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​.

Caterpillar Information System:

Interference Between Cable Assembly and Hydraulic Fan Case Drain Hose Assembly May Occur on Certain 793D Off-Highway Trucks {1408, 5057} Interference Between Cable Assembly and Hydraulic Fan Case Drain Hose Assembly May Occur on Certain 793D Off-Highway Trucks {1408, 5057}
794 AC Off-Highway Truck Field Assembly Platform - Install - Superstructure
B1, B2, B4, B6 and B8 Hydraulic Hammers Head Nuts - Tighten
New Collar and Longer Screw Hardware Improvement is Now Available for RS400 Rotation Sensor on Certain Motor Graders {1408} New Collar and Longer Screw Hardware Improvement is Now Available for RS400 Rotation Sensor on Certain Motor Graders {1408}
A Rework Procedure Is Now Available for Providing More Lubrication to the Transmission Clutch Number Three on Certain 700 Series Articulated Trucks {3030, 3160} A Rework Procedure Is Now Available for Providing More Lubrication to the Transmission Clutch Number Three on Certain 700 Series Articulated Trucks {3030, 3160}
New Air Cleaner Kit Is Now Available for Certain 836K Landfill Compactors {0679, 1051, 1071, 1408} New Air Cleaner Kit Is Now Available for Certain 836K Landfill Compactors {0679, 1051, 1071, 1408}
521B and 522B Track Feller Bunchers Tilt Platform Stabilizer - Inspect/Adjust
725C2 and 730C2 Articulated Truck Machine System Sensor - Remove and Install - Payload
A New Special Instruction Is Now Used to Rework the Weld Crack on A-Pin Doubler Plate for Certain 966L, 966M, 972L, and 972M Medium Wheel Loaders {0679, 7054} A New Special Instruction Is Now Used to Rework the Weld Crack on A-Pin Doubler Plate for Certain 966L, 966M, 972L, and 972M Medium Wheel Loaders {0679, 7054}
Payload Harness Grommets Are Now Installed on Certain 700 Series Articulated Trucks {1408, 7150} Payload Harness Grommets Are Now Installed on Certain 700 Series Articulated Trucks {1408, 7150}
Wrong Resistor May be Installed into 176-9668 Instrument Console Gp on Certain Excavators and Wheel Loaders {1408, 1437, 6129} Wrong Resistor May be Installed into 176-9668 Instrument Console Gp on Certain Excavators and Wheel Loaders {1408, 1437, 6129}
New Engine Software for Certain C7.1 Engines {1920} New Engine Software for Certain C7.1 Engines {1920}
HFW221 Felling Head Maintenance Interval Schedule
Inspection of the Rear of the Engine on Certain C4.4 Machine Engines {1201} Inspection of the Rear of the Engine on Certain C4.4 Machine Engines {1201}
New Turbo Outlet Hose Is Now Used on Certain 815K Soil Compactors and 816K Landfill Compactors {1071} New Turbo Outlet Hose Is Now Used on Certain 815K Soil Compactors and 816K Landfill Compactors {1071}
New Air To Air After Cooler (ATAAC) Core Mount Is Now Used on Certain 815K Soil Compactors and 816K Landfill Compactors {1063} New Air To Air After Cooler (ATAAC) Core Mount Is Now Used on Certain 815K Soil Compactors and 816K Landfill Compactors {1063}
New Lamp Group Flood Lights Are Now Used on Certain L Series and M Series Medium Wheel Loaders {1429, 1430, 1434} New Lamp Group Flood Lights Are Now Used on Certain L Series and M Series Medium Wheel Loaders {1429, 1430, 1434}
Improved Axle Shaft is Now Used on Certain 826K Landfill Compactors {3278} Improved Axle Shaft is Now Used on Certain 826K Landfill Compactors {3278}
HFW221 Felling Head Specifications
Procedure to Replace Drive Assembly of Starter Motor On All Cat® Products {1453} Procedure to Replace Drive Assembly of Starter Motor On All Cat® Products {1453}
High-Pressure Fuel Pump Adapter and Front Gear Inspection for Certain C175–16 and C175–20 Engines {1242, 125H} High-Pressure Fuel Pump Adapter and Front Gear Inspection for Certain C175–16 and C175–20 Engines {1242, 125H}
Transmission Clutch Failure May Occur on Certain 793F Off-Highway Trucks {3030, 3160} Transmission Clutch Failure May Occur on Certain 793F Off-Highway Trucks {3030, 3160}
New Pre-Cleaner Hose Is Now Used on Certain 24 Motor Graders {7320} New Pre-Cleaner Hose Is Now Used on Certain 24 Motor Graders {7320}
Lock Plate in Transmission Planetary Group is Failing on Certain Large Off-Highway Trucks {3030, 3160} Lock Plate in Transmission Planetary Group is Failing on Certain Large Off-Highway Trucks {3030, 3160}
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.