Swing Rack - Install

12/10/2021 15:11 SIS 2.
2021/06/18 Swing Rack - Install (M0069644)
SMCS - 6506 i08510237
Installation Procedure
Required Tools
Tool Part Number Part Description Qty
A 189-0412 Clevis 4
B 4C-5591 Anti-Seize Compound 1
C - Heating coils -
D - Thermal blankets -
525-7955 Roller As 1
E 525-7956 Torque Link As 1
478-3990 Hydraulic Torque Wrench 1
F 8H-8581 Feeler Gauge 1
Table 1
1. Verify the machine is prepared for maintenance. Refer to Testing and Adjusting Machine Preparation  for the correct procedure.
2. Verify high-voltage shutdown. Refer to Testing and Adjusting Machine Preparation  for the correct procedure.
3.
4. If installing a new swing rack, go to step 9.
Illustration 1 g06328976
5. Use a suitable lifting device to install lower rail segment (8). The weight of lower rail segment (6) is approximately 257 kg (567 lb). Install
lower rail segment (8) allowing a typical clearance of 1.0 ± 0.2 mm (0.040 ± 0.01 inch) between each lower rail segment (8). Align drain holes
(9) with the drain holes in the swing rack assembly. Lower rail segment (8) must be pushed tight against the inside diameter of the
counterbore of the swing rack assembly.
Lubricate the threads of bolts (10) with Tooling (B). Install bolts (10). Tighten lubricated bolts (10) to torque of 920 ± 100 N·m (679 ± 74 lb ft).
Repeat step 5 for the remaining lower rail segments.
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12/10/2021 15:11 SIS 2.0
6. Use a suitable lifting device to install thrust rail segment (6). The weight of thrust rail segment (6) is approximately 76 kg (168 lb). Install thrust
rail segment (6) allowing a typical clearance of 1.0 ± 0.2 mm (0.040 ± 0.01 inch) between thrust rail segments (6). Align the slot (7) on thrust
rail segment (6) with the holes in the lower rail segments to allow for oil drainage.
Note: Use this procedure if swing rack has threaded holes.
Note: Use Tooling (E) to access head of bolts (5) for tightening and installing the thrust rail segment.
7. Lubricate the threads of bolts (5) with Tooling (B). Install bolts (5) into thrust rail segments (6). Tighten lubricated bolts (5) to a torque of
920 ± 100 N·m (679 ± 74 lb ft). Repeat steps 6 and 7 for the remaining thrust rail segments.
12/10/2021 15:11 SIS 2.0
Note: Use this procedure if swing rack has through holes.
8. Lubricate the threads of bolts (5) with Tooling (B). Place plates (5A) into cutouts on thrust rail segment (6). Install bolts (5) and the washers
through swing rack assembly (3). Tighten lubricated bolts (5) to a torque of 920 ± 100 N·m (679 ± 74 lb ft). Repeat steps 6 and 8 for the
remaining thrust rail segments.
Note: Clean the rack-swing in weld area and bottom surfaces to remove all grease, oil, rust, paint, debris, and so on. Clean the top surface of
the car-body in the area that the swing rack assembly is to be located.
9. Attach Tooling (A) to a suitable lifting device to install swing rack assembly (3). The weight of swing rack assembly (3) is approximately
24063 kg (53050 lb). Use a suitable lifting device to position swing rack assembly (3) on the car body. Use hydraulic rams to align the swing
rack assembly to the bolt pattern. Center the two jack bolt access holes (2A) as shown in relation to the front of the machine (X).
10. Use Tooling (F) to verify that the gap between the swing rack assembly and the car body is less than 0.254 mm (0.010 inch).
11. Install two jack bolts (2) in swing rack assembly (3) below access holes (2A) .
12/10/2021 15:11 SIS 2.0
12. Jack bolt threads, tapered portion of rod bolt, and expansion sleeve inner diameter are pre-lubricated from the vendor with Tooling (B).
Ensure that lube film is present on these surfaces. Apply extra Tooling (B) if needed. Apply a thin film of Tooling (B) to the outer diameter of
the expansion sleeve, the swing rack assembly, and the car body holes for the expansion sleeve and the jack bolt end faces and threads.
Check base of both torque nuts to ensure that all jack bolts are flush with bottom. Insert expansion sleeve from topside, into the mating swing
rack assembly and holes.
Insert tapered stud into expansion sleeve from topside. ( Note direction of taper, with small end downward.) Slip "special" thick hardened
washer over lower threaded end of tapered stud.
Thread lower torque nut onto tapered stud by hand and spin hand-tight against "special" lower hardened washer.
13. Seat and expand the tapered sleeve in the mating car body frame base plate and swing rack frame holes. Tighten the lower torque nut jack
bolts to a torque of 36 N·m (27 lb ft) using the procedure as follows:
An impact wrench can be used for the initial run up, but a torque wrench must be used for the final values.
Using a "star" pattern, start by tightening the jack bolts (one round only) to approximately 50% torque. 18 N·m (160 lb in) each.
Change to a "circular" pattern using a torque wrench, tighten (one round only) to full torque of 36 N·m (27 lb ft).
14. Slip hardened washer over the upper threaded end of tapered stud. Thread upper torque nut onto tapered stud by hand and spin hand-tight
against hardened washer.
15. Finalize the preload of the upper torque nut. Tighten the upper torque nut jack bolts final torque to 36 N·m (27 lb ft) using the procedure as
follows:
An impact wrench can be used for the initial run up, but a torque wrench must be used for the final values.
Using a "star" pattern, start by tightening the jack bolts (one round only) to approximately 50% torque. 18 N·m (160 lb in) each.
Change to a "circular" pattern using a torque wrench, tighten to full torque of 36 N·m (27 lb ft). Continue until the torque wrench moves less
than 1/8 turn. This process may take several rounds.
16. Finally, finalize the preload of the lower torque nut. Tighten the lower torque nut jack bolts final torque to 36 N·m (27 lb ft) using the procedure
as follows:
Using a "circular" pattern tighten the lower jack bolts to full torque of 36 N·m (27 lb ft) until the jack bolts are "stabilized". Continue until the
torque wrench moves less than 1/8 turn. This process may take several rounds.
12/10/2021 15:11 SIS 2.0
17. Lubricate the threads of bolt (4) with light oil. Install two hardened washers (4A) and bolt (4) from top of the swing rack assembly. Install two
hardened washers (4A) and nut (4B) from the bottom.
Repeat step 17 for the remaining bolts.
18. Tighten bolts (4) in a star pattern to a torque of 3100 ± 350 N·m (2286 ± 258 lb ft).
Note: Wait 24 hours before continuing.
19. After 24 hours, repeat step 18.
20. Prepare to weld the swing rack assembly onto the car body as follows:
Weld Specifications
Weld Type Size Penetration
W Fillet 25 mm (1.0 inch) 19 mm (0.75 inch)
Table 2
Reference: For welding instructions, refer to Special Instruction, REHS1841, "General Welding Procedures".
12/10/2021 15:11 SIS 2.0
Note: Clean the rack-swing in weld area and bottom surfaces to remove all grease, oil, rust, paint, debris, and so on.
21. Use Tooling (C) to heat the swing rack assembly floor to temperature of 204° C (400° F) and maintain this temperature throughout the
welding procedure. Cover the area to be welded with Tooling (D) to keep the area to desired temperature.
22. Positions set up for 2, 3, or 4 welders.

Note: The low hydrogen electrodes are to be used directly from an electric drying oven maintaining a temperature of 122° to 177°C
(220° to 319°F). Electrodes should be placed in the oven immediately after removal from the hermetically sealed containers and returned to
the oven after 2 hours of exposure to the atmosphere outside of the oven.
NOTICE
If using FCAW, must use 100% CO2 shield gas.
23. Use E8018-C1 electrodes. If welding in a protected area, use E80T1-NI1, 3/32 FCAW.
24. The welding should be done by at least 2 welders, up to 4 welders working simultaneously 180 degrees apart. See step 22 for welder
positions.
(W) 25 mm (1.0 inch) Fillet weld with 19 mm (0.75 inch) Root penetration
25. Weld the temper bead (9) then starter bead (8).
Do a dry magnetic particle test on both welds to check for stress cracks.
26. Continue welding with (W) on car body (10) and swing rack assembly (3). See Step 31 below.
27. Once the welding is complete, do a dry magnetic particle test on the weld to check for stress cracks
28. Place Tooling (D) over the welds for slow cooling.
Slow cool the weld at a rate of 10° C (50° F) degrees per hour.
12/10/2021 15:11 SIS 2.0
Wait 24 hours or until ambient temperature is reached.
Do a dry magnetic particle test on the weld to check for stress cracks.
29. Repeat step 18.
30. Use Tooling (F) verify that the gap between swing rack assembly (3) and car body (10) is less than 0.254 mm (0.010 inch).
31. Verify welds with weld gauges.
32. Install high-voltage collector shoes and lighting arrestors (1) after weld area is cleaned.
End By:
a. Install upper swing roller assemblies.
b. Install truck/crawler frame under revolving frame assembly.
ER61-UP, ER71-UP, ER81-UP
PIP-10936659
2021/10/12
18:10:52-03:00
i07000945
© 2021 Caterpillar Inc.
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12/10/2021 15:11 SIS 2.

2021/06/18 Swing Rack - Install (M0069644)

SMCS - 6506 i08510237

4. If installing a new swing rack, go to step 9.

19. After 24 hours, repeat step 18.

22. Positions set up for 2, 3, or 4 welders.

Wait 24 hours or until ambient temperature is reached.

29. Repeat step 18.

31. Verify welds with weld gauges.

a. Install upper swing roller assemblies.

b. Install truck/crawler frame under revolving frame assembly.

ER61-UP, ER71-UP, ER81-UP

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