Procedure to Reinforce the Front Frame Axle Pads Is Now Available for Certain 982M Medium Wheel Loaders {0679, 3268, 3278, 3282} Caterpillar

Wheel Loader

982M (S/N: F9A1-152,201-226,228-283,401-418; K1Y1-660,1001-1071,1501-1679)

Reference: Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide"

Reference: Special Instruction, REHS1841, "General Welding Procedures" prior to performing any welding on the machine.

Description Of Change: Procedure to reinforce the front frame axle pad is now available for machines listed above.

Adaptable To: The below rework procedure is adaptable to all machines within the listed serial numbers.

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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 kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Rework Procedure

Illustration 1	g06073237

Inspect the front frame axle pads for cracks on both left and right sides at bottom of weld joint as shown in Illustrations 1 at location (A). Also inspect the top of the joint to determine if a weld seam is present.

After the inspection, review the following groups to determine which rework procedure applies to your 982M machine front axle pad.

Group 1: No Crack on Bottom Seam and Weld is Present at Top Seam

Illustration 2	g06239660
No crack on bottom seam and weld is present at top seam

This group does not require any rework of the weld seams and will provide instruction on adding an additional U-shaped 492-6403 Plate over the top weld seam.

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Illustration 3	g06239661
Top view of 492-6403 Plate (B) 8 mm (0.3 inch) Chamfer

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Illustration 4	g06239662
Bottom view of 492-6403 Plate (C) 12 mm (0.4 inch) Chamfer

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Illustration 5	g06239666
(D) 492-6403 Plate

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Illustration 6	g06239671
(E) 7Y-5231 Bolts

1. Place the 492-6403 Plate at the weld joint on top of the axle pad. Ensure that the larger chamfer side of plate (D) as shown in the view of Illustration 4 is facing down. Refer to Illustration 5.

   Note: If necessary, grind the top of the weld at the seam joint underneath to match the axle pad surface so that the 492-6403 Plate sits flat. Ensure that only four rear bolts on the axle pad are removed at this step. Keep the front set of axle mounting bolts and associated hardware in place as shown in Illustration 6.

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   Illustration 7	g06240945
   (D) 492-6403 Plate (W1) 8 mm (0.3 inch) Fillet weld over 8 mm (0.3 inch) bevel weld (W2) 8 mm (0.3 inch) Fillet weld

2. Weld the top and bottom edges of the 492-6403 Plate (D) as per dimension shown in Illustration 7.
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   Illustration 8	g06240942
   (D) 492-6403 Plate (F) Weld toe treatment

3. Apply weld toe treatment (F) to the top edges of the 492-6403 Plate (D) as shown in Illustration 8. Use either toe grind procedure, or pin needler tool, or tig welding in order to finish weld toe treatment.

   Reference: Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide" for proper application of weld toe treatment.

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   Illustration 9	g06239679
   (G) 108-7931 Bolts

4. Install four new 108-7931 Bolts and 8C-8722 Nuts along with the associated hardware as shown in Illustration 9. The old bolts and nuts will not be reused. Tighten all four nuts to 350 ± 50 N·m (258 ± 37 lb ft). Then turn an additional angle of 120 ± 10 degrees.
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   Illustration 10	g06239684
   (E) 7Y-5231 Bolts

5. Remove and replace the front set of 7Y-5231 Bolts and 8C-8722 Nuts on the axle pad as shown in Illustration 10 with a set of new bolts and nuts. The old bolts and nuts will not be reused. Tighten 7Y-5231 Bolts (E) to 350 ± 50 N·m (258 ± 37 lb ft). Then turn an additional angle of 120 ± 10 degrees.

6. Apply the Rework Procedure Step 1 to Step 5 for both the right and left side front frame axle pads.

Group 2: No Crack on Bottom Seam and Weld is Not Present at Top Seam

Illustration 11	g06239691
No crack on bottom seam and weld is not present at top seam

This group requires weld seam rework starting from top of the joint to remove the root of the crack before reworking the weld. Also add an additional U-shaped 492-6403 Plate over the top weld seam.

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Illustration 12	g06239694
(G) 108-7931 Bolts

1. Remove only the rear set of axle mounting 108-7931 Bolts (G) and associated hardware as shown in Illustration 12. Keep all other axle mounting bolts and hardware in place to avoid distortion of the axle pad during welding.
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   Illustration 13	g06239703
   (H) 10 mm (0.3 inch)

2. Remove the weld from the top side by gouging and grinding. It may be necessary to grind up to 10 mm (0.3 inch) deep as shown in Illustration 13 in order to ensure that the root of the opposite weld is removed.

   If the root of opposite weld from bottom side is found and removed within 10 mm (0.3 inch) depth, then skip next Step 3, Step 4 and Step 5 and proceed directly to Step 6.

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   Illustration 14	g06239705
   (I) Current weld pattern

3. If the root of opposite weld from bottom side is not found and removed within 10 mm (0.3 inch) depth, then lay a weld bead/one pass weld at 10 mm (0.3 inch) depth (this avoids weld blow while removing and rewelding the weld from the bottom side).

   Remove the weld from the bottom side by gouging and grinding. Illustration 14 shows the current weld pattern at the axle pad.

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   Illustration 15	g06240598
   (W3) 16.0 mm (0.63 inch) Bevel weld (W4) 2.0 mm (0.08 inch) V-groove weld

4. From the bottom side, weld the axle pad plate to the contour starting at the center going outwards as shown in Illustration 15.
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   Illustration 16	g06239706
   (J) Weld toe treatment

5. Apply weld toe treatment (J) to both weld toes as shown in Illustration 16. Use either toe grind procedure, or pin needler tool, or tig welding in order to finish weld toe treatment.

   Reference: Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide" for proper application of weld toe treatment.

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   Illustration 17	g06239707
   (K) Weld direction

6. From the top side, weld the axle pad plate to the contour starting at the center going outwards as indicated by (K) in Illustration 17. Grind the top of the weld to match the axle pad surface.
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   Illustration 18	g06240677
   (L) Weld joint

7. Repair nearby weld joint (L) if damaged while performing repair procedure as shown in Illustration 18.
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   Illustration 19	g06239692
   (G) 108-7931 Bolts

8. Remove the middle set of axle mounting 108-7931 Bolts (G) and associated hardware as shown in Illustration 19.
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   Illustration 20	g06239661
   Top view of 492-6403 Plate (B) 8 mm (0.3 inch) Chamfer

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   Illustration 21	g06239662
   Bottom view of 492-6403 Plate (C) 12 mm (0.4 inch) Chamfer

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   Illustration 22	g06239666
   (D) 492-6403 Plate

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   Illustration 23	g06239671
   (E) 7Y-5231 Bolts

9. Place the 492-6403 Plate at the weld joint on top of the axle pad. Ensure that the larger chamfer side of plate (D) as shown in the view of Illustration 21 is facing down. Refer to Illustration 22.

   Note: If necessary, grind the top of the weld at the seam joint underneath to match the axle pad surface so that the 492-6403 Plate (D) sits flat. Ensure that only four rear bolts on the axle pad are removed at this step. Keep the front set of axle mounting bolts and associated hardware in place as shown in Illustration 23.

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   Illustration 24	g06240945
   (D) 492-6403 Plate (W1) 8 mm (0.3 inch) Fillet weld over 8 mm (0.3 inch) bevel weld (W2) 8 mm (0.3 inch) Fillet weld

10. Weld the top and bottom edges of the 492-6403 Plate (D) as per dimension shown in Illustration 24.
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    Illustration 25	g06240942
    (D) 492-6403 Plate (F) Weld toe treatment

11. Apply weld toe treatment (F) to the top edges of the 492-6403 Plate (D) as shown in Illustration 25. Use either toe grind procedure, or pin needler tool, or tig welding in order to finish weld toe treatment.

    Reference: Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide" for proper application of weld toe treatment.

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    Illustration 26	g06239679
    (G) 108-7931 Bolts

12. Install four new 108-7931 Bolts and 8C-8722 Nuts along with the associated hardware as shown in Illustration 26. The old bolts and nuts will not be reused. Tighten all four nuts to 350 ± 50 N·m (258 ± 37 lb ft). Then turn an additional angle of 120 ± 10 degrees.
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    Illustration 27	g06239684
    (E) 7Y-5231 Bolts

13. Remove and replace the front set of 7Y-5231 Bolts and 8C-8722 Nuts on the axle pad as shown in Illustration 27 with a set of new bolts and nuts. The old bolts and nuts will not be reused. Tighten 7Y-5231 Bolts (E) to 350 ± 50 N·m (258 ± 37 lb ft). Then turn an additional angle of 120 ± 10 degrees.

14. Apply the Rework Procedure Step 1 to Step 13 for both the right and left side front frame axle pads.

Group 3: Crack on Bottom Weld Seam

Illustration 28	g06241644
Crack on bottom weld seam

This group requires weld seam rework starting from the bottom of the joint to remove the root of the crack before reworking the weld and adding an additional U-shaped 492-6403 Plate over the top weld seam.

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Illustration 29	g06239705
(I) Current weld pattern

1. Remove the weld from the bottom side by gouging and grinding. Illustration 29 shows the current weld pattern at the axle pad weld seam joint.
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   Illustration 30	g06240598
   (W3) 16.0 mm (0.63 inch) Bevel weld (W4) 2.0 mm (0.08 inch) V-groove weld

2. From the bottom side, weld the axle pad plate to the contour starting at the center going outwards as shown in Illustration 30.
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   Illustration 31	g06239706
   (J) Weld toe treatment

3. Apply weld toe treatment (J) to both weld toes as shown in Illustration 31. Use either toe grind procedure, or pin needler tool, or tig welding in order to finish weld toe treatment.

   Reference: Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide" for proper application of weld toe treatment.

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   Illustration 32	g06239694
   (G) 108-7931 Bolts

4. Remove only the rear set of axle mounting (G) 108-7931 Bolts and associated hardware as shown in Illustration 32. Keep all other axle mounting bolts and hardware in place to avoid distortion of the axle pad during welding.
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   Illustration 33	g06239703
   (H) 10 mm (0.3 inch)

5. Remove the weld from the top side by gouging and grinding. It may be necessary to grind up to 10 mm (0.3 inch) deep as shown in Illustration 33 in order to ensure that the root of the opposite weld is removed.
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   Illustration 34	g06239707
   (K) Weld direction

6. From the top side, weld the axle pad plate to the contour starting at the center going outwards as indicated by (K) in Illustration 34. Grind the top of the weld to match the axle pad surface.
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   Illustration 35	g06240677
   (L) Weld joint

7. Repair nearby weld joint (L) if damaged while performing repair procedure as shown in Illustration 35.
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   Illustration 36	g06239692
   (G) 108-7931 Bolts

8. Remove the middle set of axle mounting 108-7931 Bolts (G) and associated hardware as shown in Illustration 36.
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   Illustration 37	g06239661
   Top view of 492-6403 Plate (B) 8 mm (0.3 inch) chamfer

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   Illustration 38	g06239662
   Bottom view of 492-6403 Plate (C) 12 mm (0.4 inch) chamfer

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   Illustration 39	g06239666
   (D) 492-6403 Plate

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   Illustration 40	g06239671
   (E) 7Y-5231 Bolts

9. Place the 492-6403 Plate at the weld joint on top of the axle pad. Ensure that the larger chamfer side of plate (D) as shown in the view of Illustration 38 is facing down. Refer to Illustration 39.

   Note: If necessary, grind the top of the weld at the seam joint underneath to match the axle pad surface so that the 492-6403 Plate sits flat. Ensure that only four rear bolts on the axle pad are removed at this step. Keep the front set of axle mounting bolts and associated hardware in place as shown in Illustration 40.

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   Illustration 41	g06240945
   (D) 492-6403 Plate (W1) 8 mm (0.3 inch) Fillet weld over 8 mm (0.3 inch) bevel weld (W2) 8 mm (0.3 inch) Fillet weld

10. Weld the top and bottom edges of the 492-6403 Plate (D) as per dimension shown in Illustration 41.
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    Illustration 42	g06240942
    (D) 492-6403 Plate (F) Weld toe treatment

11. Apply weld toe treatment (F) to the top edges of the 492-6403 Plate (D) as shown in Illustration 42. Use either toe grind procedure, or pin needler tool, or tig welding in order to finish weld toe treatment.

    Reference: Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide" for proper application of weld toe treatment.

    Show/hide table

    Illustration 43	g06239679
    (G) 108-7931 Bolts

12. Install four new 108-7931 Bolts and four new 8C-8722 Nuts along with the associated hardware as shown in Illustration 43. The old bolts and nuts will not be reused. Tighten all four nuts to 350 ± 50 N·m (258 ± 37 lb ft). Then turn an additional angle of 120 ± 10 degrees.
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    Illustration 44	g06239684
    (E) 7Y-5231 Bolts

13. Remove and replace the front set of 7Y-5231 Bolts and 8C-8722 Nuts on the axle pad as shown in Illustration 44 with a set of new bolts and nuts. The old bolts and nuts will not be reused. Tighten 7Y-5231 Bolts (E) to 350 ± 50 N·m (258 ± 37 lb ft). Then turn an additional angle of 120 ± 10 degrees.

14. Apply the Rework Procedure Step 1 to Step 13 for both the right and left side front frame axle pads.

Group 4: Crack on Bottom Weld Seam That is Propagated to the Side Plate

Illustration 45	g06241645
Crack on bottom weld seam that is propagated to the side plate

This group cannot be reworked. Please contact MWL product support through DSN and replace the front frame with same part number.