D10R Main Frame and Fender Crossbeam Pinned Mount Conversion{7050} Caterpillar

D10R Main Frame and Fender Crossbeam Pinned Mount Conversion{7050}

Usage:

D10R 3KR

Track-Type Tractor:: D10R (S/N: 3KR1-UP)

Introduction

This Special Instruction provides the information that is necessary for the following procedures:

Inspect the mainframe.
Repair the cracks in the mainframe.
Convert to the fender crossbeam pinned mount.

Inspect the machine in order to determine the extent of the cracks in the frame. Determine the amount of disassembly that is required to repair. If the cracks in the frame on both the right side frame and the left side frame cracks are minor, or if conversion to fender crossbeam pinned mount is not required, the main frame may be repaired to the original condition.

Reference: Refer to Special Instruction, REHS1243, "Repair of the Main Frame and Radiator Mount" for additional information.

If there are major cracks in the frames, then conversion to the fender crossbeam pinned mount will be required.

Major cracks are extensive cracking in the following areas:

Inside frame side plate
Outside frame side plate
Top rail section
Bottom rail section
Area of the fender mounts

Conversion to the fender crossbeam pinned mount provides a more robust mainframe joint. Conversion should be done if continued operation in a severe application or extended usage of the machine is expected. Follow this procedure and table 1 for necessary parts.

After the repair is completed, prepare the machine for service. Refer to the Operation and Maintenance Manual for proper machine preparation.

Do not perform any procedure that is outlined in this publication until you have read all the information and you understand the information. Do not order any parts until you have read the information and you understand the information.

Reference: Service Manual, Parts Book, Operation And Maintenance Manual.

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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.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE

Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

Note: Do not coat any fasteners with oil or grease prior to tightening. Instructions are given when lubrication is required.

Repair of the D10R Main Frame

Welding Requirements

The following processes are acceptable:

Gas Metal Arc Welding (GMAW): Use 35 ± 5 CFH of 75 percent argon, 25 percent CO2 mixed shielding gas AWS class ER70S-3 electrode.
Flux Cored Arc Welding (FCAW).
AWS class E71T-1: Use the gas mixture and flow that is suggested by the manufacturer.
Shielded Metal Arc Welding (SMAW): Use E7018 electrode, direct current electrode positive.
Air Arc Gouging: The carbon arc rods are 5/16 inch or 3/8 inch diameter. Also, the carbon arc rods must have an electrode positive and the carbon arc rods must use direct current.

The following processes are the preferred processes: GMAW, FCAW and E71T-1.

Parts List

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Table 1
Purchase Parts
Item	Qty	Part Number	Description
1	4	6Y-5812	Bearing
2	2	8T-4994	Washer
3	8	164-4649	Spacer
4	8	7X-0368	Bolt
5	2	6V-8182	Nut
6	2	7X-0555	Washer
7	2	8C-3185	Bolt
8	1	7D-5135	Boss
9	1	6D-4247	Clip
10	1	6D-1641	Clip
11	1	4L-6454	Bolt
12	1	8T-4896	Washer
13	2	9D-7989	Nut
14	1	7G-6790	Plate
15	1	7G-3413	Clip
16	2	226-2387	Plate As
17	2	233-9835	Support
18	2	227-5146	Pin
19	2	5D-3954	Taperlock Stud
20	1	8T-9393	Bolt
21	1	8T-4122	Hard Washer
22	1	218-3334	Frame Rail

Material Requirements

Use low carbon structural steel that is 16 mm (0.63 inch) thick with a minimum yield strength of 290 MPa (42060 psi) to 450 MPa (65270 psi). This steel is for the replacement of the window plates.

Machine Preparation for Inspection

Prepare the machine for inspection of the mainframe and the possible conversion to the pinned crossbeam mounting.

Park the machine on level ground.
Lower the attachments to the ground.
Move the implement controls to the HOLD position. Engage the restraint for the blade control lever and for the ripper control lever.
Move the transmission control to the NEUTRAL position.
Engage the parking brake switch.
Stop the engine.
Turn the engine start switch to OFF. Remove the key.
Turn the disconnect switch to the OFF position. Remove the key.

Preliminary Inspection for Determining the Extent of Required Repair

Clean the outside of the frame.
Remove the floorplate of the operator's platform.
Clean the inside side plates of the frame.
Inspect the frames for cracks in the inside side plate, outside side plate, top rails, and the bottom rails

Repair Options

The mainframe can be restored to original condition if only minor cracks are found in the mainframe out board side plates and a more robust mainframe is not required.
Reference: Refer to Special Instruction, REHS1243, "Repair of the Main Frame and Radiator Mount" for additional information.

Repair the frames and convert the machine to the pinned fender mount if the following conditions exist:
- Major cracks are found in the side plates.
- Major cracks in the top rails
- Major cracks in the bottom rails
- Extended operation in severe applications is expected.

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Illustration 1	g01017164

Disassembly That is Required for Mainframe Repair and Conversion to Fender Crossbeam Pinned Mount

Note: Start on either the right side or the left side of the main frame.

Loosen the track adjusters in order to provide maximum slack in the track chain. See the service manual.

Separate the tracks..
Reference: Refer to Disassembly and Assembly, SENR8422, "Separation Of Track" for additional information.

Disconnect the batteries from both fender compartments.

Remove the batteries from both fender compartments.

Ensure that top two bolts (9) are tightened to the correct torque. These bolts fasten the fenders to the crossbeam that is located on the inside of the battery boxes on both sides of the machine. See Illustration 3.
Note: Check the bolts for wear or damage. Replace the bolts, if necessary. These bolts will support the following components during the repair and fender crossbeam pinned mount conversion: fender crossbeam, front of the cab and operator's station.

Turn off the shutoff valve for supply and return of fuel at the fuel tank.

Ensure that all bolts (10) that fasten the fenders to the ROPS supports have correct torque. See Illustration 3.
Note: Check the bolts for wear or damage. Replace the bolts, if necessary. These bolts will be supporting the following components during the repair and fender crossbeam pinned mount procedure: fenders, crossbeam, cab and operator's station.

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Illustration 2	g00934576

Remove bolts (1), washers (2), nuts (3), and bracket (4) from barrier assembly (5). See Illustration 2.

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Illustration 3	g01017092

Remove four bottom bolts (6) and washers (7) from plate (8) .
Note: Do not remove top two bolts (9). Ensure that the top two bolts have the correct torque. These bolts are located inside of the battery boxes on both sides.

Remove bolts (11) and washers (12) from the crossbeam support.

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Illustration 4	g00949931
Left Hand Side of the Frame

Remove bolts (13), the washers, and clips (16) from hoses (14) and hoses (15) .

Move hoses (14) and hoses (15) aside.

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Illustration 5	g00949968
Right hand side of the frame

Remove bolts (17), the washers, and clip (18) from hoses (19) .

Move hoses (19) aside.

Remove the Engine

Remove the engine. Refer to Disassembly and Assembly, SENR8418-01, "Engine - Remove".

Fabricated Tools Needed

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Illustration 6	g00934128

Modify 9D-7989 Nut with 3 by 45 degree chamfer (A) .

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Illustration 7	g00934066
Fixture Arm (B) 19 mm (0.75 inch) (C) 12 mm (0.47 inch) (D) 12 mm (0.47 inch) (E) 43 mm (1.69 inch) (F) 977.72 mm (38.49 inch) (G) 137.03 mm (5.40 inch) (H) 342.41 mm (13.48 inch) (I) 52.6 mm (2.07 inch) (K) 60 mm (2.36 inch) (L) 26.3 mm (1.04 inch) (M) 30 mm (1.18 inch) (N) 50 mm (1.97 inch) (O) 25 mm (0.98 inch) (P) 269.07 mm (10.59 inch) (R) 316.09 mm (12.45 inch) (S) 990.41 mm (38.99 inch) (T) 633.26 mm (24.93 inch) (U) 12 degrees (V) 60 mm (2.36 inch) (W) 30 mm (1.18 inch) (X) 140.22 mm (5.52 inch) (Y) 198.86 mm (7.83 inch) (Z) Three 16.5 mm (0.65 inch) Diameters (AA) 3 by 45° chamfer

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Illustration 8	g00934156
Fixture Pin (BB) 155 ± 1 mm (6.102 ± 0.039 inch) (CC) 56.5 ± 0.15 mm (2.224 ± 0.006 inch) diameter (DD) 13.8 mm (0.54 inch) diameter with 41 mm (1.61 inch) depth (DD) Tap the diameter (C) for 5/8-11-2B threads with 29 mm (1.14 inch) depth.

Fabricate the tools by using the dimensions in Illustration 6, Illustration 7, and Illustration 8, as shown above.

Remove the Window Plate for the Final Inspection

Note: The following Step 1 through Step 5 must be completed in order to inspect the frame for cracks in the inside side plate of the mainframe.

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Illustration 9	g00934786
(EE) 50.8 mm (2 inch) (FF) 50.8 mm (2 inch) (GG) 40 mm (1.58 inch)

Scribe two vertical lines (22) on the side plate outside all of the cracks. These lines will be the sides of a window opening in order to be cut in the outside plate. The front vertical line must be at least at the front edge of the fender bracket. The front vertical line must not be more than 40 mm (1.6 inch) in front of the front edge of the fender bracket in order to avoid internal mainframe welds. The rear line must be at least at the edge of the rear side of the fender bracket. See Illustration 9.

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Illustration 10	g00988389
Template for location of the weld (20) Plug weld (HH) 262 mm (10.3 inch) (II) 238 mm (9.4 inch) (KK) 35 mm (1.4 inch) (LL) 62 mm (2.4 inch) (MM) 35 mm (1.4 inch) (NN) 67 mm (2.6 inch) (OO) 195 mm (7.7 inch) (PP) 227 mm (8.9 inch) (R1) 10 mm (0.4 inch) radius (four places) (R2) 30 mm (1.2 inch) radius (two places)

If the fender bracket weld on mainframe (20) is not visible, create a template in order to determine the location of the plug weld for the fender bracket. Use Illustration 10 for dimensions of the template.

Use the template from Illustration 10 in order to determine the location of the weld on fender bracket (25). See Illustration 9. Gouge out weld (20) on the fender bracket on the outside plate of the fender bracket. Remove weld (21) between the outside plate of the fender bracket and the top plate of the fender bracket. Remove the fender bracket outside plate (25). See the Illustration. 9

Gouge out the top J-groove weld (23) between the two vertical scribed lines away from the top rail (EE). Gouge out the bottom J-groove weld (24) between the two vertical scribed lines away from the bottom rail (FF). Do this procedure carefully in order to minimize the damage to the rails. Also, use the air carbon arc to begin cutting the vertical window lines in order to clear the internal sections of the top and bottom rail. See dimensions (EE) and (FF) in Illustration 9. A cutting torch may be used to finish removing the rest of the sideplate window.

Repeat Step 1 through Step 4 on the opposite rail.

Final Inspection of the Mainframe with the Engine and the Outside Mainframe Window Plates Removed

Note: Step 1 through Step 10 is the start of the pinned crossbeam mounting conversion. These steps are necessary in order to be able to do the required inspection.

Use a grinder in order to remove carbon on the surface area that has been cut by the air carbon arc or the torch. Restore the J-groove in the rails at the top of the window and the bottom of the window. Clean up the sides of the window opening in order to remove slag or carbon.

Install two 5D-3954 Taperlock Studs in the two rear holes that are marked (SS). This is located on the lower enclosure on the case and frame. See Illustration 11 for the location of the two holes. Secure the fixture arm with the studs and the conical nuts. The third non-chamfered hole should be pointed to the rear of the machine and in the up position.

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Illustration 11	g00955053
(RR) 112 mm (4.4 inch) Diameter (SS) Taperlock studs

Attach the fixture pin onto the fixture arm assembly with the 8T-9393 Bolt and 8T-4122 Hard Washer through the non-chamfered hole. The fixture pin should be installed into the frame box. Locate the outside diameter of the pin. Scribe a line around the end of the pin on the inside of the inner side plate.

Remove the fixture arm and remove the fixture pin from the fixture arm.

Determine the center of the circle.

Use the center that was just located to scribe a circle with a diameter of 112 mm (4.4 inch) on the inside of the inner side plate.

The 112 mm (4.4 inch) circle is for the bore that will be machined in a later step. This bore is for the pinned fender mount.

Repeat Step 1 through Step 7 on the opposite frame rail.

Inspect the top rail under the fender bracket. Inspect the inside side plate of the frame. Determine the amount of cracking. Repeat on the frame rail on the opposite side of the machine.

If the inside mainframe side plate is cracked, determine the amount of the crack that will be eliminated once the 112 mm (4.4 inch) diameter is removed from the inside side plate. Minor cracks that extend outside of the circle can be repaired later.
Note: For a successful repair, remove any crack well beyond the point of origin. Use the dye penetrant to locate the cracks. No compromise should be allowed for removal of cracks. Determine if there is sufficient space for properly repairing any crack., Gouge out the crack. Grind the carbon that still remains from the air arc gouging. Prepare a proper weld joint. Reweld the joint. After the initial weld pass, inspect the weld for cracks. Grind the surface smooth. If the frame is cracked all the way through or nearly through the parent material, the crack must be back gouged from the opposite side into the new parent weld. Grind the carbon and remove the carbon. Reweld the surface and grind the surface smooth. Needle peen all welded surfaces.
Note: If the separation of the frame top rail is greater than 2 mm (0.08 inch), it may be necessary to remove a window plate from the inside plate of the frame. This will allow you to realign the frame to the original geometry. The window plate should also remove any cracks that may be on the inside plate. Remove the window plate in a similar manner as the outside window plate. Make the size of the inside window plate large enough to remove all of the separation in the top rail.

Determine which of the following five repair scenarios should be followed based on severity of cracking seen on your machine:

Prior to starting any of these repair scenarios, ensure that the support of the crossbeam fender is still in place and is stable. Ensure that top two bolts (9) have the correct torque. These bolts fasten the fenders to the crossbeam. The crossbeam is located inside the battery boxes on both sides. See Illustration 3. Ensure that all bolts (10) have the correct torque. These bolts fasten the fenders to the ROPS supports. See Illustration 3. Check the bolts for wear or damage. Replace the bolts, if necessary. These bolts will support the following components during the repair and fender crossbeam pinned mount conversion: fender crossbeam, front of the cab and operator's station.

Repair Scenario (One)

The Outside Mainframe Plate is Cracked

Complete the removal of the old fender mount by removing the vertical plates and the horizontal inside mounting plates. Use the template in order to determine the location of the inside weld on the fender bracket. Gouge out the weld on the fender bracket on the inside plate of the fender bracket. Remove the fender bracket assembly. Discard all of the removal parts.

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Illustration 12	g00932753

Cut a hole to 112 mm (4.4 inch) diameter by burning through the inside of the inner plate that was just scribed in Step 2 through Step 8. See Step 2 through Step 8. These steps are in ""Final Inspection of the Mainframe with the Engine and the Outside Mainframe Window Plates Removed" ".

Make a 30 degree bevel of the edge of the hole. The bevel is located from the outside of the inner plate (engine side of the case and frame). See Illustration 12.

Use a grinder in order to remove any carbon that was left from the air carbon arc. Also, remove any slag in order to prepare the weld joint.

Create a plate in order to replace the window opening in the outside of the mainframe. The plate is 10 mm (0.4 inch) smaller in width and in height in contrast to the existing cut-out in order to create a 5 mm (0.2 inch) root opening on all sides of the window plate. Make 15 degree bevels on the top and on the bottom of the plate. Make 30 degree bevels on the sides of the plate.

Create two back up strips for the side welds. The back up strips should be 25 mm (0.98 inch) wide and 10 mm (0.4 inch) thick. The length of the strips is the distance from the bottom of the top rail to the top of the bottom rail.

Install the two back up strips along the sides of the window opening. Position the back up strips so that one edge extends 15 mm (0.6 inch) toward the inside of the window opening. Tack weld the back up strips to the mainframe side plates.

Position the window plate in the opening. Leave a 5 mm (0.2 inch) root opening on all sides of the window plate. Temporarily clamp or tack weld the plate in position.
Note: After you locate the new center hole for the fender support plate, a new window plate will need to be removed.

Mark the window and record the location relative to the mainframe for the final installation at a later step.

Reinstall the fixture arm to the outside of the frame. The fixture pin does not attach to the fixture arm in this step.

Use the third non-chamfered hole in the fixture arm in order to locate the center hole. Center punch a hole on the surface of the new window plate.

Remove the fixture arm and the new window plate.

Use the center point on the plate in order to scribe a circle with a 112 mm (4.4 inch) diameter.

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Illustration 13	g00974797

Cut the hole to the 112 mm (4.4 inch) diameter. Make 30 degree bevels on the hole. Grind the carbon and the slag from the beveled hole. See Illustration 13.

Assemble the fixture pin to the fixture arm.

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Illustration 14	g00996849

Note: The fixture arm and the pin will be used to locate the pin support into the mainframe. This location is critical for final machining. The pin support cannot be premachined to the final dimension before installation in the mainframe.

Install 197-9038 Pin Support onto the fixture pin. One end of the 197-9038 Pin Support has a length of 16 mm (0.63 inch) length. Insert this end of the pin support in the hole that is in the inner mainframe side plate. The end of the pin support should be flush with the outside surface of the inner side plate. See Illustration 14.

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Illustration 15	g00996850

Push the pin support firmly against the inside of the inner frame side plate. Inspect the bevel groove weld opening at the location of the pin support and the inner plate. Ensure a 5 mm (0.2 inch) root opening all the way around support in opening. Grind the opening if this has not been achieved. See Illustration 15. Secure the fixture arm onto the studs with two conical nuts.

Retain the support against the inner plate. Weld small tack welds at the root of the bevel in order to secure the support. The tack welds should be small enough that the welds are easily burned out with the first root pass of the permanent weld.
Note: Do not tack or weld the pin support to the inner surfaces of the frame.

Remove the fixture arm and the fixture pin together.

Reposition the outer window plate to the former marked location.

Inspect the bevel groove weld joint. There must be a 5 mm (0.2 inch) root opening between the 112 mm (4.4 inch) hole diameter in the window plate and the support of the windows. Adjust by grinding the window plate, if necessary. This was done for the support to inside plate in Illustration 15.

Weld the outside window plate in place. Use tack welds in the bottom of the bevel groove weld, to the top and bottom rails, and to the outboard side plate.

Reinstall the fixture arm assembly with the fixture pin onto the frame. The fixture pin should slide into the pin support. If the fixture pin will not slide into the pin support, reposition the pin support.

Weld small tack welds at the joint at the root of the outer side plate bevel in order to secure the pin support. The tack welds should be small enough that the welds are easily burned out with the first root pass of the permanent weld.

Remove the fixture arm assembly with the fixture pin from the studs.

Weld both ends of the pin support to the inner side plate and the outer side plate with a full depth of bevel groove welds.

Weld the outer window plate with the full depth bevel groove weld.

Grind the welds and smooth the surfaces.

Repair Scenario (Two)

The Inside Mainframe Side Plate is Cracked

Note: An Inside Window is not Required to Repair.

Complete the removal of the old fender mount by removing the vertical plates and the horizontal inside mounting plates. Use the template in order to determine the location of the inside weld on the fender bracket. Gouge out the weld on the fender bracket on the inside plate of the fender bracket. Remove the fender bracket assembly. Discard all of the removal parts.

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Illustration 16	g00932753

Cut the hole to a diameter of 112 mm (4.4 inch) by burning through the inside of the inner plate. The hole was just scribed in Step 2 through Step 8. Refer to the information in ""Final Inspection of the Mainframe with the Engine and the Outside Mainframe Window Plates Removed" " that is on page (8) and page (9) .

Make a 30 degree bevel of the edge of the hole. The bevel is located from the outside of the inner plate (engine side of the case and frame). See Illustration 16.

Gouge out any remaining cracks on the inside side plate in a V-groove until you have just broken through the entire side plate. Grind the V-groove in order to remove the carbon or the slag. Weld the V-groove to the full depth.

On the opposite side of the side plate, gouge out the root of the V-groove weld that is deep enough to ensure good welding metal. Grind the V-groove in order to remove the carbon or the slag. Weld the gouged out area to the full depth.

Grind both sides smooth. Needle peen all welded surfaces.

Follow the instructions in the previous section, starting at step 4 for cleaning the circular opening, creating an outer window plate, installing the pin support, and installing the outer window plate.

Repair Scenario (Three)

The Mainframe Side Plates are Cracked and the Top Rail is Partially Cracked

Note: Depending on the size and location of the top rail crack(s), in order to obtain adequate access to do a quality repair you may need to remove the following components: fender crossbeam, fender, ROPS, cab and platform.

Reference: Refer to Disassembly and Assembly, SENR8426-01 for additional information.

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Illustration 17	g00932085

Repair the frame top rail by completing the following procedures:
- Gouge out the crack in order to create a large V-groove that allows full access for the welding gun. See Illustration 17.
- Grind the welded area in order to remove any carbon.
- Use a dye penetrant in order to inspect the welded area. Be sure that the crack has been completely removed.
- Weld the V-groove to the full depth.
- Grind the weld smooth.
- Needle peen the welded surface.

Complete the repair of the side plates. Install the pin support per previous repair scenario (one) or scenario (two), as appropriate.

Repair Scenario (Four)

The Mainframe Side Plates are Cracked and the Top Rail is Cracked Completely Through with Possible Separation

Note: An Inside Frame Sideplate Window may be Required.

Reference: Refer to Disassembly and Assembly, SENR8426-01 for additional information.

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Illustration 18	g00994610

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Illustration 19	g00994613

Repair the frame top rail by completing the following procedures:
- Support the front end of the main frame with lift jacks and determine the amount of separation in the frame top rail.
- If the separation of the frame top rail is less than 2 mm (0.08 inch), gouge out the crack in order to create a large V-groove. Remove the material until you penetrate through the section of the rail. This will allow full access for the welding gun. Grind the welded area in order to remove any carbon. Weld the V-groove to the full depth. On the opposite side of the section of the rail, gouge out the root of the V-groove weld that will be deep enough to ensure good welding metal. Weld the gouged out area to the full depth. Grind all surfaces smooth in order to create the original geometry. Needle peen all the welded surfaces.
- If the separation of the frame top rail is greater than 2 mm (0.08 inch), remove a window plate from the inside plate of the frame in order to realign the frame to original geometry. The window plate should also remove any cracks that may be on the inside plate. Remove the window plate in a similar manner as the outside window plate. Make the size of the inside window plate large enough to allow closure of the separation in the frame rail.
- Lift the front section of the frame that has separation in order to close the gap in the rail. If lifting the front of the frame does not adequately close the gap in the rail, it may be necessary to use puller bolts and possibly additional heating of deformed bottom frame rail to close gap. Weld a temporary weld across the bottom of the rail at the crack in order to secure the rail together. Repeat on the opposite frame rail, if necessary.
- Start at the top of the rail. Remove the crack by creating a V-groove down to within 5 mm (0.2 inch) to 10 mm (0.4 inch) of the bottom of the rail. Keep the V-groove weld wide enough to allow full access for the welding gun. Do not go completely through the rail. See Illustration 18. Grind the surfaces in order to remove any carbon that remains from the air carbon arc. Weld the V-groove area to full depth. Grind the weld flush with the top and sides of the rail.
- Remove the temporary bottom weld and the remaining crack from the bottom by gouging up into the new top weld. Use a dye penetrant in order to inspect the rail. Ensure that the area of the crack has been completely removed and that the welded material is secure. See Illustration 19. Grind the gouged area in order to remove any carbon from the air carbon arc. Weld the gouged out area and grind the weld flush with the bottom surface. Grind all surfaces smooth in order to create the original geometry. Needle peen all the welded surfaces.

If an inside mainframe sideplate window was opened, replace inboard side plate with the following Step 2 through Step 7. If an inboard window was not opened, proceed to Step 8.

Use a grinder in order to remove the carbon and the slag. This should be done in order to prepare the weld joints for installation of the window plate.

Create a plate in order to replace the window opening in the inside of the mainframe. The plate is 10 mm (0.4 inch) smaller in width and in height in contrast to the existing cut-out in order to create a 5 mm (0.2 inch) root opening on all sides of the window plate. Make 15 degree bevels on the top and on the bottom of the plate. Make 30 degree bevels on the sides of the plate.

Create two back up strips for the side welds. The back up strips should be 25 mm (0.98 inch) wide and 10 mm (0.4 inch) thick. The length of the strips is the distance from the bottom of the top rail to the top of the bottom rail.

Install the two back up strips along the sides of the window opening. Position the back up strips so that one edge extends 15 mm (0.6 inch) toward the inside of the window opening. Tack weld the back up strips to the mainframe side plates.

Position the window plate in the opening. Leave a 5 mm (0.2 inch) root opening on all sides of the window plate. Weld the plate into position with a full penetration weld.

Complete the repair of the side plates. Install the pin support by using the previous repair scenario (one) or scenario (two), as required.

Repair Scenario (Five)

The Mainframe Side Plates are Cracked and the Top Rail is Cracked Completely Through with Separation in Multiple Locations

Note: Replacement of part of the rail section and inside frame side plate window are required.

Follow the procedures in the Disassembly and Assembly, SENR8426-01 in order to remove the following components: ROPS, cab, platform, fenders, crossbeam and fender bracket.

Remove a window plate from the inside plate of the frame in order to realign the frame to original geometry. The window plate should also remove any cracks that may be on the inside plate. Remove the window plate in a similar manner that was used for the outside window plate. Make the size of the inside window plate large enough to allow closure of the separation in the frame rail.

Lift the front section of the mainframe rail that has separated in order to establish the original mainframe geometry and alignment. Weld straps across the upper portion of the window opening on both the outer plates and the inner plates. This will secure the position of the frame rail.

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Illustration 20	g00932209
Section of the Rail (VV) 304.8 mm (12.0 inch) minimum length

Replace the damage portion of the mainframe rail with a new rail section. Remove failed section of mainframe rail that has multiple through cracks and complete separations. Cut a 30 degree chamfer on the remaining mainframe rail ends in order to create an opening for a new frame rail section. Grind the cut ends in order to remove any carbon remaining from the cutting process. Cut a new length of rail section. Grind the cut ends in order to remove any carbon remaining from the cutting process. Leave a 5 mm (0.2 inch) gap (27) on each end for a root opening. See length (VV) in Illustration 20.. The window opening in the inner plates and in the outer plates should extend past the cracks.

Install backup strips (28) under the 5 mm (0.2 inch) root opening. Weld the V-groove weld to the full depth. Grind the weld flush with the top of the rail. See Illustration 20.

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Illustration 21	g00995483

Remove the backup strips which would create a stress riser in the mainframe rail. Repair any suspect welds or incomplete welds by gouging up into the mainframe rail weld. See Illustration 21. Grind the welded area in order to remove any carbon remaining from the air carbon arc. Weld the gouged out area (28A) and grind the weld flush with the bottom surface. Grind all surfaces smooth in order to create the original geometry of the rail. Needle peen all welded surfaces.

Follow the previous Step 2 through Step 6 in ""Repair Scenario (Four)" " procedure in order to replace the inside window plates.

Complete the repair of the outside plate and install the pin support. Refer to ""Repair Scenario (One)" "

Machining of Supports

Note: The supports can not be machined before installation into the mainframe.

If the locating fixture arm was used throughout the rework, the center locations of the pin supports should be very close to the required location. The pin support centers can be used to set up the machining.

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Illustration 22	g01017093

The outboard end of the pin support must be machined. The distance between the original outer surface of the mainframe and the outer pin support surface must be 4 mm (0.16 inch). This will remove approximately 7 mm (0.28 inch) of material from the pin support in order to achieve the 4 mm (0.16 inch) dimension.

Bore a hole to a diameter of 63.5 ± 0.5 mm (2.5 ± 0.02 inch) through the support as seen in Illustration 22. Use the dimensions that are shown in Illustration 22.

Bore two holes to a diameter of 69.92 ± 0.04 mm (2.7528 ± 0.0016 inch) that are shown Illustration 22.
Note: The tight tolerance is required since the bearings will be installed in these bores later.

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Illustration 23	g01017094

Bore the hole to a diameter of 72 ± 0.5 mm (2.84 ± 0.02 inch). See Illustration 23.

Repeat Step 2 through Step 5 for the other side of the machine.

Install a 6Y-5812 Sleeve Bearing into each of the 69.92 ± 0.04 mm (2.7528 ± 0.0016 inch) diameter holes in each side of both pin supports. Refer to 23 for the location of the 6Y-5812 Sleeve Bearings .

Rework The Fender and The Crossbeam

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Illustration 24	g00933520

Start the rework of the fender by removing the bottom portion of the existing bolt head protection plate from the fender on both sides of the machine. This will allow you to remove the lower section of the bolt head protection plate. Measure down 40 ± 5 mm (1.58 ± 0.2 inch) from the bottom of the battery box and mark the plate for cutting. Remove the plate by air-carbon arcing through bolt head protection plate at the 40 ± 5 mm (1.58 ± 0.2 inch) dimension. Remove the vertical welds on the sides of the existing bolt head protection plate. Remove the fillet welds from the center of the existing bolt head protection plate. Grind the air arced area in order to remove any carbon remaining from the air-carbon arc on the existing fender plate. Repair any gouges in the fender vertical side plate that were created by removing the bolt head protection plate. Restore the fender to a smooth, flat surface. See Illustration 24.

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Illustration 25	g00998394

Remove the lower eight welded nuts (XX) on the fender crossbeam, as shown. There are four welded nuts on each side of the machine. See Illustration 25. Repair the surfaces and grind the surfaces flat.

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Illustration 26	g00951908
Right Hand Inboard Side of the Frame 7G-6790 Plate

Install a 7G-6790 Plate on the inside surface of the right hand mainframe. This is for mounting the dozer tilt hoses later. See Illustration 26 for the dimensions.

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Illustration 27	g00952368
Left Hand Inboard Side of the Frame New location of the boss

Install a 7D-5135 Boss on the inside surface of the left hand mainframe. This is for mounting the air conditioning lines later. See Illustration 27 for the dimensions.

Assemble The Fender and The Crossbeam

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Table 2
Fender Parts List
Item	Qty	Part Number	Description
1	2	6Y-5812	Bearing
2	2	8T-4994	Washer
3	8	164-4649	Spacer
4	8	7X-0368	Bolt
5	2	6V-8182	Nut
6	2	7X-0555	Washer
7	2	8C-3185	Bolt
16	2	226-2387	Plate As
18	2	227-5146	Pin

Note: Fender parts are included in the Purchase Parts List. See Table 1 for the Purchase Parts List.

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Illustration 28	g00933540

Use a suitable press to install bearing (1) into plate assembly (16) .

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Illustration 29	g00933567

Position plate assembly (16) to the fender. Install spacers (3) and bolts (4) to plate assembly (16). Hand tighten the bolts at this point in order to position plate assembly (16) in place.

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Illustration 30	g00933576

Position plate assembly (16) in order to install the pin in the new bore of the case and frame.

Assemble plate assembly (16) so that the bottom surface of plate (JJJ) of the crossbeam and the top surface of plate (KKK) of the plate assembly are in contact with each other. These surfaces must be in contact with each other for a better position for tightening the bolts. See Illustration 30.

Note: Some adjustment of fender position may be required for proper assembly. This adjustment may be done by installing a suitable lifting device, loosening bolts (10), and adjusting the position of the fender in order to properly align plate assembly (16) with the new pin bore in the mainframe for the pin installation. See Illustration 31.

Install pin (18) with washer (6), washer (2), bolt (7), and the nut (5). Tighten bolt (7) and nut (5) .

Tighten bolts (4) to the fender.

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Illustration 31	g00933550

Repeat Step 1 through Step 6 for the other side of the machine.

Make a full depth bevel groove weld at location (III). Refer to Illustration 31. Grind the welded surface flat and smooth. Weld on both sides of machine.

Weld a 25 mm (0.98 inch) weld groove at location (III). Refer to Illustration 31.

Tightening bolts (4) and bolts (10) to the correct torque. See Illustration 30 and Illustration 31 on both sides of the machine.

Remove any additional external supports that may have been added in order to support the crossbeam and the fender.

Final Assembly of the Machine

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Illustration 32	g00951615
Right Hand Inboard Side of the Mainframe

Reinstall the dozer tilt hoses with the original clip, the original washers, and the original bolts to the plate, as shown above. See Illustration 26 for the location of the 7G-6790 Plate on the right hand side mainframe.