CX38 CL6 Top Hat Rework Conversion of Assemblies 367-9371 to 490-8824 {3030, 3160} Caterpillar


CX38 CL6 Top Hat Rework Conversion of Assemblies 367-9371 to 490-8824 {3030, 3160}

Usage:

745 3F6


Articulated Truck
735C (S/N: LFJ1-UP; TFJ1-UP)
740 EJECTOR (S/N: 3F71-UP; 3T71-UP)
740 GC (S/N: 3F81-UP; 3T81-UP)
740C EJECTOR (S/N: LFN1-UP; TFN1-UP)
745 (S/N: 3F61-UP; 3T61-UP; JHW1-UP; JHX1-UP)
745C (S/N: JE81-UP; JE91-UP; LFK1-UP; TFK1-UP)

Introduction

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

Note: This rework procedure is an option that can be used if the ability to machine parts is available and the new version of the part 490-8824 is not available in the time needed.

Safety Section

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

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.


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

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.


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

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.


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

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


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

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.


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

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


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

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.


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

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.


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

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.


Required Parts

Table 1
Required Parts 
Item  Qty  Part Number  Part Name 
367-9371  Plate As 

Rework Procedure



    Illustration 1g06420436
    Lathe setup for plate 367-9371.

  1. Setup plate 367-9371 in lathe.


    Illustration 2g06421824
    (D1) 320 mm +/- 0.05 mm (12.59840 inch +/- 0.0002 inch)
    (D2) 6.69 mm +/- 0.13 mm (0.26339 inch +/- 0.005 inch)
    (D3) 2.63 mm +/- 0.06 mm (0.10354 inch +/- 0.002 inch)
    (D4) 327.77 mm +/- 0.08 mm (12.90430 inch +/- 0.003 inch)
    (D5) 322.69 mm +/- 0.13 mm (12.70431 inch +/- 0.005 inch)
    (R2) R2 +/- 0.5 radius
    (D11) 1 mm +/- 0.25 mm (0.03937 inch +/- 0.01 mm)

  2. Using a single point tool, open 320 mm +/- 0.05 mm (12.59840 inch +/- 0.0002 inch) (D1) to a diameter of 320.66 mm +/- 0.05 mm (12.62438 inch +/- 0.0002 inch). Clean up transition at the bottom of the pocket with R2 +/- 0.5 radius.

  3. Machine diameter 322.69 mm +/- 0.13 mm (12.70431 inch +/- 0.005 inch) (D5) to a depth of 6.69 mm +/- 0.13 mm (0.26339 inch +/- 0.005 inch) (D2) from the face​.

  4. Using a (0.094 inch) groove tool or other correct sizing tool, machine a 2.63 mm +/- 0.06 mm (0.10354 inch +/- 0.002 inch) (D3) groove to a diameter of 327.77 mm +/- 0.08 mm (12.90430 inch +/- 0.003 inch) (D4). See Illustration 3 for more details.


    Illustration 3g06420486
    Groove detail.

  5. Machine 1 mm +/- 0.25 mm (0.03937 inch +/- 0.01 mm) (D11) chamfer at 30 degrees +/- 1 degree. See Illustration 2 for more details.

  6. Measure and record the diameters and depth to compare to given specification.


    Illustration 4g06420507
    CNC vertical/end milling machine setup for plate 367-9371.

  7. Setup plate 367-9371 in the CNC Vertical/end milling machine.

  8. Locate the area to be slotted by centering the probe with hole or coordinates from the center of the part. See Illustration 5 for more detail.


    Illustration 5g06420955
    (D6) 14.5 mm +/- 0.13 mm​ (0.5709 inch +/- 0.005 inch)
    (D7) 18 mm +/- 0.13 mm​ (0.7087 inch +/- 0.005 inch)
    (D8) 7.25 mm +/- 0.13 mm​ (0.2854 inch +/- 0.005 inch)
    (D9) 80 mm (3.14960 inch)
    (D10) 120 mm (4.72440 inch)
    (4X R5) R5 +/- 0.5 radius

  9. Using a (0.187 in) end mill or other correct size tool,​ machine slot to 14.5 mm x 18 mm +/- 0.13 mm​ (0.5709 inch x 0.7087 inch +/- 0.005 inch) with four R5 +/- 0.5 radius. See Illustration 5 for details.


    Illustration 6g06420519
    View of completed slot.

  10. See Illustration 5 for details.


    Illustration 7g06420521
    Clean and mark.

  11. Using an acid etch pen or other permanent marking method, erase the old number and identify with 490-8824 part number​.

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