- Load Haul Dump:
- R2900G (S/N: JLK1-1202,1204-1207)
- R3000H (S/N: RCM1-UP)
Introduction
This special instruction covers the procedure to rework the radiator guard on the above R2900G and R3000H Load Haul Dump Machines. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.
Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures".
ReferenceDisassembly and Assembly, RENR8556, "R2900G Load Haul Dump Machine Systems".
ReferenceDisassembly and Assembly, UENR1483, "R3000H Load Haul Dump Machine Systems".
Safety Section
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.
Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering. |
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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas. |
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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. 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 cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 |
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Parts Required
| Parts Required | ||
| Qty | Part Number | Description |
| 1 | 456-8763 | Radiator Guard Kit |
| 1 | 318-7733 | Guard As (1) |
| 1 | 332-0434 | Guard As (1) |
| 1 | 461-9529 | Guard As (1) |
| 4 | 4L-6454 | Bolt |
| 4 | 5P-1075 | Hard Washer |
| ( 1 ) | Part of 456-8763 Radiator Guard Kit |
Machine Preparation
Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.
- Move the machine to a hard level surface away from operating machines and away from personnel.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Stop the engine.
- Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".
- Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.
- Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".
Procedure
- Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove".
- Remove all additional components including hosing, electrical harnesses and hood latches from the radiator guard.
- Remove and discard plate assembly (1), two radiator guards (2), the bolts, and the washers. Grind flush the removal area.
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| Illustration 1 | g03739768 |
(1) Plate assembly (2) Radiator guard | |
- Weld in position 332-0434 Guard As (5) and 318-7733 Guard As (7). Refer to Illustration 2 through Illustration 6, and Table 2.
Note: Install 461-9529 Plate As (6) and cross beam (8) as bracing, in order to maintain dimension (D) and dimension (E). Refer to Illustration 6.
Show/hide tableTable 2 Item Dimension W1
6 mm (0.25 inch) Tacking weld all around.
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| Illustration 2 | g03739772 |
View of the right side radiator guard (3) 4L-6454 Bolt (4) 5P-1075 Hard Washer (5) 332-0434 Guard As (6) 461-9529 Plate As (A) 41 mm (1.60 inch) (B) 5 mm (0.20 inch) | |
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| Illustration 3 | g03739776 |
View of the right side radiator guard (5) 332-0434 Guard As (A) 41 mm (1.60 inch) (C) 51 mm (2.0 inch) | |
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| Illustration 4 | g03739777 |
View of the left side radiator guard (3) 4L-6454 Bolt (4) 5P-1075 Hard Washer (6) 461-9529 Plate As (7) 318-7733 Guard As (A) 41 mm (1.60 inch) | |
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| Illustration 5 | g03739778 |
View of the left side radiator guard (7) 318-7733 Guard As (A) 41 mm (1.60 inch) (C) 51 mm (2.0 inch) | |
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| Illustration 6 | g03740303 |
(3) 4L-6454 Bolt (4) 5P-1075 Hard Washer (5) 332-0434 Guard As (6) 461-9529 Plate As (7) 318-7733 Guard As (8) Cross beam (D) 1812 mm (71.25 inch) (E) 1320 mm (52.0 inch) | |
- Install the radiator and the header tank in order to check for correct alignment. Adjust as required. Ensure that the following measurements are maintained.
- 15 mm (0.60 inch) clearance between fan shroud (9) and fan blades (10). Refer to Illustration 7
- Fan blades (10) must protrude 10 ± 5 mm (0.40 ± 0.20 inch) from fan shroud (9). Refer to Illustration 8
- 15 mm (0.60 inch) clearance between fan shroud (9) and fan blades (10). Refer to Illustration 7
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| Illustration 7 | g03740306 |
Typical example (9) Fan shroud (10) Fan blade (F) 15 mm (0.60 inch) | |
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| Illustration 8 | g03740307 |
Typical example (9) Fan shroud (10) Fan blade (G) 10 ± 5 mm (0.40 ± 0.20 inch) | |
- Remove the radiator and the header tank.
- Weld in position 332-0434 Guard As (5) and 318-7733 Guard As (7). Refer to Illustration 2 through Illustration 6, and Table 3.
Note: Ensure 461-9529 Plate As (6) and cross beam (8) are installed as bracing in order to maintain dimension (D) and dimension (E). Refer to Illustration 6.
Note: Weld the inside edges of the radiator guards first in order to prevent the assembly pulling outward.
Show/hide tableTable 3 Item Dimension W2
6 mm (0.25 inch) Fillet weld all around, with
1.5 mm (0.06 inch) penetration.
- Install the radiator and the header tank, check for correct alignment. Adjust as required.
- Remove the radiator and the header tank.
- Prime and paint weld areas.
- Install all additional components including hosing, electrical harnesses and hood latches to the radiator guard.
- Install the radiator. Refer to Disassembly and Assembly, "Radiator - Install".