Chassis - Frames Section 100-0010 Straightening 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) 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.
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.
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. 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. 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. Painting Note: Prior to welding, switch off/disconnect the following in the order given.
Failure to do so may seriously damage the machines electrical components. 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. a - Turn keyswitch off b - Turn battery master switch off c - Battery earth cables * * * * 2 SM 1372 Rev 1 2-00