1997/05/19 Caterpillar

Dimensions For Installing Attachment Tailgate Mounting Hardware On Articulated Truck Dump Bodies{7271,7258}

Usage:

D350E (9LR),
D400E (2YR) Articulated Trucks

Reference: Parts Manual, SEBP2535-01, "D350E Articulated Truck".

Parts Manual, SEBP2455-03, "D400E Articulated Truck".

There have been requests for dimensions to add the attachment 7U-3854 Tailgate Group and 129-9657 Underslung Tailgate Arrangement mounting hardware on the dump bodies used on D350E and D400E Articulated Trucks that are in the field.

NOTE: The 7U-3854 Tailgate Group is part of the 129-9657 Underslung Tailgate Arrangement.

The following gives the required dimensions for welding the mounting hardware for 7U-3854 Tailgate Group and 129-9657 Underslung Tailgate Arrangement on the dump body.

NOTE: A complete parts listing for the 7U-3854 Tailgate Group is found on Page 234 of Parts Manual, SEBP2535-01, "D350E Articulated Truck", and Parts Manual, SEBP2455-03, "D400E Articulated Truck". A complete parts listing for the 7U-3851 Tailgate Cylinder &Mounting Group is found on Page 261 of Parts Manual, SEBP2535-01, "D350E Articulated Truck", and Parts Manual, SEBP2455-03, "D400E Articulated Truck".

Illustration 1. Dimensions for Fabricated Plate (1) (A) 160.0 mm (6.30 in). (B) 30.0 mm (1.18 in). (C) 250.0 mm (9.84 in).

1. For D350E Articulated Trucks, fabricate plate (1) from ASTM A572 structural steel.

Illustration 2. Dimensions for Filler Bar
(2) (D) 50.0 mm (1.97 in). (E) 10.0 mm (.39 in) diameter.

2. For D350 E and D400E Articulated Trucks, fabricate a filler bar (2) from ASTM A572 structural steel.

Illustration 3. Location of Plate (1) on D350E Articulated Trucks (F) 125.0 ± 2.0 mm (4.92 ± .08 in). (G) 1500.0 mm (59.06 in). (H) 3000.0 mm (118.11 in). (J) 242.0 ± 2.0 mm (9.53 ± .08 in).

3. On D350E Articulated Trucks only, weld plate (1) in position using and 8.0 mm (.31 in) fillet weld all around.

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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 instructions 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 general area. Wear correct eye, ear, and body protection. Do not touch live electrical parts.

See 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 CRF 1910, available from U.S. Dept. of Labor, Washington, D.C. 20408.

NOTE: Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OSHA limits.

All repair welding operators must be qualified for groove and fillet welding, as outlined the current ANSI/AWS D14.3, or Caterpillar Manufacturing Practices MC1000-105. The qualification will be for the SMAW (Shielded Metal Arc Welding) process in the vertical, overhead, and horizontal welding positions. The welding operator must also have used this welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications. The alternate process for this repair could be FCAW (Flux Cored Arc Welding) or GMAW (Gas Metal Arc Welding), when welding in an enclosed environment where proper shielding of the electrode is unaffected.

The area to be welded and the surrounding area, in most cases, must be at a minimum temperature of 10° C (50° F) before and during welding. Refer to the following chart for specific requirements.

NOTE: Since weld distortion is a possibility, minimizing the heat into the metal is important.

The SMAW process shall be used with E7018 (ANSI/AWS A5.1) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:

500 MPa (72 KSI) Tensile Strength

420 MPa (60 KSI) Yield Strength

22% elongation in 50 mm (2 in)

27 J (20 ft lb) Notch Toughness at -29° C (-20° F)

These are low hydrogen electrodes and must be stored in an electrode oven at 121° C (250° F) when not in use. If the electrodes get damp, scrap or recondition them to the manufacturer's specifications. Scrap any electrodes that have been submerged in water. Once an E7018 electrode is removed from the oven, it must be used within 4 hours.

The following chart relates to the electrodes diameter and approximate current settings for welding in the horizontal, vertical, and overhead positions:

Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed two times the electrode diameter.

As an alternate process the FCAW process may be used with E71T-1 (ANSI/AWS/A5.20) welding electrode and the manufacturer's specified shielding gas(es). The weld deposited by three electrodes will have the following minimum mechanical properties:

500 MPa (72 KSI) Tensile Strength

420 MPa (60 KSI) Yield Strength

22% elongation in 50 mm (2 in)

27 J (20 ft lb) Notch Toughness at -18° C (0° F)

NOTE: This type of electrode has limitations if it is used to carry larger weld pass volumes in the flat welding position. Due to the fast freezing characteristics of this electrodes slag system, there is a chance of trapping evolving gases in the weld melt. Precaution should be taken by controlling weld pass size.

Welding parameters will vary due to weld position and manufacturer of the welding electrode. Refer to the following chart to determine typical welding parameters for welding in the horizontal position:

Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The Electrical Stick Out (ESO) for the E71T-1 electrode should be 19.05 - 31.75 mm (.75 - 1.25 in). The weld pass size shall not exceed 8.0 mm (.31 in) fillet volume.

As another alternate process, the GMAW process may be used with ER70S-3 (ANSI/AWS/A5.18) welding electrode and the manufacturer's specified shielding gas(es). The weld deposited by this method will have the following minimum mechanical properties:

500 MPa (72 KSI) Tensile Strength

420 MPa (60 KSI) Yield Strength

22% elongation in 50 mm (2 in)

27 J (20 ft lb) Notch Toughness at -18° C (0° F)

Use the direct current electrode positive (DC reverse polarity) polarity setting. The Electrical Stick Out (ESO) for the ER70S-3 electrode should be 12.7 - 25.4 mm (.50 - 1.0 in).

Clean the metal of oil, grease, paint, and dirt in the area to be welded. Attach the welding ground cable directly to the area to be welded. Protect all machined surfaces from sparks or splatter produced by the welding, chipping, and/or grinding operations.

When welding, either the stringer or weave bead technique may be used. If weave beads are used, the amount of weave is restricted to three times the diameter of the electrode.

The welds shall be free from cracks, porosity, undercut, and incomplete fusion. All weld quality shall conform to Caterpillar Specification 1E0099 or ANSI/AWS D14.3.

NOTE: For welding purposes, the material of the components to be welded can be compared to ASTM A572 Structural Steel.

Illustration 4. Parts Location and Dimensions View A-A
(K) 349.0 ± 1.0 mm (13.74 ± .04 in). (L) 76.0 mm (2.99 in) Reference. (M) 341.0 mm (13.43 in) Reference. (N) 565.0 ± 2.0 mm (22.24 ± .09 in). (P) 60.0 mm (2.36 in). (Q) 868.0 ± 2.0 mm (34.17 ± .08 in) Radius. (R) 90.0 mm (3.54 in). (S) 90.0 mm (3.54 in).

Illustration 5. View D-D
(T) 1389.0 ± 2.0 mm (54.69 ± .08 in). (U) 2828.0 ± 2.0 mm (111.34 ± .08 in).

Illustration 6. View C-C
(V) 11.0 mm (.43 in). (W) 11.0 mm (.43 in).

4. Weld lever (3) in position using an 8.0 mm (.31 in) fillet weld along either side of lever (3).

5. Weld fabricated filler bar (2) and gussets (9) in position using 8.0 mm (.31) fillet welds all around.

6. Bolt mounting assembly (10) to bracket assembly (8) with shim (11) between them.

7. Position the entire assembly in position on the body as shown in Illustrations 5 and 6. Weld bracket assembly (8) to the body with 8.0 mm (.31 in) fillet welds as shown in Illustration 6.

Illustration 7. Section B-B.

Illustration 8. Location of bracket (4), plate (5) and plate (6).

8. Position bracket (4), plate (5) and plate (6) on the machine using the dimensions given in Illustrations 4 and 5. Weld bracket (4) and plates (5) in position using an 8.0 mm (.31 in) fillet weld all around. Weld plates (6) in position using 6.0 mm (.24 in) bevel welds.