09180-06354 Suzuki SPACER

Introduction
This publication contains procedures to replace a cracked 183-2299 Bar . Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.Problem
Cracks may develop on the outside edge of the 183-2299 Bar . Cracks may occur in the locations that are shown in Illustration 2. The crack does not structurally affect the bracket. The crack will not propagate to the rear frame rail.Solution
Do not attempt to repair the old bracket by welding. This will cause a stress riser on the rear frame. Added stress could cause a failure of the rear frame rail. If the bracket has cracks that necessitate replacement of the bracket, follow the procedure that is specified below. Refer to Illustration 2 for the location of the 183-2299 Bar on the machine frame.
Table 1
Welding Process     AWS Specification     Electrode Designation    
SMAW (Stick Welding)     A5.1     E7018    
GMAW (MIG Welding)     A5.18     ER70S-3    
FCAW (Gas Shielding)     A5.20     E70T-1 (1)
E71T-1 (2)    
( 1 ) For welding horizontal positions and flat positions
( 2 ) For welding all positionsPlease refer to the directions in Illustration 1 for this rework procedure.
Illustration 1 g01229169
(A) Inside. (B) Front. (C) Outside. (D) Rear.This rework procedure will provide instructions for the following:
Supporting the engine mounting plate
Removal of the cracked bar
Installation of a new 183-2299 Bar
Removal of the supports for the engine mounting plate
Illustration 2 g01229231
(1) 183-2299 Bar . (2) Cracks may occur along the outside edge of the plate.Cracks may occur in the locations that are shown in Illustration 2. During the repair of these welds, the engine will not be removed from the mounting. Only the specified welding is permitted on top of the frame side plate. Only the specified welding is permitted within 3 inches of any other weld.Repair Procedure
Illustration 3 g01229236
(E) Support
Attach support (E). Refer to Illustration 3. Support (E) can be made of mild steel. Support should be approximately 170 mm (6.693 inch) in length.
Tack weld support (E) in the center of the top plate of the side plate assembly. No weld should be within 25 mm (0.984 inch) of the edge.
Tack weld support (E) to the engine mounting plate.
Illustration 4 g01229272
(F) 10 mm (0.394 inch) bevel weld
Remove 10 mm (0.394 inch) bevel weld (F) from either side of the engine mounting plate. Refer to Illustration 4.Note: Remove the welds carefully. This area will be rewelded when the new 183-2299 Bar is installed.
Illustration 5 g01229288
(G) 75 mm (2.953 inch) No weld area
Illustration 6 g01229292
Attach two support legs. Refer to Illustration 5. The legs should be made from 14 mm x 25 mm (0.551 inch x 0.984 inch) strip stock or similar material. Tack weld the legs to the engine mounting plate and to the side plates. No tack welds should be within 75 mm (2.953 inch) of existing welds. Place the support legs at the approximate locations that are shown in Illustration 5 and Illustration 6.
Illustration 7 g01229304
View HH-HHRemove the welds at locations (J) .
Remove the welds that are shown in Illustration 7. Use a grinder in order to remove these welds. Do not use an air carbon arc in order to remove these welds.
Remove the 183-2299 Bar .
Insert a new 183-2299 Bar between the added supports. Make sure that the new bar is securely placed under the engine support.
Illustration 8 g01229311
View HH-HH (K) 12 mm (0.472 inch) fillet weld with 1.5 mm (0.059 inch) of penetration. Start the weld and stop the weld at location (L) .
Weld the new bar. Refer to the weld specification in Illustration 8.Note: Start the weld and stop the weld at locations (L) .