Rework Procedure to Update the Support Mounts for the Radiator {0679, 1350, 1353, 7051, 7051} Caterpillar

Off-Highway Truck/Tractor

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

Introduction

This Special Instruction provides the procedure to install new plate assemblies (radiator mounts) for the radiator. The new support mounts will reduce stress on the bracket assemblies due to higher than expected loads. The new supports will allow the bracket to withstand more demanding applications.

Refer to the necessary parts list.

Prepare the machine for service after installation of the support mounts. Follow the procedure in the Operation and Maintenance Manual for your machine.

Safety

Show/hide table

Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

Show/hide table

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.

Show/hide table

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

Show/hide table

When a hoist is used to lift any part or assembly, stand clear of the area under the part being raised. Always make sure that the hoist has adequate lifting capacity and the wire cable is not damaged. Failure to follow this instruction could lead to injury or death. Approximate weights of the components are shown in the table which follows.

Required Tool List

Processes for Welding

Do not weld in areas if there is a strong movement of air or in temperatures of less than 16 deg C (61 deg F).

The following welding processes are acceptable for this procedure:

• Gas metal arc welding (GMAW)Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The AWS Class ER70S-3 is a welding process that can be used with the following welders: Lincoln L-50 and Hobart HB-25. Comparable equipment may be used.

• Flux cored arc welding (FCAW)Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The FCAW process is called the AWS Class E71T-1 process.

• Shielded metal arc welding (SMAW)Use E7018 electrodes in this DCEP process.

• Air arc gouging (DCEP)Use 5/16 inch diameter rods for carbon arc.

References

Reference: Refer to Operation and Maintenance Manual, SEBU7696, "Welding on Machines and Engines with Electronic Controls" for additional welding instructions.

Reference: Refer to Special Instructions, REHS1841, "General Welding Procedures" for additional welding instructions.

Reference: Guide, SEBD0512, "Service Welding Guide".

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturer's weight's to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows to see the effect of the lift angle on the working load limit.

Note: The lifting devices that are shown in this publication are not Caterpillar parts.

Illustration 1	g00629745
Lift angles for lifting slings. (A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling.

Fabrication of Blocks and Plates

Show/hide table

Illustration 2	g01949658
View of block (1) ( aa) 175.0 mm (6.89 inch) (bb) 25.0 mm (0.98 inch) (cc) 75.0 mm (2.95 inch)

Show/hide table

Illustration 3	g01949707
View of block (2) ( dd) 75.0 mm (2.95 inch) (ee) 25.0 mm (0.98 inch) (ff) 75.0 mm (2.95 inch)

1. Fabricate two blocks (1) and two blocks (2) from the dimensions that are shown above. Blocks (1) and blocks (2) will be installed later in this Special Instruction on the mounting pads.
   Show/hide table

   Illustration 4	g03413682
   View of plate (3) ( gg) 540.0 mm (21.26 inch) (hh) 250.0 mm (9.84 inch) (jj) 4.0 mm (0.16 inch) (kk) 12.0 mm (0.47 inch) at 45 degrees (mm) 12.0 mm (0.47 inch) (ZZ) 50.0 mm (2.0 inch) Radius

2. Fabricate four plates (3) from the dimensions that are shown above. Plates (3) will be installed later in this Special Instruction on the inside rail and the outside rail of the frame assembly.
   Show/hide table

   Illustration 5	g01949662
   View of plate (4) ( nn) 50.0 mm (1.97 inch) (pp) 25.0 mm (0.98 inch) (rr) 12.0 mm (0.47 inch) (ss) 25.0 mm (0.98 inch) (tt) 40.0 mm (1.57 inch) (uu) 200.0 mm (7.87 inch) (vv) 25.0 mm (0.98 inch)

3. Fabricate four pieces of gusset (4) from the dimensions that are shown above. Gussets (4) will be installed later in this Special Instruction on the outside of each frame rail.
   Show/hide table

   Illustration 6	g01949663
   View of plate (5) ( ww) 12.0 mm (0.47 inch) (xx) 307.0 mm (12.09 inch) (yy) 12.0 mm (0.47 inch) (zz) 189.0 mm (7.44 inch)

4. Fabricate two plates (5) from the dimensions that are shown above. Plates (5) will be installed later in this Special Instruction between the two gussets on the outside of each frame rail.
   Show/hide table

   Illustration 7	g01949666
   View of plate (6) ( ab) 320.0 mm (12.60 inch) (ac) 14.0 mm (0.55 inch) (ad) 12.0 mm (0.47 inch) (ae) 187.0 mm (7.36 inch)

5. Fabricate two plates (6) from the dimensions that are shown above. Plates (6) will be installed later in this Special Instruction on the inside of each frame rail.

Preparation for Installation of the Support Mounts

Note: This rework procedure will need to be completed for the right-hand side and the left-hand side of the frame assembly.

Show/hide table

Illustration 8	g01946608
View of the current mounts for frame

Show/hide table

Illustration 9	g01946609
Side view of mounting pad (A), gussets (B), and backing plate (C) before removal.

1. Remove two mounting pads (A) from the right hand and left-hand top of the frame assembly. Remove one platform mount assembly (D) from the right hand outside of the frame assembly. Retain mounting pads (A) and platform mount assembly (D) for later use in this Special Instruction.

2. Remove six gussets (B) and two backing plates (C) from the right hand and left hand outside of the frame assembly. Discard gussets (B) and backing plates (C).
   Show/hide table

   Illustration 10	g01946610
   Inside view of gussets (B) and backing plate (C) before removal.

3. Remove six gussets (B) and two backing plates (C) from the right hand and the left hand inside of the frame assembly. Discard gussets (B) and backing plates (C).

4. Remove two supports (E) and four bosses (F) from the right hand and left-hand side of the inside of the frame assembly. Retain supports (E) and bosses (F) for later use in this Special Instruction.
   Show/hide table

   Illustration 11	g01946611
   Inside view of upper gusset (G) before removal

5. Remove two upper gussets (G) from the right hand and left-hand side of the inside of the frame assembly. Retain upper gussets (G) for later use in this Special Instruction.
   Show/hide table

   Illustration 12	g01946612
   View of block (H)

6. Remove one block (H) from the left hand inside of the frame assembly. Retain block (H) for later use in this Special Instruction.

Rework Procedure for Installation of the Support Mounts, Fabricated Blocks, and Plates

Note: This rework procedure will need to be completed for the right-hand side and the left-hand side of the frame assembly.

Show/hide table

Illustration 13	g01955872
Dimensions for blocks (1) and (2) on left side mounting pad (A) ( af) 75.0 mm (2.95 inch) (ag) 45.0 mm (1.77 inch) (ah) 117.5 mm (4.63 inch)

Show/hide table

Illustration 14	g01955875
Illustration of the welds for blocks (1) and (2) on mounting pads (A) ( N1) P - R

1. Prepare mounting pads (A) for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

2. Weld blocks (1) and (2) onto the bottom of mounting pads (A).

   Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

   Note: The left and right sides of mounting pads (A) are mirror images of each other.

   Show/hide table

   Illustration 15	g01954113
   Top view (aj) 3220 mm (126.8 inch)

   Show/hide table

   Illustration 16	g01946614
   Top right side view Dimensions for locating mounting pads (A) ( ak) 200.5 mm (7.89 inch)

   Show/hide table

   Illustration 17	g01946615
   View of mounting pad (A) that is in position

3. Center both mounting pads (A) on the respective frame rails as close as possible.

4. Position mounting pads (A) to ensure that pads (A) are within 3.0 mm (0.12 inch) to the same height. Mounting pads (A) must be installed parallel to each other. There can only be less than a 0.5 degrees difference.
   Show/hide table

   Illustration 18	g01947752
   Illustration of the welds for blocks (1) and blocks (2). (N2) S - T (N3) U - V

   Show/hide table

   Illustration 19	g01946622
   View of mounting plates (A) that are installed

5. Prepare the area for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

6. Weld blocks (1) and (2) onto each of the frame rails.

   Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

   Show/hide table

   Illustration 20	g01946623
   View of plate (3) that is located on rail

   Show/hide table

   Illustration 21	g01950076
   Illustration of the welds for plate (3) ( N3) Weld start and stop shall be 45 mm (1.8 inch) from the top surface of the frame rail. Weld from W to X.

7. Prepare the area for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

8. Tack weld four plates (3) securely to both sides of each rail. Begin the tack weld at point (W). End the tack weld at point (X).

   Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

9. Weld four plates (3) on both sides of each rail. Plates (3) must be mounted against the rail. Mount plates (3) to the bottom of the mounting pad (A). Plates (3) must span the full length of mounting pad (A).
   Show/hide table

   Illustration 22	g01946624
   (am) 67.6 mm (2.66 inch)

   Show/hide table

   Illustration 23	g01947245
   Illustration of welds for plate (3) and gussets (4)

10. Prepare the area for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

11. Weld two pieces of gusset (4) to plate (3) to the right-hand side and the left-hand side on the outside of each frame rail.

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

    Show/hide table

    Illustration 24	g01946627
    View of plate (5) ( an) 234.0 mm (9.21 inch) (ap) 329.0 mm (12.95 inch)

    Show/hide table

    Illustration 25	g01946625
    View of plate (5) that is located

    Show/hide table

    Illustration 26	g01950191
    Illustration of welds for plate (5)

12. Prepare the area for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

13. Weld plates (5) between two gussets (4) on plates (3) on the outside of each frame rail.

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

    Show/hide table

    Illustration 27	g01946628
    View of plate (6) ( ar) 238.0 mm (9.37 inch) (as) 110.0 mm (4.33 inch)

    Show/hide table

    Illustration 28	g01950193
    Illustration of welds for plate (6)

14. Prepare the area for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

15. Weld plates (6) to plates (3) on the inside of each frame rail.

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

    Show/hide table

    Illustration 29	g01949724
    View of plate (G) ( at) 16.0 mm (0.63 inch) (au) 80.0 mm (3.15 inch) (av) 130.0 mm (5.12 inch) (aw) 30.0 mm (1.18 inch) (ax) 240.0 mm (9.45 inch)

    Show/hide table

    Illustration 30	g01946629
    View of gusset (G) that is located

    Show/hide table

    Illustration 31	g01949747
    Illustration of the welds for upper gussets (G)

16. Prepare the area for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

17. Modify upper gussets (G) to allow gussets (G) to fit over new plates (3). Weld gussets (G) in the original position.

    Reference: Refer to Illustration 29.

    Note: Gussets (G) were removed in Step 5 of section "Preparation for Installation of the Support Mounts".

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

    Show/hide table

    Illustration 32	g01950032
    View of plate (E) ( ay) 410.0 mm (16.14 inch) (az) 389.0 mm (15.31 inch) (ba) 20.0 mm (0.79 inch) (bb) 320.0 mm (12.60 inch) (bc) 98.0 mm (3.86 inch)

    Show/hide table

    Illustration 33	g01946630
    View of plate (E) and bosses (F) that are located

    Show/hide table

    Illustration 34	g01951598
    Illustration of welds for plate (G) and plate (E)

    Show/hide table

    Illustration 35	g01950031
    Illustration of welds for plates (E) ( N4) Y - Z

18. Modify support plates (E) for clearance around plate (C).

    Reference: Refer to Illustration 32.

19. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

20. Weld plates (E) in original location. Weld plates (E) in the original location on the lower gusset. The lower gussets were not removed in this rework procedure.

    Note: Plates (E) were removed in Step 4 of section "Preparation for Installation of the Support Mounts".

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

21. Weld bosses (F) on plate (C) in original location.

    Note: Bosses (F) were removed in Step 4 of section "Preparation for Installation of the Support Mounts".

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

    Show/hide table

    Illustration 36	g01946632
    View of block (H) that is installed

22. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

23. Weld block (H) in original location.

    Note: Block (H) was removed in Step 6 of section "Preparation for Installation of the Support Mounts".

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.

    Show/hide table

    Illustration 37	g01950216
    A view of platform mount assembly (D) that is installed.

24. Cut 12 mm (0.47244 inch) off the back of the platform mount assembly (D) that was removed in Step 1. Platform mount assembly (D) was removed in Step 1 of section "Preparation for Installation of the Support Mounts".

25. Prepare the area for welding. Use a grinder to clean the weld areas. Completely remove all paint, rust, scale, slag, dirt, moisture, tape, and so on, before welding.

26. Weld platform mount assembly (D) to the original location on the machine.

    Note: Use platform mounting plate (J) as a reference to locate platform mount assembly (D).

    Note: Before welding, preheat the welding areas to the proper temperature. Use 164-3310 Infrared Thermometer to check for the proper preheat temperature.