SFN-20240116D Install reinforcement bars to DT frame

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TICO Document #: SFN-20240116D (formerly TES 143)

Description of Procedure: Procedure for installation of reinforcement bars to top of DT frame rails.

Units Affected: Frame Serial Numbers: 2498 – 2501

Parts Required: Bar, flat, 3/4” x 2” (185” required) 880120 (QTY 1)

Plate, Doubler, Cab Bar, DT 12345-6 (QTY 2)

Guide, boom-qty of 12002 (QTY 2)

Bar-frame top 880120 (QTY 1)

Angles-qty of 12273 (QTY 2)

Planned Labor: N/A

Instructions:

  1. Park vehicle on flat surface, apply parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.

  2. Raise boom to highest position and support with appropriate lifting device.

  1. Raise cab to highest position and engage cab latch.

  1. Remove battery box cover and disconnect battery cables. Remove batteries from box and set aside to be installed later.

  1. Inspect frame rails for fractures and/or weak points.

  2. To repair fractures on frame rail, bevel, both sides of the crack with hand grinder to the full depth of the fracture.

  3. Using weld settings above, fill in bevel with weld and grind flush to top of frame rail.

Note: Weld settings are for GMAW process using metal-cored wire, Metalshield MC-6, and 90% Argon/10% CO2 gas mixture.

  1. Support cab bar with appropriate lifting device.

  2. Remove 5/8”-11 bolts, washers, and nuts securing one side of cab bar to frame rail.

  3. Position harnesses and airlines away from inner wall of frame rail so that it is exposed.

  4. Insert 12345-6, doubler plate, as shown and reattach cab bar with hardware previously removed.

  5. Torque 5/8”-11 nuts to 125 ft.*lbs.

  6. Route harness and airlines appropriately to prevent chafing.

  7. Repeat the above steps to the other side of cab bar.

  1. Prepare unit for the addition of frame rail reinforcement by removing platform above transmission. Retain hardware for reinstallation later.

  1. Remove 3/4”-10 x 4” lg. bolts, spacers, washers, and nuts securing rear of engine cradle to frame rail. Retain hardware for reinstallation and discard spacers.

  1. Support engine cradle using appropriate lifting device, and remove 1/2”-13 bolts, washers, and nuts securing front of engine cradle to frame rail. Retain for reinstallation later.

  1. Protect exposed components, air lines, and harnesses with a welding blanket.

  1. Remove transmission platform mount, 12273, from frame rail on both sides of unit and retain it to be installed later.

  2. Remove and retain boom guides, 12002, from frame rail on both sides. Grind any residual weld smooth.

  3. Elevate rear of engine cradle so that frame rail underneath is exposed.

  1. Prepare top of frame rails for weld by removing paint from top flanges using wire brush attachment on hand grinder. Start at 41” from forward face of front cross member and proceed to skid ramps at rear of frame.

  2. Cut 880120 into two equal sections of 92.25” in length.

  3. Prepare the two sections of 880120 as shown above.

  1. Position 880120, flat bar, as shown above. Leading edge should be 41 15/16” from forward face of front cross member.

  2. Bar should be positioned ½” inboard of the outside face of frame rail.

  3. Ensure rear engine cradle mount hole is concentric with hole already in frame rail.

  4. Tack weld into place.

  1. Using weld settings shown above weld 880120 to top of frame rail by depositing 1/4” fillet weld in a back step sequence of 12” sections and alternating between inside and outside edges of reinforcement bar. Performing the back step sequence will help minimize distortion of the reinforcement bar over the continuous weld.

  2. Do not weld outer side of reinforcement in sections shown above. These sections correspond to cab bar mounting location.

    Note: Weld settings are for GMAW process using metal-cored wire, Metalshield MC-6, and 90% Argon/10% CO2 gas mixture.

  1. Position boom guides, 12002, as shown above. Tack weld components into place.

  2. For boom guides, employ the same back step sequence as before to deposit 1/8” fillet weld to top and bottom edges of guides.

Note: Weld settings are for GMAW process using metal-cored wire, Metalshield MC6, and 90% Argon/10% CO2 gas mixture.

  1. Position transmission platform mounts, 12273, as shown above. Tack weld components into place.

  2. Weld 1/8” fillet to front and rear edges of transmission platform mounts.

Note: Weld settings are for GMAW process using metal-cored wire, Metalshield MC6, and 90% Argon/10% CO2 gas mixture

  1. Apply rust inhibitive primer to all bare metal surfaces and welds. Paint primed surfaces Vulcan Black.

  1. Lower rear of engine cradle into place. Reinstall 3/4”-10 x 4” bolts, washers, and nuts.

  1. Reinstall 1/2”-13 bolts, washers, and nuts into front engine cradle mounts.

Torque hardware on cradle as follows:

• 3/4”-10 nut: 320 ft.*lbs.

• 1/2”-13 nut: 80 ft.*lbs.

  1. Reinstall platform above transmission and secure with hardware previously removed.

  1. Reinstall batteries into battery box and connect power and ground circuits

  1. Lower cab and start the engine.

  1. Raise and lower boom several times to ensure proper clearance of boom guides.

  1. Remove “Lock Out, Tag Out” plaque.

  1. Return vehicle to service.