Auxiliary	Brown	3
      Auxiliary	Blue	4

8. Install the fenders onto the machine. Refer to ""References" ".

9. For machines with welded steps, perform the following:
   Show/hide table
   
   

   Illustration 28	g01331445
   Typical example

   1. Install plate (53) to the end of handrail (15) with bolt (51) and washer (52) .
   Show/hide table
   
   

   Illustration 29	g01330256

   2. Mark the centers of the bolt holes in plate (53). Remove the plate and drill 11 mm (0.43 inch) holes through the bracket for the step. Reinstall the plate.
   Show/hide table
   
   

   Illustration 30	g01330257

   3. Secure plate (53) to the step with bolts (54), nuts (55) and washers (56) .

10. For machines with cast steps, perform the following:
    Show/hide table
    
    

    Illustration 31	g01331471
    Typical example

    1. Remove 8T-4136 Bolts (57) and 8T-4121 Hard Washer (58) that secure step (59) to the bracket on the machine. Retain the bolts and washers for use later.
    Show/hide table
    
    

    Illustration 32	g01331446

    2. Position plate (53) between the end of handrail (15) and the bracket on the machine. Secure the plate and step (59) to the bracket on the machine with bolts (57) and washers (58). Do not tighten the bolts at this time.
    Show/hide table
    
    

    Illustration 33	g01331470

    3. Line up the bolt hole in the end of handrail (15) with the slotted hole in plate (53). Secure the end of the handrail to the plate with bolt (51) and washer (52). Tighten all the bolts that secure the handrail, the plate and step (59) in place.

11. For machines with heated mirrors, perform the following additional steps:
    Show/hide table
    
    

    Illustration 34	g01334906
    Left hand side of the machine and above the hydraulic tank

    1. On the left hand side of the machine, connect connector receptacle (50) on the end of wires (44) to the harness connector on top of the tank and secure the connectors to the top of the tank with cable strap (43) .
    Show/hide table
    
    

    Illustration 35	g01334905
    Left hand side of the machine and above the hydraulic tank

    2. On the left hand side of the machine, secure wires (44) to the side of the machine with a cable strap (43) .
    Show/hide table
    
    

    Illustration 36	g01334930
    Right hand side of the machine and above the hydraulic tank

    3. On the right hand side of the machine, connect connector receptacle (50) to the harness connector on the side of the machine and secure the connectors to the side of the machine with cable strap (43). Secure wires (44) to fender assembly (12) with a cable strap.

Weld Specifications and Qualifications

Show/hide table

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.

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.

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.