863239 Mercruiser HOSE, To Transom

Introduction
This Special Instruction outlines the procedure for installing an improved hood support assembly on 305.5 Mini Hydraulic Excavators. The former support arrangement used two gas spring assemblies. The assemblies were used in order to raise the hood. The assemblies were used to support the hood. The 170-2762 Gas Spring As was used on the left side to raise the hood. The 210-1793 Gas Spring As was used on the right side to raise the hood and used to support the hood in the raised position. Refer to Illustration 1.
Illustration 1 g01687215
Former Arrangement (A) 170-2762 Gas Spring As (B) 210-1793 Gas Spring As The 210-1793 Gas Spring As can fail due to operators that attempt to close the hood without releasing the lock. Heat from the exhaust muffler can also be a factor.An improved hood support is now used. The improved hood support utilizes two 170-2762 Gas Spring As for opening the hood and a mechanical support to hold the hood open. Plates have been added in order to reduce a transfer of heat to the right side gas spring assembly.The improved arrangement can be installed on earlier machines if it is required. The following work is necessary in order to install the improved hood support.
The upper frame assembly must be drilled and tapped in three places in order to support the plates that protect against heat.
The upper frame assembly requires a plate to be welded in position. This plate supports the plates, that protect against a heat transfer.
The hydraulic tank requires a plate to be welded in position. This plate allows the lower mounting of the gas spring to be moved.
The hood must be modified by welding brackets for the new gas spring and for the mechanical support.Note: The parts that are required are listed in Table 1.Reference
Reference Service Guide, SEBD0512, "Caterpillar Service Welding Guide"
Reference Special Instruction, REHS1841, "General Welding Procedures"Welding Requirements
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
Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.Prepare the metal for welding. Refer to """". Refer to the illustrations in this Special Instruction for welding symbols and specifications.Use AWS E7018 electrodes or equivalent electrodes to weld the guards to the work tool.All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300°C (572°F). The electrodes must be dried for at least 30 minutes.Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).Penetration characteristics may vary greatly depending on the following conditions:
Electrode diameter
Shielding gas
Welding current
Plate thicknessThe following items also affect the welds:
Geometry of welded joints
Surface conditions
Composition of the base metal and of the electrodeA root pass should be applied before each weld is finished.Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.All welds to the stick must be welded in the direction from the rear of the stick toward the front of the stick.For more welding information, consult the Caterpillar Service Welding Guide, SEBD0512.Preparing the Metal for Welding
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.
All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.Remove foreign objects with a wire brush, a buffer, or a grinder. Shot blasting the appropriate areas will also remove foreign material.Remove any oil or grease with a Caterpillar approved solvent.Welding on Machines and Engines with Electronic Controls
Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. The following steps should be followed in order to weld on a machine or an engine with electronic controls.Note: If you are welding on a work tool, Caterpillar recommends removing the work tool from the host machine before welding.
Turn off the engine.
Turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, then remove the negative battery cable at the battery.
Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to reduce the possibility of damage to the following components:
Bearings of the drive train
Hydraulic components
Electrical components
Other components of the machine
Do NOT use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.
Protect any wiring harnesses from the debris which