TURBOCHARGER GP 3620856 - Caterpillar

These bumpers are the service replacement for the former bumpers on the above machines. The bumpers can be installed separately or all three can be installed together. Be careful when the old bumper is removed; do not remove any of the bumper supports. Remove only the weld that holds the bumper. Check the bumper supports for cracks or damaged areas and make repairs to them as needed. (1) Use an Arcair torch or similar tool to remove bumpers (1), (2) and/or (3). Do not burn through the bumper supports or the plates where the bumpers are fastened. (2) Grind smooth the ends of the supports at (A) and (B) and the main frame rails at (C). The lengths at (A), (B) and (C) should be as shown. (3) Tack weld 1U989 Bumper (4) and 9G7286 Bumper (5) in position against the ends of the supports on each side of the machine. The rear ends of the two bumpers should be at the dimension shown from the centerline of the axle. The top of bumper (4) should be against the top of the right side supports but bumper (5) should be in the position shown in relation to the left supports. Tack weld angle (X) of 2T211 Bumper (6) behind bumpers (4) and (5). Tack weld angle (Y) between the ends of the bumpers. Make 3.0 (.12") fillet welds all around the supports at ends (A) on the left side and around the supports on the right side. Make 3.0 (.12") fillet welds around the ends of the frame rails at the front of the main frame. Make 2.3 (.09") square groove welds across the top and down the front on each end of angle (Y); grind the welds smooth. Make 12.7 (.5") long 2.3 (.09") fillet welds, 38.1 (1.5") apart along ends (Z) of bumpers (4) and (5). Fasten panels (7) and (8) under the top of bumpers (4) and (5), respectively, with 1.5 (.06") fillet welds. (4) Install strips (9) and (10) and steps (11); use the original hardware. Put paint on all the new welds and the new bumpers.