EH 4500 DUMP TRUCK FRAME REPAIR

BY HITACHI PROJECT TEAM.

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The repaired chassis after all the rework been done on it in a 16 days
period in conjunction of a day and night shift.
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The dump truck lower frame plate developed cracks in the operational
field as shown below.
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The project team cut and gouge out the lower frame plate with the teardrops with
all the wrap plate to leave the main frame as shown below after all the preparation
work been done.
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As seen below, the teardrops been welded to the new main frame bottom
plate with new upgraded bolt on nose cone been bolted to the main frame plate
and torqued to factory specifications before installation.
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Left shown the new main frame bottom plate in position ready for instalment.
Right shown the main frame bottom plate installed and all the rute
runs been welded with crack testing done on all the welding.
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Left shown more rute runs been done on main bottom frame plate with crack
testing done.
Right shown the new centre wrap plates been installed on main frame.
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Left shown all the welding been done on the centre wrap plates
and exhaust tube installed.
Right shown the completed job after installation and painted.
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Below show the high arch and the new upgrade that’s need to been done to
prevent cracking on the high stress area’s
Right shown window cut out for the new upgrade on high arch area.
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Left shown the new upgrade inner plate installed on high arch.
Right shown the new front plates installed and tested for cracks on the welding.
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Left shown more crack testing done on welding rute runs.

Right shown the final welding been done before painting take place.
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New upgrade on front suspension mount goes in conjunction with the high arch
upgrade.
On the right shown the new horse shoe been welded to the suspension mount.
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Pictures below shown the completed job after the high arch upgrade been done.
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As shown on the left the cracks that developed on the torque tube mount.
Right shown the cracks been gouged out and tested for any other cracks before
any welding commenced.
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The completed job after the repair has been done.

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Cracks that developed on the side web plate .

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The side web plate been cut out and prepared for the new plate
installation.
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The new side web plate instalment shown the complete job after painting.
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Cracks shown on the top main frame plate that developed metal fatigue
due to excessive welding repairs on plate.
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Top main frame plate cut and gouged out ,been prepared for new plate
installation.
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Top main frame plate been installed and welded with the complete installation on
the right.
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Rear frame cracked and needs replaced.

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Cracked rear frame been cut off for a new replacement frame.
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New rear frame installed on main frame with a new side web plate.
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New rear frame installed with side web plate.

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New rear frame installed with all welding completed.

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Cracked cast track bracket on rear frame.

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Instalment of the new cast track bracket on rear frame.

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The cast track bracket has been transition grind after final weld to prevent any
cracking on weld area.
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High arch inner radius cracks needs to be cut out, gouged and welded to do a
proper repair to prevent any further cracking on inner radius.
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Cracks developed on both left and right hand side that needs to be repaired.
Picture on the right show the inner high arch completed.