Rework Procedure for Fender Covers and Mud Flaps on Certain 700 C-Series Articulated Trucks {4220, 7150, 7252} Caterpillar

Articulated Truck

735C (S/N: LFJ1-UP; TFJ1-UP)

740C EJECTOR (S/N: LFN1-UP; TFN1-UP)

745C (S/N: JE81-UP; JE91-UP; LFK1-UP; TFK1-UP)

Introduction

The special instruction is to detail the work required to replace the factory fit fender covers and mud flaps on the listed machines with fender covers with a shorter length and longer flaps.

The revised fender design extends component longevity and reduces repair costs by preventing permanent damage to the lower section of the fender plastic.

Do not perform any procedure in this special instruction until you have read the information and you understand the information.

Safety Section

Show/hide table

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Show/hide table

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

Show/hide table

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

Show/hide table

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

Show/hide table

Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Show/hide table

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

Show/hide table

Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Show/hide table

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

Show/hide table

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Torque Specification

Reference: Refer to Torque Specifications, SENR3130 for the latest standard torque specifications used for Caterpillar^® fasteners.

Caterpillar Channel 1 Videos

Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or copy the link that follows.

Illustration 1	g06379261

Reference: For more information, refer to “Rework Procedure for Fender Covers and Mud Flaps on Certain 700 C-Series Articulated Trucks” on Caterpillar Channel1.

Required Parts

Removal Procedure of Original Fender Covers and Mud Flaps

Note: The following procedure is shown with the tire installed on the machine.

Show/hide table

Illustration 2	g06364337
(A) Fender cover

1. Remove the panel on the front side of the fender to access all the mounting points for the fender cover. Remove and discard the original fender cover (A) and all mounting hardware, as shown in Illustration 2.
   Show/hide table

   Illustration 3	g06364342
   (B) Existing mud flap

2. Remove mud flaps (B), mounting components and discard the parts.

3. Repeat Step 1 through Step 2 on the other side of the machine.

Preparation for Rework

Note: The following procedure is shown with the tire installed on the machine.

Note: Removing the tire will aid the following steps. In the given procedure, the rework was completed with the tire installed. Depending on the condition and size of the tire, and the equipment available, it might be necessary to remove the tire to complete the following steps.

1. Start from the left fender.
   Show/hide table

   Illustration 4	g06364366

2. Mark the identified section of fender for removal, as shown in Illustration 4.

   Note: The portion of removed plate avoids fouling with the intended position of the new mud flap. Only remove the thin plate material. Do not cut into the box section, this gives structural support to the fender.

   Show/hide table

   Illustration 5	g06364368

3. Cut out the required section of fender by using a suitable tool. Avoid damaging the box section of fender.

   Use a suitable grinder to dress the edges of cut out to the required size, without damaging the box section.

   Show/hide table

   Illustration 6	g06366674
   Right-Hand side Fender as shown from the outside of the wheel arch (R1) 12 mm (0.5 inch) (D1) 280 mm (11.0 inch) (D2) 280 mm (11.0 inch) (D3) 105 mm (4.1 inch)

   Show/hide table

   Illustration 7	g06366679
   Left-Hand side Fender as shown from the outside of the wheel arch (R1) 12 mm (0.5 inch) (D4) 95.5 mm (3.76 inch) (D5) 280 mm (11.0 inch) (D6) 280 mm (11.0 inch)

4. Locate and drill three holes in the channel on the lower back edge of fenders per the dimensions, for mounting the new mud flap, as shown in Illustration 6 and Illustration 7.

   Note: The new holes may foul one of the captive nuts for the original mud flap. If this happens, use suitable tooling to remove the captive nut.

   Show/hide table

   Illustration 8	g06366682
   Right-Hand side Fender (D7) 100 mm (4.0 inch) (D8) 45 mm (1.8 inch)

   Show/hide table

   Illustration 9	g06366691
   Left-Hand side Fender (D9) 100 mm (4.0 inch) (D10) 50 mm (2.0 inch)

5. Locate and remove corner, per the dimensions shown in Illustration 8 and Illustration 9.

   Note: Round off any sharp edges.

   Show/hide table

   Illustration 10	g06365606
   (D11) 91 mm (3.6 inch) (1) 9R-3761 Boss

6. Position boss (1) against the inside edge of the box section, measure from the bottom of the box section as per the dimensions shown in Illustration 10. Tack weld the boss in position.

   Note: Do not fully weld at this step.

   Show/hide table

   Illustration 11	g06365627
   (D12) 218 mm (8.6 inch) (1) 9R-3761 Boss

7. Position boss (1) against the inside edge of the box section, per the dimensions shown in Illustration 11. Tack weld the boss in position.

   Note: Do not fully weld at this step.

   Show/hide table

   Illustration 12	g06365660
   (2) 542-2345 Mud Flap (4) 8T-4121 Hard Washer (5) 8T-4196 Bolt (8) 492-7431 Plate As

8. Position mud flap (2) to the fender and secure using plate assembly (8), hard washers (4) and bolts (5) to secure the mud flap in place, as shown in Illustration 12.

9. Hold mud flap (2) to the fender and against bosses installed in Step 6 and Step 7.

   Note: Check that the bosses are aligned with the holes in the new mud flap.

   Show/hide table

   Illustration 13	g06366636
   (2) 542-2345 Mud Flap (4) 8T-4121 Hard Washer (6) 500-5932 Plate (7) 8T-4136 Bolt

10. Use plate (6), hard washers (4), and bolts (7) to hold the mud flap (2) to the fender, as shown in Illustration 13.
    Show/hide table

    Illustration 14	g06366637
    (1) 9R-3761 Boss (2) 542-2345 Mud Flap

11. Hold the mud flap (2) to the fender to find the correct position of boss (1). Tack weld the boss (1) in place and then remove the mud flap (2) and all mounting components, as shown in Illustration 14.
    Show/hide table

    Illustration 15	g06366638
    (W1) 3 mm (0.1 inch) fillet weld (1) 9R-3761 Boss

12. Fillet weld bosses (1) per the dimensions to secure in position , as shown in Illustration 15.

13. Check the area of the fender and remove the burrs and sharp edges before using CAT primer and CAT yellow paint for all the exposed bare metal.

14. Repeat Step 2 through Step 13 to the fender on the right side of the machine.

Installation Procedure

1. Start with the fender on the left side of the machine
   Show/hide table

   Illustration 16	g06366639
   (2) 542-2345 Mud Flap

   Show/hide table

   Illustration 17	g06366640
   (2) 542-2345 Mud Flap (3) 492-7405 Plate (4) 8T-4121 Hard Washer (6) 500-5932 Plate (7) 8T-4136 Bolt (8) 492-7431 Plate As (9) 541-0826 Plate

2. Position the mud flap (2) as shown in Illustration 16 and install to the fender using plate (8), hard washers (4), bolts (5), and plate (9), as shown in Illustration 17.

   Secure the mud flap in position using plate (6) and plate (3), hard washers (4), and bolts (7).

   Note: The orientation of plate (9) should support the mud flap when it bends back towards the rear of the machine.

   Show/hide table

   Illustration 18	g06366641
   (10) 226-1240 Film (11) 226-1274 Film

3. Replace the existing warning films with new warning film (10) and warning film (11), shown in Illustration 18.

4. Repeat Steps 2 and Step 3 for installing mud flap on the other side of the machine.
   Show/hide table

   Illustration 19	g06366642
   (12) 550-1603 Fender Cover (13) 8T-4224 Hard Washer (14) 8T-4908 Bolt

5. Install fender cover (12) on the left side of the machine and secure using washers (13) and bolts (14), as shown in Illustration 19.

   Note: The mounting position at the forward end of the fender cover is accessed through the panel in the fender, removed in the Section "Removal Procedure of Original Fender Covers and Mud Flaps".

   Show/hide table

   Illustration 20	g06366643
   (13) 8T-4224 Hard Washer (14) 8T-4908 Bolt (15) 550-1602 Fender Cover

6. On the right side of the machine, install fender cover (15) and secure using washers (13) and bolts (14), as shown in Illustration 20.

   Note: The mounting position at the forward end of the fender cover is accessed through the panel in the fender, removed in the Section "Removal Procedure of Original Fender Covers and Mud Flaps".

7. Reinstall the panels on the front side faces of the fender, removed in Section "Removal Procedure of Original Fender Covers and Mud Flaps".

For Machines with Fender Extensions Installed

Illustration 21	g06366703
Machine with fender extension

Illustration 22	g06366704
(2) 542-2346 Mud Flap (16) 8T-4196 Bolt (17) 7X-0578 Hard Washer (18) 8T-0389 Locknut

Trim the existing fender extension to match the shortened fender cover using suitable tooling and secure the mud flap (2) using bolt (16), washer (17), and locknut (18), as shown in Illustration 21 and Illustration 22.