Rework Procedure to Reinforce the Cowl Assembly{0679, 7051, 7155, 7251, 7254, 7267} Caterpillar

Off-Highway Truck:

789C (S/N: 2BW1-UP)

Introduction

The following Special Instruction is used to reinforce the cowl assembly and the mount for the cowl.

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

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceDisassembly and Assembly, SENR1520, "Cowling (Radiator) - Remove"

Remove the Cowl and Modify the Parts

Show/hide table



Illustration 1	g01955097

1. Remove the radiator 212-2759 Cowl As from the truck.

   ReferenceDisassembly and Assembly, SENR1520, "Cowling (Radiator) - Remove"

Show/hide table



Illustration 2	g01955113
LH rear view of the cowl (A) 212-2754 Plate (B) 212-3214 Gusset (C) 211-0682 Gusset (D) 212-2757 Plate (E) 211-0897 Plate

2. Identify the parts that are located on the left hand side of the cowl assembly. Refer to illustration 2.

   Note: Do not disassemble the cowl assembly.

Show/hide table



Illustration 3	g01955114
RH rear view of the cowl (A) 212-2754 Plate (B) 212-3214 Gusset (C) 211-0682 Gusset (F) 212-2756 Plate (G) 211-0927 Plate

3. Identify the parts that are located on the right hand side of the cowl assembly. Refer to Illustration 3.

   Note: Do not disassemble the cowl assembly.

Show/hide table



Illustration 4	g01955134
View of plate (D) (D) 212-2757 Plate (H) Metal strip

4. Use a suitable tool in order to remove metal strip (H) from plate (D) .

Show/hide table



Illustration 5	g01955142
(AA) 208.1 mm (8.20 inch) (BB) 17 mm (0.67 inch) (CC) 1430 mm (56.30 inch) (DD) 18 mm (0.71 inch) (EE) 18 mm (0.71 inch) (FF) 59 mm (2.30 inch) (GG) 10 mm (0.40 inch) at 45 degrees (HH) 65 mm (2.60 inch)

5. Use a suitable tool in order to complete the modifications to plate (D). Refer to Illustration 5.

Show/hide table



Illustration 6	g01955220
Area of modification for plate (F) (F) 212-2756 Plate (J) Metal strip

6. Use a suitable tool in order to remove metal strip (J) from plate (F) .

Show/hide table



Illustration 7	g01955247
(JJ) 208.1 mm (8.20 inch) (KK) 1430 mm (56.30 inch) (LL) 17 mm (0.67 inch) (MM) 18 mm (0.70 inch) (NN) 59 mm (2.30 inch) (PP) 18 mm (0.71 inch) (GG) 10 mm (0.40 inch) at 45 degrees (RR) 68 mm (2.70 inch)

7. Use a suitable tool in order to complete the modifications to plate (F). Refer to Illustration 7.

Show/hide table



Illustration 8	g01955376
(S) 13 mm (0.50 inch) (T) 123 mm (4.80 inch)

8. Modify plate (G). The modification will create a larger notch in the existing notched area.

   Note: The shaded area represents material that needs to be removed.

Show/hide table



Illustration 9	g01955394
(U) 32 mm (1.30 inch) (V) 13 mm (0.50 inch)

9. Modify four gussets (C). The modification will create a larger notch in the existing notched area.

   Note: The shaded area is the existing notched area.

Show/hide table



Illustration 10	g01955480
(W) 123 mm (4.80 inch) (X) 13 mm (0.50 inch)

10. Modify plate (E). The modification will create a larger notch in the existing notched area.

    Note: The shaded area represents material that needs to be removed.

Show/hide table



Illustration 11	g01955495
(Y) 13 mm (0.50 inch) (Z) 34.6 mm (1.40 inch)

11. Modify two gussets (B). The modification will create a larger notch in the existing notched area.

    Note: The shaded area is the existing notched area.

Show/hide table



Illustration 12	g01955674
(SS) 58.8 mm (2.3 inch) (TT) 12.4 mm (0.48 inch)

12. Modify plate (A) at both the left and the right corners. The shaded area represents material that needs to be removed. The modification will create a larger notch in the existing notched area.

Reassemble the Cowl Assembly

1. Use the modified parts and the required parts in order to reassemble the cowl assembly. Refer to Step 3 through Step 12 in the ""Remove the Cowl and Modify the Parts" " section of this Special Instruction.

Show/hide table



Illustration 13	g01955866
LH rear view of the cowl assembly (UU) 214.6 mm (8.45 inch) (VV) Do not weld 50 mm (2 inch) from the corner. (WW) Starting point of weld (XX) End point of weld (D) 212-2757 Plate (3) 338-0631 Plate

2. Install plate (3). Weld plate (3) with a 4 mm (0.16 inch) fillet weld on the edge of the plate. Start the weld at point (WW) and end the weld at point (XX) .

   Note: Do not weld within 50 mm (2 inch) from the corner.

Show/hide table



Illustration 14	g01955962
RH rear view of the cowl assembly (YY) 214.6 mm (8.45 inch) (ZZ) Do not weld 50 mm (2 inch) from the corner. (WW) Starting point of weld (XX) End point of weld (F) 212-2756 Plate (2) 338-0630 Plate

3. Install plate (2). Weld plate (2) with a 3 mm (0.12 inch) fillet weld on the edge of the plate. Start the weld at point (WW) and end the weld at point (XX) .

   Note: Do not weld within 50 mm (2 inch) from the corner.

Reinforce the Mounting Area of the Truck Frame

Show/hide table



Illustration 15	g01956036
(1) 340-8386 Plate

1. Install plate (1) in the corner of the frame.

2. Weld plate (1) along the top and along the bottom to the frame with a 4 mm (0.16 inch) fillet weld on the edge of the plate.

3. Paint the welded areas in order to protect the area from corrosion.

Install the modified Cowl Assembly

1. Position the modified cowl that has been reworked on the truck. Use 14 9B-7237 Bolts and 14 5P-1075 Hard Washers in order to secure the cowl.

   Refer to Disassembly and Assembly, SENR1520-, "789C Off-Highway Truck Engine Supplement ", "Cowling (Radiator) - Install".