Usage:
Introduction
Cracks in the front frame can occur in area (A) as shown. Cracks will start at the junction between the sloping surface of the side member and the main longitudinal member. In most severe cases the frame has separated. This repair is for the machines shown in the following chart, except for low profile models.
Reference: Service Manual; Parts Book.
Repair Procedure
NOTE: See the illustration on the last page for the correct location of each reinforcement plate.
Use AWS E7018 Electrodes or equivalent for all welds.
NOTE: Use structural type steel with 290 MPa (42,000 psi) minimum yield strength and with 435 MPa (63,000 psi) minimum tensile strength for all fabricated plates.
This repair involves welding stiffener plates to the top of the frame, immediately inboard of the suspension towers, and to the bottom of the frame, immediately below the suspension towers. However, if the damage is severe, it may be necessary to weld an additional plate to the inside of the frame vertical member. This is only required when the damage has progressed to the point where the crack has started to open up. If the damage has not progressed beyond the crack stage (no opening) proceed as follows:
1. Fabricate two stiffener plates (1) using the dimensions shown (left side shown). The stiffener plate for the right side is identical, except the 15 mm × 45° (.39" × 45°) chamfer is on the opposite edge (same side).
2. Fabricate two stiffener plates (2) using the dimensions shown (left side shown). The stiffener plate for the right side is identical except the chamfer and bend are on the opposite side.
3. Using mild type steel bar stock, fabricate two bosses (3) using the dimensions shown. Machine surfaces (A) and (B). Drill and tap the hole as shown.
4. Park the machine in a straight ahead position.
 |
An accumulation of any flammable substance may ignite and cause personal injury. Wipe away any spilled oil or other flammable substance before burning with a cutting torch or similar tool. |
 |
5. Operate the handle on the suspension control valve to release the pressure in the suspension system. Wait until the hissing noise stops before releasing the handle.
6. Raise the tractor unit and put supports under it
7. Remove the front wheels.
8. Remove the suspension frame and front axle assembly.
9. Disconnect the pipes and fittings as necessary so that the area behind the suspension towers is clear. Mark each pipe and fitting to ensure correct reassembly. Plug all open ports and fittings.
10. Clean the area thoroughly and inspect the damage. Check to make sure the crack has not opened up.
11. Vee out the crack, reweld and grind smooth.
12. Tack weld lower plate (2) in position on the front frame (each side).
13. Make a 8 mm (.31") bevel groove weld at location (C) and 10 mm (.39") fillet welds at locations (D), (E) and (F), and square groove welds at locations (G) and (H). Make run out welds at location (J) as shown (both sides). Grind the weld at location (K) to a smooth radius.
14. Put boss (3) in position on plate (2) (each plate) and make an 8 mm (.31") fillet weld all around.
15. Put top plate (1) in position on the frame as shown and tack weld (both sides).
16. Weld the plates in position using 8 mm (.31") fillet welds all around at locations (L), except along the outside edges at (M). Make a full bevel groove weld at location (M).
17. Make 8 mm (.31") fillet welds all around the inside of holes (4). Do not weld from (N) to (O) (both ends of each plate).
18. Cut and grind a 15 mm (.59") × 10 mm (.39") chamfer on the back edge of the suspension brackets at location (P).
19. Remove all weld spatter and paint the areas.
20. Connect all pipes, hoses and fittings, making sure that none have been damaged during repair.
21. Install the suspension frame and wheels.
| NOTICE |
|---|
Make sure all systems are operating correctly before putting the machine back to work. |
22. If damage has progressed to the point where the crack has started to open up, it will be necessary to remove the engine to allow access to the inside of the frame.
23. Make the plates and bosses given in steps one, two and three.
24. Fabricate two plates (5) as shown.
25. Vee out the crack and reweld.
26. Weld plates (1), (2) and boss (3) in position as shown in steps twelve through seventeen.
27. Weld plate (5) in position with an 8 mm (.31") fillet weld all around at location (Q).
28. Do steps twelve through twenty-one to complete the repair.
29. Reassemble the machine. (See the Service Manual.)
| NOTICE |
|---|
Make sure all systems are operating correctly before putting the machine back to work. |
Location of Reinforcement Plates
NOTE: No welds at locations (X), as described earlier in step seventeen.