Procedure to Rework Felling Head Frame{6319} Caterpillar

Felling Head:

HF181 (S/N: CFG132-140,279-288,290-301,303-303,306-306,400-400,18500-18500,24700-24700)

Introduction

This special instruction contains five sections for reworking the HF181 Felling Heads for Feller Bunchers: ""Structural Reinforcements" ", ""Increase the Size of the Vent" ", ""Fabricate a Seal Retainer" ", ""End Play Adjustment" " and ""Change the Grease" ".

Do not perform any procedure in this publication until you understand the information that is contained in this publication.

Safety

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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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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.

References

ReferenceRefer to Special Instructions, REHS1841, "General Welding Procedures" for additional welding instructions.

ReferenceGuide, SEBD0512, "Service Welding Guide".

Structural Reinforcements

The frame assembly may experience cracking in various locations on certain HF201 Felling Heads. The reinforcing plates will reduce cracking of the frame. Reinforcing plates will increase the service life of the frame.

Twelve plates must be fabricated for this procedure. Illustrations of the parts are included in this instruction. The locations for the plates are shown.

Rework Procedure

1. Remove the felling head from the machine.

2. Remove all hydraulic hoses from the felling head.

3. Remove all hydraulic cylinders from the felling head.

4. Remove all guards in order to access the hydraulic saw motor. Remove the saw motor.

5. Clean all grease, oil, and debris from the felling head. Wash the felling head.

6. Provide protection for all film groups near the areas that will be reworked on the felling head.

Fabricate Plates

Note: Fabricate all plates from ASTM A514 steel.

Illustration 1	g01389792
Plate (1)

Note: All measurements from center line

Illustration 2	g01394337
Plates (2) . Two plates are required.

Illustration 3	g01389794
Plate (3)

Illustration 4	g01389797
Plate (4) Four plates are required.

Illustration 5	g01389798
Plate (5) Four plates are required.

Illustration 6	g01398642
Plate (6) Two plates are required.

Illustration 7	g01398694
Plate (7)

Illustration 8	g01398710
Plate (8)

Illustration 9	g01398760
Plate (9) Two plates are required.

Illustration 10	g01398802
Plate (10)

Illustration 11	g01389802
Plate (11)

Illustration 12	g01398944
Plate (12)

Cut and Remove Plates

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Illustration 13	g01389743

1. Cut and remove existing plates. Refer to Illustration 13.

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Illustration 14	g01350689

2. Cut and remove the existing plates. Refer to Illustration 14.

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Illustration 15	g01396362

3. Cut frame assembly in order to allow placement of plates (7) .

Installation of Plates for Reinforcement of the Frame

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Illustration 16	g01389816
(1) Plate

1. Fit Plate (1) to the frame assembly. Tack weld the plate to the frame.

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Illustration 17	g01389848
(2) Plates

2. Fit Plate (2) to the frame assembly. Tack weld the plate to the frame.

   Note: Install frame pins before plates (2) are fully welded.

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Illustration 18	g01401505
(3) Plate

3. Fit Plate (3) to the frame assembly. Tack weld the plate to the frame.

   Note: Install frame pins before plates (3) are fully welded.

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Illustration 19	g01401506
(4) Plates

4. Fit Plates (4) to the frame assembly. Tack weld the plate to the frame.

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Illustration 20	g01401507
(5) Plates

5. Fit Plates (5) to the frame assembly. Tack weld the plate to the frame.

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Illustration 21	g01399004
(6) Plates

6. Fit Plates (6) to the frame assembly. Tack weld the plate to the frame.

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Illustration 22	g01389742
Location of Plates

7. Fit Plates (7), (8), (9), (10), (11) and (12) to the frame assembly. Tack weld the plates to the frame.

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Illustration 23	g01398994

8. Location for Plates (9) to the frame assembly

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Illustration 24	g01398997

9. Location for Plates (10) and (11) to the frame assembly

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Illustration 25	g01397628

10. Location for Plate (12) to the frame assembly

Welding the Reinforcements

Use the following specifications for materials that are used for welding:

ANSI/AWS A5.17 F7A2-EM12K and F7A2-EM13K

ANSI/AWS A5.18 ER70S-2, ER70S-3, ER70S-6 and ER70C-6M

ANSI/AWS A5.20 E70T-1. E70T-5, E71T-1

Tensile Strength ... 428 MPa (62000 psi)

Yield Strength ... 345 MPa (50000 psi)

Elongation ... 22%

Impact Toughness at 29 °C (84 °F) ... 13.6 N·m (10 lb ft)

Use proper welding practices in order to ensure minimum distortion of the frame and pin boss. Weld all reinforcement plates with solid welds to the frame assembly. Specific welding instructions for each plate are included below.

After welding the plates to the frame, clean the felling head. Repaint the felling head. Reassemble the hydraulic cylinders and the hydraulic hoses.

Weld Instructions for Plate 1

Illustration 26	g01394623
Plate 1

Weld an 8 mm (0.32 inch) fillet weld around the plate. Refer to Illustration 26.

Weld Instructions for Plate 2

Illustration 27	g01402202
Plate 2

1. Weld a 10 mm (0.39 inch) fillet weld around two plates. Refer to Illustration 27.

2. Weld an 8 mm (0.32 inch) fillet weld around the boss.

3. Weld an 8 mm (0.32 inch) fillet weld around holes in the plate.

Note: Install frame pins before plates (2) are fully welded.

Note: Make a single pass weld. Make sure that the edges do not burn.

Weld Instructions for Plate 3

Illustration 28	g01351254
Plate 3

1. Weld a 10 mm (0.39 inch) fillet weld around the plate. Refer to Illustration 28.

2. Weld an 8 mm (0.32 inch) fillet weld around the boss.

3. Weld an 8 mm (0.32 inch) fillet weld around holes in the plate.

Note: Install frame pins before plates (4) are fully welded.

Note: Make a single pass weld. Make sure that the edges do not burn.

Weld Instructions for Plates 4

Illustration 29	g01396617
Plates 4

1. Weld a 10 mm (0.39 inch) fillet weld around the plate. Refer to Illustration 29.

   Note: Make a single pass weld. Make sure that the edges do not burn.

Weld Instructions for Plates 5

Illustration 30	g01396642
Plates 5

1. Weld a 10 mm (0.39 inch) fillet weld around the plate. Refer to Illustration 30.

   Note: Make a single pass weld. Make sure that the edges do not burn.

Weld Instructions for Plate 6

Illustration 31	g01396896
Plates6

1. Weld a 10 mm (0.39 inch) fillet weld around the plate. Refer to Illustration 31.

   Note: Make a single pass weld. Make sure that the edges do not burn.

Weld Instructions for Plates 7 and 8

Illustration 32	g01396994
Plates 7 and 8

1. Weld a 10 mm (0.39 inch) fillet weld around the plate. Refer to Illustration 32.

2. Weld an 6 mm (0.24 inch)weld around the plate.

   Note: Make a single pass weld. Make sure that the edges do not burn.

Weld Instructions for Plates 9, 10, 11

Illustration 33	g01397604

1. Weld a 10 mm (0.39 inch) fillet weld around the plates. Refer to Illustration 33.

2. Weld an 8 mm (0.32 inch) fillet weld around the plates.

Weld Instructions for Plate 12

Illustration 34	g01397619

1. Weld a 10 mm (0.39 inch) fillet weld around the plates. Refer to Illustration 34.

Increase the Size of the Vent

Table 1

Reference Number	Part Number	Description	Quantity
1	8L-3282	Connector	2
2	9K-7638	Hose Assembly	1

Illustration 35	g01354127

1. Remove original 185-1833 Hose Assembly .

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Illustration 36	g01354131

2. Drill and tap two locations with 3/8-18 NPTF threads.

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Illustration 37	g01401817

3. Screw two 8L-3282 Connectors (1) into 3/8-18 NPTF threaded locations.

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Illustration 38	g01401815

4. Install new 9K-7638 Hose Assembly (2) to 9/16-18 JIC threads by using standard torque.

Fabricate a Seal Retainer

Table 2

Reference Number	Part Number	Description	Quantity
1	8T-4171	Bolt	6
2	5C-0609	Nut	6

Note: Fabricate all plates from ASTM A514 steel.

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Illustration 39	g01385569
4 mm (0.157 inch) thick (A) 110.4 mm (4.346 inch) (B) 90 mm (3.543 inch) (C) 62.5 mm (2.461 inch) (D) 55 mm (2.1654 inch) (E) 110 mm (4.331 inch) (F) 125 mm (4.921 inch) (G) 6.6 mm (0.260 inch) radius (2 places) (H) 95.3 mm (3.752 inch) (J) 75.5 mm (2.972 inch) (K) 40.2 mm (1.583 inch) (L) 2.5 ± 0.5 mm (0.098 ± 0.020 inch) at 45 degrees

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Illustration 40	g01384436

1. Fabricate ring retainers.

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Illustration 41	g01385571
3 mm (0.118 inch) thick (A) 6.6 mm (0.260 inch) radius (6 places) (B) 20.4 mm (0.803 inch) (C) 115.7 mm (4.555 inch) (D) 178 mm (7.008 inch) radius (E) 250 mm (9.842 inch) radius (F) 40.2 mm (1.583 inch) (G) 75.5 mm (2.972 inch) (H) 90 mm (3.543 inch) (I) 110.4 mm (4.344 inch)

2. Fabricate the ring plate.

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Illustration 42	g01384438

3. Position ring retainers and the ring plate on the housing for the arbor.

4. Use bolts (1) and nuts (2) to attach ring retainers to the ring plate.

5. Tack weld (3) sides of ring retainers to housing. Remove the ring plate to complete welds.

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Illustration 43	g01384439
Ring retainers with welds

6. Use 0.035 mm (0.0014 inch) wire for the weld. Welds are 20 mm (0.787 inch) in length. Weld in the chamfer of the outside diameter of the saw housing. Weld in the chamfer of the inside diameter of the ring retainers.

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Illustration 44	g01384444

7. Grind the welds flush with the housing and ring retainers.

   Note: Install the ring plate before installing the shaft for the saw.

   Note: Apply Loctite to the bolts of the retainer plate.

End Play Adjustment

Illustration 45	g01061813

Apply 9S-3263 Thread Lock Compound to the bolt threads prior to assembly.

(1) Torque for the bolts ... 100 ± 10 N·m
(74 ± 7 lb ft)

Apply 1P-0808 Multipurpose Grease to the following components that are listed below prior to assembly.

• Outside surface of bearing cup (3)

• Outside surface of bearing cup (6)

• Outside surface of lip seal (8)

In order to achieve the proper bearing end play, perform the procedure that follows.

1. Install bearing cup (3) and bearing cup (6). Use the proper bearing driver in order to seat bearing cups (3) and (6) properly into the bearing housing.

2. Lubricate the sealing lip of lip seal (8) lightly with 1P-0808 Multipurpose Grease .

3. Install lip seal (8) into the bearing housing with the proper driver. Seat lip seal (8). Refer to detail (A) .

4. Lubricate the inside of the lip seal (8) lightly with 1P-0808 Multipurpose Grease prior to assembly.

5. Lubricate lower bearing cone (7). Install lower bearing cone (7) onto drive shaft (5). Use the proper bearing driver in order to locate lower bearing cone (7) onto drive shaft (5) .

6. Protect the threads of drive shaft (5) and install drive shaft (5) until lower bearing cone (7) seats to bearing cup (6) .

7. Lubricate upper bearing cone (4). Install upper bearing cone (4) onto drive shaft (5). Use the proper bearing driver in order to locate upper bearing cone (4) onto drive shaft (5) .

8. Apply 4C-5591 Anti-Seize Compound (Thread Lubricant) to the threads of locknut (2). Install locknut (2) onto drive shaft (5) with 186-3646 Wrench . Tighten locknut (2) to a minimum torque of 490 N·m (360 lb ft).

   Note: Locknut (2) uses left hand threads.

Note: The end play can not be measured unless the output shaft is pressed downward in order to move the bearing cone relative to the shaft. It is not necessary to press the shaft downward because normal operating loads will cause this movement in order to create the desired end play.

9. Apply 9S-3263 Thread Lock Compound to the threads of four bolts (1) .

Note: Each graduation on Tooling 186-3646 Wrench represents 1/32 of a turn.

10. Use Tooling 186-3646 Wrench in order to turn locknut (2). Adjust locknut (2) by 1/32 of a turn clockwise in order to obtain the desired bearing end play of 0.076 to 0.127 mm (0.003 to 0.005 inch).

    Note: The end play can not be measured unless the output shaft is pressed downward in order to move the bearing cone relative to the shaft. It is not necessary to press the shaft downward because normal operating loads will cause this movement in order to create the desired end play.

11. Install four bolts (1) in locknut (2). Tighten to a torque of 100 ± 10 N·m (74 ± 7 lb ft).

12. Prior to installation of retaining plate (10), clean all mounting surfaces of the disc saw blade, drive shaft (5) and retaining plate (10) .

13. Use the proper guide rods in order to position the disc saw blade and retaining plate (10) onto drive shaft (5) .

14. Apply 4C-5591 Anti-Seize Compound (Thread Lubricant) to the threads of bolts (9). Install bolts (9) and torque bolts (9) to 405 ± 40 N·m (300 ± 30 lb ft).

15. Ensure that the disc saw blade rotates properly. The proper rotation of the disc saw blade is counterclockwise, when the disc saw blade is viewed from the bottom.

16. Lubricate the splines on the shaft end at grease fitting (12) .

17. Install plug (11) .

Change the Grease

Table 3

Part Number	Description	Quantity
1P-0808	Multipurpose Grease	6

Fill the bearing housing with 1P-0808 Multipurpose Grease . Approximately six tubes will be required to fill the housing.

1. Fill the housing with grease. Rotate the shaft of the saw in order to help distribute grease.

2. Fill the housing with grease until grease is expelled through the new vent.