Inspection and Repair of the Door Strut System on Certain Forest Machines and Track Feller Bunchers{5138, 7308} Caterpillar


Inspection and Repair of the Door Strut System on Certain Forest Machines and Track Feller Bunchers{5138, 7308}

Usage:

TK711 101
Excavator:
320C (S/N: SAH1001-UP; TBR1001-UP)
320D (S/N: BZF1-UP; GKS1-UP; EAX1-UP)
322C (S/N: M2H1001-UP; C3R1001-UP; LAR1001-UP; BYL1-UP)
324D (S/N: JGK1-UP; JKR1-UP; JLS1-UP)
325C (S/N: M2K1001-UP; G1L1001-UP; S3M1001-UP)
325D (S/N: C7K1-UP; C8L1-UP; C9M1-UP)
330C (S/N: B1K1001-UP; B3M1001-UP; B4N1001-UP)
330D (S/N: E4K1-UP; H3K1-UP; L2K1-UP)
Track Feller Buncher:
511 (S/N: 5111-UP)
521 (S/N: 5211-UP)
522 (S/N: 5221-UP)
532 (S/N: 5321-UP)
541 (S/N: 5411-UP)
551 (S/N: 5511-UP)
552 (S/N: 5521-UP)
TK711 (S/N: 1011-UP)
TK721 (S/N: 1021-UP)
TK732 (S/N: 1041-UP)

Introduction

On certain Forest Machines and Track Feller Bunchers, issues with the strut for the door or the respective mounting hardware have appeared. These issues can occur when the strut is extended or the strut is compressed beyond the capacity of the strut. The door includes 2A-6397 Straps , which are intended to prevent the strut from reaching full capacity of extension.




Illustration 1g01468647

The systems for both cabs provide proper operational restrictions. However, instances with incorrectly placed components or inadvertently substituted components have been seen. The following information can help to identify issues.

The capacity of the stroke for the strut is 248 mm to 391 mm (9.8 inch to 15.4 inch). The greatest compression of the strut occurs at approximately 14° open. The greatest extension of the strut occurs at the full open position.

Possible issues are the following:

  • Brackets on the door are wrong.

  • Brackets on the door are incorrectly substituted between applications.

  • The bracket on the cab is not located properly.

Replacing the ball studs and/or the strut for the door without these confirmations can lead to a repeat failure.

Two simple measurements can be conducted in order to determine the probability of failures. Both measurements are attained by measuring the distance between the center of ball stud on the cab and the center of the ball stud on the door with the door in different positions.

Reference Refer to the Disassembly and Assembly Manual and the Operation and Maintenance Manual for your machine.

Reference Refer to Special Instruction, REHS1841, "General Welding Procedures".

Affected Parts

Table 1
Affected Parts    
263-3954     Strut    
117-6910     Ball Stud    
263-5814     Bracket As    
266-0831     Bracket    
248-0549     Bracket As    
281-9217     Bracket As    
282-2160     Bracket As    
282-2079     Bracket As    
282-2154 (1)     Bracket As    
( 1 ) No bolt on bracket assembly for the cab was used in early configurations of the cab.



Illustration 2g01468648

Early Forest Machine cabs

237-2405 Cab Door Gp

Shown open at 14°

(A) 252 mm (9.9 inch) space between the studs

(1) 263-3954 Strut

(2) 248-0549 Bracket As

(3) 263-5814 Bracket As




Illustration 3g01468649

Early Forest Machine cabs

237-2405 Cab Door Gp

Shown open at 95°

(B) 357 mm (14.0 inch) space between the studs

(1) 263-3954 Strut

(2) 248-0549 Bracket As

(3) 263-5814 Bracket As




Illustration 4g01468651

Current Forest Machine cabs

293-7652 Cab Door Gp

Shown open at 14°

(C) 244 mm (9.6 inch) space between the studs

(1) 263-3954 Strut

(4) 282-2154 Bracket As

(5) 282-2079 Bracket As

(6) 282-2160 Bracket As

Note: The Current Forest Machine cabs will have only one bracket. The bracket will be 282-2154 Bracket As (4) or 282-2079 Bracket As (5).




Illustration 5g01468652

Current Forest Machine cabs

293-7652 Cab Door Gp

Shown open at 95°

(D) 359 mm (14.1 inch) space between the studs

(1) 263-3954 Strut

(4) 282-2154 Bracket As

(5) 282-2079 Bracket As

(6) 282-2160 Bracket As

Note: The Current Forest Machine cabs will have only one bracket. The bracket will be 282-2154 Bracket As (4) or 282-2079 Bracket As (5).




Illustration 6g01468653

Early Track Feller Buncher cabs

238-5010 Enclosed Cab

Shown open at 14°

(E) 273 mm (10.8 inch) space between the studs

(1) 263-3954 Strut

(2) 248-0549 Bracket As

(7) 266-0831 Bracket




Illustration 7g01468654

Early Track Feller Buncher cabs

238-5010 Enclosed Cab

Shown open at 95°

(F) 375 mm (14.8 inch) space between the studs

(1) 263-3954 Strut

(2) 248-0549 Bracket As

(7) 266-0831 Bracket




Illustration 8g01468655

Current Track Feller Buncher cabs

282-2696 Cab

Shown open at 14°

(G) 271 mm (10.7 inch) space between the studs

(1) 263-3954 Strut

(5) 282-2079 Bracket As

(4) 282-2154 Bracket As

(8) 281-9217 Bracket As




Illustration 9g01468748

Current Track Feller Buncher cabs

282-2696 Cab

Shown open at 95°

(H) 382 mm (15.0 inch) space between the studs

(1) 263-3954 Strut

(5) 282-2079 Bracket As

(4) 282-2154 Bracket As

(8) 281-9217 Bracket As

Instruction for Measurements

Two simple measurements can be conducted in order to determine the probability of failures. Both measurements are attained by measuring the distance between the center of the ball stud on the cab and the center of the ball stud on the door with the door two different positions.

Measurement of the Compression

The full compression of the strut is 248 mm (9.8 inch). The first measurement should be taken with the door open at 14 degrees. From the inside of the cab, swing the door slowly through the full range of motion in order to observe when the strut reaches the shortest length. Once the strut is compressed to the shortest length, hold the door in position and measure the distance between the ball studs. If the strut compresses to 248 mm (9.8 inch), failure of the ball stud could occur.

Measurement of the Extension

------ WARNING! ------

Personal injury can result from parts under pressure.

Stored energy force will be released when struts are removed.

Support covers, hoods, or other components prior to the removal or the installation of struts.

----------------------

------ WARNING! ------

Personal injury or death can result when working with the strut rod.

Sudden release of the spindle from the strut rod or the snapping of a bolt when removing the plate can result in injury.

Loosen all bolts one-half turn, working around the plate in a circular pattern. Perform this again and again until the torque is released for the bolts.

----------------------

The second measurement will require the removal of the strut.

Note: Use extreme caution when removing the strut or injury can occur! The strut is under extreme compression even when the door is in the full open position. The strut will extend very quickly when the strut is removed from the first ball stud.

Note: When you remove the strut, wear the proper safety equipment. Stand as far away from the strut as possible. Keep your face away from the strut. Be aware of pinch points when you remove the strut.

Remove 263-3954 Strut (1) .

The full extension of the strut is 391 mm (15.4 inch). With the door in the full open position, and with no strut on the door, measure the distance between ball studs. The distance should not exceed 391 mm (15.4 inch). In the above Illustrations, the full extension is shown at 95°. This exceeds the nominal design to account for stretch of the strap and a variation in components.

If both measurements were between 248 mm (9.8 inch) and 391 mm (15.4 inch) then no failures would be anticipated. If either measurement exceeded the limits of the strut, proceed with the Procedure for Rework.

Rework Procedure

Inspect the affected components in order to ensure that the correct parts were originally installed. The brackets may have been substituted on assembly between the cabs of the Track Feller Buncher and the Forest Machine. In some instances, the brackets may have been fabricated incorrectly. The following items are the proper configurations for installation:

  • Early Forest Machine cabs included a weld on 248-0549 Bracket As and a bolt-on 263-5814 Bracket As . Refer to Illustrations 2 and 3.

  • Current Forest Machine cabs include a weld on 282-2079 Bracket As , a bolt-on 282-2154 Bracket As , and a bolt-on 282-2160 Bracket As . Refer to Illustrations 4 and 5.

  • Early Track Feller Buncher cabs included a weld on 248-0549 Bracket As and a bolt on 266-0831 Bracket . Refer to Illustrations 6 and 7.

  • Current Track Feller Buncher cabs include a weld on 282-2079 Bracket As , a bolt on 282-2154 Bracket As , and a bolt on 281-9217 Bracket As . Refer to Illustrations 8 and 9.

If the measurements for the strut exceeded the limits of the strut, and all of the installed components are correct, check the placement of the weld on bracket on the cab. Sometimes, the brackets have been incorrectly located. The bracket can affect the strut. If the bracket on the cab is improperly located, the bracket can be carefully removed and relocated. The bracket is welded to sheet metal. The sheet metal is not a component of the ROPS structure. Approximate locating dimensions are included in the following Illustrations.




Illustration 10g01469309

Early Forest Machine cabs

(J) 302 mm (11.9 inch)

(2) 248-0549 Bracket As

The 248-0549 Bracket As (2) should be located at dimension (J). If necessary, the dimension (J) can be moved from 302 mm (11.9 inch) to 314 mm (12.4 inch).




Illustration 11g01469307

Current Forest Machine cabs

(K) 263 mm (10.4 inch)

(5) 282-2079 Bracket As

The 282-2079 Bracket As (5) should be located at dimension (K). If necessary, the dimension (K) can be moved from 263 mm (10.4 inch) to 275 mm (10.8 inch).




Illustration 12g01469269

Early Track Feller Buncher cabs

(L) 319 mm (12.6 inch)

(2) 248-0549 Bracket As

The 248-0549 Bracket As (2) should be located at dimension (L).




Illustration 13g01469287

Current Track Feller Buncher cabs

(M) 279 mm (11.0 inch)

(5) 282-2079 Bracket As

The 282-2079 Bracket As (5) should be located at dimension (M) .

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