Rework Procedure for the Tether Hitch Group on Certain 552 Track Feller Bunchers {7100} Caterpillar

Track Feller Buncher

552 Series 2 (S/N: F7G1-UP)

Introduction

This Special Instruction provides information on how to rework the Tether Hitch Group on the machines listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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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.

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Be sure all personnel are clear of equipment while equipment is being lowered. Failure to stay clear may result in personal injury.

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Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Be sure to always use proper PPE when performing all handling, welding, and grinding operations. Follow all Caterpillar safety procedures.

Welding Preparation

1. Parts must be free of rust, dirt, scale, and burn dross using the cleaning operations/tools such as blasting, grinding, wire wheel, etc. When cleaning the parts (especially those with significant rust) wear a "sanding" respirator.

2. Gap in the weld seams greater than 2.0 mm (0.08 inch) must be filled with the root pass. Vertical down root welds are not allowed. Root the weld to be welded in position or vertical up. Root the welds cannot exceed 4.0 mm (0.16 inch) weld size or this will cause problems with the robot cycle. Dress root the welds with the grinder if needed.

3. Welding follows 1E0099 specification.

4. Tacking convention:

   • Standard = 3.0 mm (0.12 inch) weld, 25.0 mm (0.98 inch) length spaced 300 mm (11.8 inch)on center

   • Heavy duty = 3.0 mm (0.12 inch) weld, 50.0 mm (1.97 inch) length spaced 300 mm (11.8 inch) on center

5. Check chamfered edges are up to specification, 2 mm max.

Welding Parameters

• 1E0559 0.052 Dia Solid Wire

• Volts Welding - 29 +/- 7% Stringering - 27 +/- 7%

• Wfs Welding 400 +3% -10% Ipm Stringering - 350 +3% -10%

• Gas 40 Cfh Argon/Co2

Installation on 552 TFB Lower Ar

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Illustration 1	g06145702

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Illustration 2	g06156017
511-0561 Tether Hitch Gp (1) Track welds

Note: The 511-0561 Tether Hitch Gp ( 445.1 kg (981.3 lb)) has temporary tack welds as shown in Illustration 2.

Note: The load rating is displayed on the tag pointed out in Illustration 2.

1. Remove four tack welds and separate the top plate assembly from the 511-0556 Plate ( 128.5 kg (283.3 lb)).

   Grind, free all the affected areas of any material remaining from four tack welds.

   Sequence Time = 20 mins

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   Illustration 3	g06145724
   (2) Tack and Weld along entire beveled joint

2. Relocate the 511-0556 Plate to correct position at front end of 552 Lower AR with appropriately rated hoist.

   Clamp the 511-0556 Plate to the bottom plate of the carbody.

   Tack weld as appropriate and weld the 511-0556 Plate to the bottom plate along entire beveled joint.

   Grind until flat top weld surface between the 511-0556 Plate and the bottom plate of carbody.

   Sequence Time = 1 hr

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   Table 1

   1E	Dia	Pos	Size	Type	WFS	Volt
   0559	0.52	F	25	BW	400	29.0

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   Illustration 4	g06145743
   (3) Track weld three places (4) Track weld two places

3. Relocate the remaining tether mount weldment to the correct position relative to the carbody and the bottom plate with appropriately rated hoist.

   Clamp as necessary to secure weldment.

   Tack two 511-0557 Plate As ( 100.2 kg (220.9 lb)) to the 511-0556 Plate ( 128.5 kg (283.3 lb)) and the carbody bottom plate as shown in Illustration 4.

   Tack the 511-0559 Plate ( 97.3 kg (214.5 lb)) the carbody top plate as shown in Illustration 4

   Sequence Time = 30 min

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   Table 2

   1E	Dia	Pos	Size	Type	WFS	Volt
   0559	0.52	H	3	T	370	27.0
   0559	0.52	F	3	T	400	29.0

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   Illustration 5	g06145757
   (5) Weld all around (Outside)

4. Complete the welding two 511-0557 Plate As ( 100.2 kg (220.9 lb)) and the 511-0558 Plate ( 18.8 kg (41.4 lb)) as shown in Illustration 5.

   Sequence Time = 1.5 hrs

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   Table 3

   1E	Dia	Pos	Size	Type	WFS	Volt
   0559	0.52	H	12	F	370	27.0
   0559	0.52	H	12	FO	370	27.0

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   Illustration 6	g06145764
   (6) Weld along entire beveled joint

5. Complete the welding 511-0559 Plate ( 97.3 kg (214.5 lb)) to the top plate along entire beveled joint as shown in Illustration 6.

   Sequence Time = 45 mins

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   Table 4

   1E	Dia	Pos	Size	Type	WFS	Volt
   0559	0.52	F	10	BW	370	27.0

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   Illustration 7	g06145770
   (7) Weld two places

6. Weld the two 511-0557 Plate As ( 100.2 kg (220.9 lb)) the top plate of the carbody as shown in Illustration 7.

   Sequence Time = 20 mins

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   Table 5

   1E	Dia	Pos	Size	Type	WFS	Volt
   0559	0.52	O	12	F	265	26.0