SHIM (.060" Thick) 3D0436 - Caterpillar

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.Welding can cause fumes, burn skin and produce ultraviolet rays.Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125
See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.U.S. Department of Labor
Washington, D.C. 20210
Personal injury can result from flame cutting or welding on painted areas.The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.Do not flame cut or weld on painted areas.
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.
Rework Procedure
Perform the following rework procedure to prevent cracking of the Electric Retarder Group:
Move the machine to a smooth level surface that will support the weight of the machine.
Turn the machine key switch to the OFF position and disconnect machine power with the battery disconnect switch in the OFF position.
Prepare the machine for maintenance. Perform lockout/tagout procedure on the machine by attaching a "Do Not Operate" warning tag to the machine start switch of the controls before you perform any service.Note: Refer to the Operation and Maintenance Manual, SEBU8349-08, "795F AC Off-Highway Truck" for additional information.
Perform the electrical shutdown and voltage discharge procedure in the Operation and Maintenance Manual, SEBU8349-08, "Electrical Shutdown and Voltage Discharge".
Perform electric retarder removal process outlined in the Disassembly and Assembly, KENR8727-03, "795F Series AC Off-Highway Truck Machine Systems", under the IE title "Electric Retarder - Remove". Follow all steps and references in the removal and reinstallation procedures for the Retarder Grid.
Illustration 1 g03199897
The arrow in the illustration points to the location of the crack.
Locate the mounting support bracket on the 293-2208 Electric Retarder Gp (1). Refer to Illustration 1.
Illustration 2 g03199920
Remove part of the existing top plate (3) leaving 1.5 inches of existing top plate. Grind a "V" notch in the existing crack and weld the crack as shown in illustration 2.Note: Refer to the Operation and Maintenance Manual, SEBU8349-08, "795F AC Off-Highway Truck", "Welding on Electric Drive Machines" for more information.
Fabricate a top plate (4) and two gussets (5) on to the 293-2208 Electric Retarder Gp (1) for each cracked foot.
Illustration 3 g03201583
Fabricate top plate (4) as shown in Illustration 3.
Illustration 4 g03201587
Fabricate two gussets (5) as shown in illustration 4 to repair cracked foot.
Illustration 5 g03201597
Affix one cap (4)