Adapting 140M and 160M Snow Wings to 140M Series 2 and 160M Series 2 Motor Graders{6158, 6159} Caterpillar

Motor Grader:

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

Introduction

This Special Instruction provides information about the parts and procedures that are required to install an M Series Snow Wing to an M Series 2 Motor Grader. Do not perform any procedure in this publication until you understand the information that is contained within this publication. Do not order any parts until you understand the information that is contained within this publication.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

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Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

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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.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

Reference Documents

ReferenceSpecial Instructions, REHS1841, "General Welding Procedures".

Required Parts

Welding Details

Shielded Metal Arc Welding

The Shielded Metal Arc Welding (SMAW) process may be used with the E7018 (ANSI/AWS A5.1) welding electrode. The weld that will be deposited by these electrodes will have the following mechanical properties.

These low hydrogen electrodes must be stored in an electrode oven at 120 °C (248 °F) when the electrodes are not being used. Scrap the electrodes if the electrodes get damp.

Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the manufacturer of the welding electrode.

The following chart relates to the electrode diameter and approximate current settings for welding.

The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.

Flux Cored Arc Welding

The Flux Cored Arc Welding (FCAW) process may be used with the E71T-1 (AWS A5.20) welding electrode. The FCAW process may also be used with shielding gas. The weld that will be deposited by these electrodes will have the following mechanical properties.

Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the manufacturer of the welding electrode.

For a 1.1 mm (0.045 inch) electrode, the typical welding parameters should be the following.

For a 1.3 mm (0.052 inch) electrode, the typical welding parameters should be the following.

The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.

Note: All vertical welds will be welded with a vertical up technique.

Machine Preparation

1. Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

2. Move the machine to a smooth horizontal location. Move the machine away from any machines that are working and any personnel.

3. Move the transmission control to the "NEUTRAL" position.

4. Ensure that all implements are grounded and at a zero energy state.

5. Activate the parking brakes. Stop the engine.

6. Place blocks in front of the wheels and behind the wheels.

Adapting the M Series Snow Wing to an M Series 2 Motor Grader

Required Parts

Adapting Procedure

For machines with a Manual or Hydraulic Rear Brace Height Adjustment Wing, the 268-7873 Mounting Bracket Gp needs changed to a 335-3028 Mounting Bracket Gp .

For machines with a Ripper Height Adjustment Wing, a steel link needs welded on the tube assembly of the snow wing and on the RH side of the ripper.

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Illustration 1	g02556237
Tube assembly of snow wing (A) 2073.4 mm (81.63 inch) (1) Link (2) Tube assembly

1. Weld a 277-5555 Link (1) on the tube assembly (2) at distance (A) 2073.4 mm (81.63 inch) from the end.

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Illustration 2	g02556238
Right-hand side of ripper (3) Link

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Illustration 3	g02556239
Right-hand side of ripper (B) 187.5 mm (7.38 inch) (C) 39.5 mm (1.55 inch) (3) Link

2. Weld a 277-5555 Link (3) on the RH side of the ripper. Refer to Illustration 3 for dimensions.