Operation and maintenance manual

2 SM 1372 Rev 1 2-00
Chassis - Frames
Section 100-0010
Straightening
If the frame is not too badly sprung or twisted,
hydraulic straightening and aligning equipment can be
used to straighten the frame without dismantling the
machine. However, if the frame is severely damaged,
it will be necessary to disassemble the machine in
order to repair or replace the frame assembly.
All straightening operations should be performed
without application of heat if possible. If heat must be
applied, do not heat the metal beyond a dull cherry red
colour, as it will result in serious weakening of the
frame by decreasing the tensile strength of the steel.
When it is necessary to apply heat, apply it uniformly
over the area to be straightened until the metal
reaches a uniform colour. Protect the heated surface
from drafts to prevent sudden cooling of the metal. If
the frame or frame parts cannot be straightened they
must be replaced.
Welding
WARNINGS
Before any welding is done on a machine
equipped with the DDEC system, disconnect
wiring harnesses at the ECM, connections at
body hydraulics joystick, all battery
connections at both positive and negative
terminals and ground cable to alternator to
avoid damage to electrical components. Turn
battery master switch to the 'Off' position
before disconnecting any components.
Remove battery ground cable first, and
reconnect last, to avoid damaging electrical
components.
Before any welding is done ensure all paint
has been removed from the area to be welded.
Failure to do so may result in hazardous fumes
being given off from the paint.
Note: Prior to welding, switch off/disconnect the
following in the order given. Failure to do so may
seriously damage the machines electrical
components.
a - Turn keyswitch off
b - Turn battery master switch off
c - Battery earth cables
d - Battery supply cables
e - Alternator earth cables
f - Alternator supply cables
g - Body hydraulics joystick
h - Transmission (Est-37) connector
i - ECM interface harness connector (30 pin RHS)
j - ECM power harness connector (5 pin RHS)
k - ECM sensor harness connector (30 pin LHS)
l - ECM engine to transmission datalink connector
(6 pin RHS)
After welding, connect all of the above in the reverse
order.
Note: Always fasten the welding machines ground
cable to the piece/frame being welded if possible.
Electric arc welding is recommended for all welded
frame repairs. Since the nature and extent of damage
to the frame cannot be predetermined, no definite
repair procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Service Department
can be consulted regarding the feasibility of welding
repairs.
Reinforcement
Frame reinforcement can be made with channel, angle
or flat structural stock. Whenever possible, the
reinforcement should extend well beyond the bent,
broken or cracked area. The reinforcement stock
thickness should not exceed that of the frame stock
and the material should be of the same tensile
strength.
Painting
To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
on the frames is highly recommended.
If painting of a frame is required, thoroughly clean the
areas to be painted. Apply a primer coat of synthetic
red oxide and then a finish coat of synthetic enamel.
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