Usage:
Introduction
This Special Instruction describes the installation of an improved panhard rod mounting arrangement. The improved arrangement is an adaptation of the arrangement used on the D300D Articulated Trucks.
Installation of the improved arrangement requires the removal of the existing panhard rod mounting brackets from the rear frame and welding new brackets in place. New suspension components must also be installed.
Do not perform any procedure outlined in this publication, or order any parts, until you read and understand the information contained in this Special Instruction.
Reference: Service Manual, Parts Manual.
Necessary Parts
Removal Of Existing Components And Frame Preparation
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The rear frame can drop suddenly resulting in reduced clearances between the frame, axles and "A" frames if there is a failure in a hydraulic component. Block the rear frame securely before working under the machine. |
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1. Park the machine on a level surface with the transmission in Neutral. Engage the park brake.
2. Start and operate the engine at low idle.
3. Open the two gate valves at the front of the rear frame.
4. Use the machine hydraulics to fully extend the rear suspension of cylinders.
5. Block the frame securely in the raised position and close the gate valves.
6. Stop the engine. Remove the key and turn off the battery disconnect switch.
Illustration 1. Existing parts to be removed.
7. Remove the existing panhard rods (1), plate assemblies (2 and 3) and associated hardware shown in Illustration 1.
Illustration 2. Parts to be removed using a cutting torch.
8. Use a cutting torch to carefully remove existing center and rear axle panhard rod mounting brackets (4 and 7) and flange (8) from the rear frame. Be careful not to cut into the bottom of the frame rails (6) or remove any of the original profile of the diaphragm assembly (5).
9. Finish removing the remnants of the two brackets by grinding. Make sure the bottom frame rails are clean and smooth after grinding.
Installation Of New Components
Illustration 1. Dimensions for the fabricated flange (20).
1. Fabricate a flange using the dimensions given in Illustration 1. The flange should be fabricated from 12.0 mm (.47 in) thick steel plate with a minimum yield strength of 355.0 MPa (51525.00 psi) and minimum tensile strength of 490.0 MPa (71120.00 psi). Bend the flange up at Location A. The 362.0 mm (14.25 in) is the length of the flange after bending.
Illustration 2. Location of the new brackets and fabricated flange.
2. Tack weld the new brackets (14) and flange (20) in position.
3. Temporarily put the new panhard rods in position to check the bracket assembly fit. Adjust the position of the brackets as required. Weld the brackets in place when the fit is correct.
Use an 8.0 mm (.32 in) fillet weld at Locations B. The weld should run past the ends of the bracket as shown at Location F. Do not weld across the ends.
At Locations C, use a 12.0 mm (.47 in) fillet weld to fill in the area between the new brackets and the frame and flange. Weld either side of the bracket or flange at Locations D with an 8.0 mm (.32 in) fillet weld.
Fill in the area across the end of the fabricated flange (Location E) with a 10.0 mm (.39 in) fillet weld.
4. After the welds have cooled, grind the repair smooth and paint the area.
NOTE: Do not paint the mounting boss faces.
Illustration 3. Parts location for the center axle.
Illustration 4. Parts location for the rear axle.
Illustration 5. Detail of Area G.
Illustration 6. Detail of Area H.
5. Install the remaining hardware as shown in Illustrations (3 and 4). Apply light oil to the threads of bolts (3, 9 and 15) before assembly. Tighten bolts (3 and 9) to 370 ± 50 N·m (275 ± 35 lb ft). Bolt (15) should be tightened to 1150 ± 100 N·m (850 ± 75 lb ft).