Field Service for Positive Pin Retention 2 (PPR 2) {4169, 4170, 4171, 4174, 4175, 4180} Caterpillar

Caterpillar Products

Machines with Positive Pin Retention 2 (PPR2) Track

Introduction

© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Undercarriage Reconditioning Bulletin contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Cat dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Undercarriage Reconditioning Bulletin must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

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• Caterpillar Technical Representative

• Knowledge Network

Summary

To eliminate pin walking for the above machines, Caterpillar has developed a new track that is called Positive Pin Retention 2 (PPR 2). The information in this Undercarriage Reconditioning Bulletin describes the tooling and the procedures that are required to service Positive Pin Retention 2 (PPR 2) track.

Safety

Illustration 1	g02139237

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

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Inspect all threaded components before use. Damaged threads may fail under hydraulic pressure. Broken threads may release flying objects that are propelled with great force. Personal injury or death can occur if struck by flying objects.

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Do not stand near the hydraulic press while the press is in operation. A component that slips or breaks under pressure may fly into the air with great force. Personal injury or death can occur if struck by flying objects.

References

Reference: DVD, SERF8890, "Undercarriage Service Guide"

Reference: Undercarriage Reconditioning Guide, SEBF8599

Reference: Catalog, NENG2500, "Dealer Service Tool Catalog"

Reference: Tool Operating Manual, NEHS0946, "Positive Pin Retention 2 (PPR2) Tooling for D6R, 325, and 345 Machines"

Reference: Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts"

Reference: See Testing and Adjusting for your machine.

Reference: See Disassembly and Assembly for your machine.

Reference: See Operation and Maintenance Manual for your machine.

Required Tooling

Track Press

Illustration 2	g01146047
Typical track repair group (1) Nut (2) Bolster (3) Connecting rod (4) Cylinder

Various track presses are available. Any track press with a similar design to Illustration 2 will accomplish the process. Many tools for the track repair group are available. You may already have the tooling in stock, but as a different part number. Before purchasing new tooling, inspect the tooling for the track repair group. The only new tooling is Tooling (L) and the tooling in Table 5.

The pilot pin must have a diameter that is smaller than the bores of the track links. The pilot pin aligns the track links before the track pin is installed.

Illustration 3	g01148889
Typical receiver

The receiver that is used must have a hole that is large enough to accept the pilot pin.

Illustration 4	g01148891
Typical adapter

The rod cap or the adapter must have a spot face that will set the pin projection. Refer to Table 7 for the correct pin projection. See Illustration 30 for more information.

Note: Do not attempt to use the 5P-2379 Track Press Tool Gp to form the swage. An improper swage will be formed.

Tooling Setup for the MD6640, 5090, 390, 385, 374 and 365

Illustration 5	g01618684
(5) Tooling for the bolster (6) Tooling for the ram

The tooling for swaging the track joints on the 385 and 365 will need to be assembled. Refer to Table 5 for the additional tooling that must be assembled. This tooling fits on the 216-3914 Track Repair Group. Refer to Illustration 5 for the assembled tooling.

Removal of the Damaged Joint

1. Position the damaged joint between the front idler and the front carrier roller.

2. Remove the track shoes that are next to the damaged joint.

   Note: Use Tooling (B) to remove the track bolts.

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   Personal injury can result from grease under high pressure. The adjuster cylinder for the track is under high hydraulic pressure. Grease under high pressure can cause injury. Do not visually inspect the adjuster to see if grease is released when the valve is opened. Check the rod to see that it moves to the rear into the front support on the track roller frame.

3. Release the pressure from the track adjusting mechanism.
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   Illustration 6	g01289090

4. Place cribbing under the grouser bar.
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   Illustration 7	g01289079

5. Place cribbing between the track roller frame and the link assembly.
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   Illustration 8	g01288697

6. Position Tooling (A) around the track link assembly.

7. Install the bolster onto Tooling (A) with the two nuts that are provided.

8. Install Tooling (J) on Tooling (A).
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   Illustration 9	g01619018

9. Position Tooling (P) between Tooling (J) and the track pin of the track joint.

10. Press the track pin out of the track joint.

11. Remove Tooling (A).
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    NOTICE
    While you spread the track links, use only enough force to allow the bushing to clear the seals. If excessive force is used to spread the track links, the track links may move on the previous bushing. If the track links move on the previous bushing, the life of the link assembly will be decreased.

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    Illustration 10	g01619021

12. Use Tooling (C) in order to spread the adjacent pair of track links.

13. Carefully lay the track on the ground.
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    Illustration 11	g01289373

14. Use cribbing in order to provide clearance for Tooling (A).

    Note: All illustrations in this document are shown with the rail downward.

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    Illustration 12	g01524969
    (7) Track pin

15. Position Tooling (A) around the track link assembly.

16. Install the bolster onto Tooling (A) with the two nuts that are provided.

17. Position Tooling (P) between Tooling (J) and the track pin of the track joint.

18. Press the track pin out of the track joint.

19. Remove Tooling (A).
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    NOTICE
    While you spread the track links, use only enough force to allow the bushing to clear the seals. If excessive force is used to spread the track links, the track links may move on the previous bushing. If the track links move on the previous bushing, the life of the link assembly will be decreased.

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    Illustration 13	g01619033

20. Use Tooling (C) in order to spread the adjacent pair of track links and remove the damaged track joint.

Preparation of Positive Pin Retention 2 (PPR 2) Track for Installation

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Illustration 14	g01146048

1. All paint, loose rust, metal debris, and dirt must be removed from the mating surfaces of the track components.

   The paint on the mating surfaces of new track link assemblies must be removed before installation of the track shoes. The correct clamping force cannot be achieved if all the paint is not removed. The following methods may be used in order to remove the paint:

   • Use sandpaper (24 grit) to remove the paint from the mating surfaces of the track links and the track shoes. A light mist of water should be sprayed on the mating surface during the sanding. The water will help keep the sandpaper clean during sanding.

   • A paint remover may be used to remove the paint from the mating surfaces of the track links and the track shoes. Make sure that the paint remover does not contact the track seal. The paint remover can damage the track seal.

   • Do not use a torch to remove the paint from the mating surfaces of the track links and the master track links. The high temperatures will damage track seals.

   • Do not drag the track link assembly across the ground in order to remove the paint from the mating surfaces of the track links. Dragging the track link assembly can damage the master track joint and other track components. High spots may be created on the track links. Dragging the track link assembly may cause the track joints to open.

   Note: The track bolt and threads of the track nuts must be in good condition.

   Note: Verify that no paint is present on the counterbore of the track link. Verify that no paint is present on the internal diameter of the bushing. These components must be kept clean.

Installation of Positive Pin Retention 2 (PPR 2) Track

1. Use 161-9203 Grease Cartridge to apply an even coat of grease to the track pin. Apply an even coat of grease to the end of the bushing. Apply an even coat of grease to the inside of the bushing.

   Note: Once the grease is applied, care must be taken in order to ensure that the grease does not become contaminated.

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   Illustration 15	g01524991
   (8) Track seal (9) Thrust ring (10) Track pin (11) Bushing

2. Use Tooling (R) in order to install the track seals into the counterbore of the track link. Install the thrust ring into the counterbore of the track link.

   Note: Apply a small amount of grease to the thrust ring so the thrust ring will stay in the bore of the track link.

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   NOTICE
   While you spread the track links, use only enough force to allow the bushing to clear the seals. If excessive force is used to spread the track links, the track links may move on the previous bushing. If the track links move on the previous bushing, the life of the link assembly will be decreased.

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   Illustration 16	g01619041

3. Use Tooling (C) in order to spread the adjacent track links open so the bushing can pass by the seals.

4. Carefully align the bushing with the seals. Slide the track links together.
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   Illustration 17	g01619042

5. Install Tooling (P) into the track links.

6. Release the hydraulic pressure from Tooling (C). Remove the hydraulic cylinder from the track link assembly.
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   Illustration 18	g01289409

7. Position Tooling (A) around the track link assembly.

8. Install the bolster onto the track repair group. Fasten the bolster to the track repair group with the two nuts that are provided.

9. Install Tooling (J). Install Tooling (K) onto Tooling (A).

10. Position the track pin between Tooling (P) and Tooling (J).
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    Illustration 19	g01524998

11. Press the track pin into the bores of the track link with Tooling (M). Refer to Table 7 for the correct dimension for the pin projection.

    Note: The track pin will push the pilot pin through the track links.

12. Measure the pin projection with Tooling (H).

13. Attach a hoist to the end of the link assembly. Lift the end of the link assembly over the front idler.
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    Illustration 20	g01146050

14. Position the track link assembly around the track roller frame. The ends of the track link assembly should be positioned between the front idler and the first carrier roller.
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    Illustration 21	g01146205

15. Apply cribbing on both ends of the track link assembly.

16. Apply cribbing between the track link assembly and the track roller frame. This cribbing is necessary so that the connecting rods that are on the track press will not contact the track roller frame.

17. Use 161-9203 Grease Cartridge to apply an even coat of grease to the track pin. Apply an even coat of grease to the end of the bushing. Apply an even coat of grease to the inside of the bushing.

    Note: Once the grease is applied, care must be taken in order to ensure that the grease does not become contaminated.

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    Illustration 22	g01524991
    (8) Track seal (9) Thrust ring (10) Track pin (11) Bushing

18. Use Tooling (R) in order to install the track seals into the counterbore of the track link. Install the thrust ring into the counterbore of the track link.

    Note: Apply a small amount of grease to the thrust ring so the thrust ring will stay in the bore of the track link.

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    NOTICE
    While you spread the track links, use only enough force to allow the bushing to clear the seals. If excessive force is used to spread the track links, the track links may move on the previous bushing. If the track links move on the previous bushing, the life of the link assembly will be decreased.

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    Illustration 23	g01619021

19. Use Tooling (C) in order to spread the track links.
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    Illustration 24	g01146055

20. Carefully align the bushing with the seals. Slide the track links together.
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    Illustration 25	g01619049

21. Install Tooling (P) into the track links.

22. Release the hydraulic pressure from Tooling (C). Remove the hydraulic cylinder from the track link assembly.
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    Illustration 26	g01288697

23. Position Tooling (A) around the track link assembly.

24. Install the bolster onto the track repair group. Fasten the bolster to the track repair group with the two nuts that are provided.
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    Illustration 27	g01619050

25. Install Tooling (J). Install Tooling (K) onto Tooling (A).
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    Illustration 28	g01619051

26. Position the track pin between Tooling (P) and Tooling (J).
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    Illustration 29	g01524998

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    Illustration 30	g01525016
    (AA) Pin projection

27. Press the track pin into the bores of the track link with Tooling (M). Refer to Table 7 for the correct dimension for the pin projection.

    Note: The track pin will push the pilot pin through the track links.

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    Table 7

    Pin Projection
    Sales Model	Dimension
    MD6640 5090 390 385	2.70 ± 0.50 mm (0.106 ± 0.020 inch)
    374 365	2.70 ± 0.50 mm (0.106 ± 0.020 inch)
    345 349	2.20 ± 0.50 mm (0.086 ± 0.020 inch)
    TK711 511	2.00 ± 0.50 mm (0.079 ± 0.020 inch)
    325C 325D 521 522 TK721 TK722	5.90 ± 0.08 mm (0.232 ± 0.003 inch)

28. Measure the pin projection with Tooling (H).

Swaging of the Pin Boss

1. Set the hydraulic pump to 0 kPa (0 psi).

2. Install Tooling (F) onto Tooling (L).
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   Illustration 31	g01619053

3. Use Tooling (F) in order to position both of Tooling (L) on Tooling (A). Slowly extend the hydraulic cylinder until contact is made.

   Note: Tooling (F) is a handle assembly that can be used in order to position Tooling (L).

   Note: Verify that Tooling (N) is properly on the track pin. If the track has already been swaged, Tooling (N) will need to be rotated 45 degrees from the previous swage.

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   Illustration 32	g01146066

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   Illustration 33	g02100574
   Tooling (L) before the swage (L) Extruder Gp (12) Pin boss (13) Track pin

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   Illustration 34	g02100594
   Tooling (L) after the swage (L) Extruder Gp (12) Pin boss (13) Track pin

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   NOTICE
   If the force that is applied is greater than the specified value, the thrust rings will break. If the force that is applied is less than the specified value, an improper swage will form.

4. Increase the pressure of the hydraulic pump so that the cylinder will start to move. Apply hydraulic pressure to the swaging tools. Gradually increase the hydraulic pressure until the force that is specified in Table 8 is reached.

   Note: The approximate setting of the pump should be 31000 kPa (4500 psi). Adjust the pump in order to achieve the assembly force in Table 8.

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   Table 8

   Swaging Force
   Sales Model	Assembly Force
   MD6640 5090 390 385	880 kN (197833.0 lb)
   374 365	880 kN (197833.0 lb)
   345 349 TK711 511 325C 325D 521 522 TK721 TK722	670 kN (150600.0 lb)

5. After the assembly force has been reached, release the pressure from the hydraulic cylinder. Remove the swaging tools from the track links.

   Note: Tap the tooling with a hammer if the swaging tool sticks to the pin boss.

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   Illustration 35	g01146067

6. Visually inspect each swage in order to ensure that the swage has been properly formed. Each swage should have a uniform depth.

Unlocking the Track Joint

After the pin boss has been swaged, all of the internal components of the track link assembly are pressed together with zero end play. If the components remain pressed together, the track link assembly will not articulate. Galling will occur on the thrust rings.

Unlocking a track joint is a process that is crucial to the success of a proper repair or proper installation. Unlocking is performed by applying a specified force to both ends of the track pin. As the specified force is released from the track pin, the track link, the seal, and the thrust ring will be carried slightly away from the bushing. For the correct end play dimension, refer to Table 10. If the track joint is properly unlocked, the track joint will articulate. If the track joint is properly unlocked, galling will not occur on the thrust rings.

1. Install Tooling (F) onto Tooling (E).

2. Position Tooling (E) in order to unlock the track joint. Tooling (E) should only contact the track pin. If the tooling contacts another track component, the track joint will not become unlocked. Refer to Table 9 for the correct force that is required to unlock the track joint.
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   Table 9

   Unlocking Force
   Sales Model	Unlocking Force
   MD6640 5090 390 385	980 kN (220315.0 lb)
   374 365	980 kN (220315.0 lb)
   345 349	444 kN (100000.0 lb)
   TK711 511	444 kN (100000.0 lb)
   325C 325D 521 522 TK721 TK722	670 kN (150622.7)

3. Verify that the track joint articulates. Use a pry bar to pry up on the track links.

4. Measure the end play of the track joint. For the correct end play dimension, refer to Table 10.
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   Table 10

   End Play
   MD6640 5090 390 385 374 365 345 349 TK711 511 325C 325D 521 522 TK721 TK722	0.07 + 0.13 − 0.07 mm (0.003 + 0.005 − 0.003 inch)

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   Illustration 36	g01289403

5. Install the track shoes onto the link assembly. Follow the correct pattern in Illustration 36 in order to torque the bolts. For the proper torque value, refer to Table 11.

   Note: Use Tooling (B) in order to tighten the track bolts.

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   Table 11

   Torque Values
   Sales Model	Bolt Size	Dynamic Torque	Torque Turn
   MD6640 5090 390 385	M30 X 2.0	900 ± 100 N·m (664.0 ± 74.0 lb ft)	Additional 120° ± 5°
   374 365	M27 X 2.0	550 ± 70 N·m (405.0 ± 52.0 lb ft)	Additional 120° ± 5°
   345 349	M24 X 1.5	500 ± 70 N·m (369.0 ± 52.0 lb ft)	Additional 120° ± 5°
   TK711 511	M20 X 1.5	400 ± 70 N·m (295.0 ± 50.0 lb ft)	Additional 120° ± 5°
   325C 325D 521 522 TK721 TK722	3/4 X 16	400 ± 70 N·m (295.0 ± 50.0 lb ft)	Additional 120° ± 5°

6. Adjust the tension in the track. For more information, refer to Operation and Maintenance Manual, "Track Adjustment - Adjust".

Rework Procedure for the Track Guide Guard on the 385

New track guards are available in order to provide suitable clearance between the guard and the track link on PPR 2. Refer to Table 12 for these track guards.

This section describes the procedures to rework the existing track guards on the 385. Plates will be added to the following guards in order to provide suitable clearance between the guard and the track link on Positive Pin Retention 2 (PPR 2):

• 172-3001 Track Guide Guard Gp (Center)

• 186-5655 Track Guide Guard Gp (Segment)

• 248-1709 Track Guide Guard Gp (Full Length (LC))

• 248-1710 Track Guide Guard Gp (Std Full Length)

Illustration 37	g01661593
Center guard after rework (14) Plate 1

Illustration 38	g01661594
Segment guard after rework (15) Plate 2

Illustration 39	g01661596
Full length guard (LC) after rework (16) Plate 3

Illustration 40	g01661597
Std full length guard after rework (17) Plate 4

Preparation

1. Remove the paint and clean the area that will be welded.

2. Keep the area dry during the welding process in order to prevent cracking of the weld.

   Note: The surfaces of the plate and the welding rods should be dry.

3. Do not tack weld both ends of the plate.

Center and Segment Guards

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Illustration 41	g01663393

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Illustration 42	g01663394

1. Use the dimensions in Illustration 41 in order to make Plate (14) for the center guards. Use the dimensions in Illustration 42 in order to make Plate (15) for the segment guards.
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   Illustration 43	g01665353

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   Illustration 44	g01665354

2. Locate Plate (14) and Plate (15) with the correct dimensions. Refer to Illustration 43 and Illustration 44.

   Note: Grind the weld or the plate cutting to keep up a good fit. The good fit will prevent an excessive gap.

3. Weld Plate (14) in four locations on the center guard. Weld Plate (15) in 12 locations on the segment guard. Refer to Illustration 44.

4. Check the quality of the weldments. Defects are not permitted in the weld. Any defects should be ground out to be smooth.

Full Length Guards (LC)

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Illustration 45	g01665374

1. Use the dimensions in Illustration 45 to make Plate (16) for the full length guards (LC).
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   Illustration 46	g01665378

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   Illustration 47	g01665379

2. Locate Plate (16) with the correct dimensions. Refer to Illustration 46 and Illustration 47.

   Note: Grind the weld or the plate cutting to keep up a good fit. The good fit will prevent an excessive gap.

3. Weld Plate (16) in 16 locations on the full length guard. Refer to Illustration 47.

4. Check the quality of the weldments. Defects are not permitted in the weld. Any defects should be ground out to be smooth.

Std Full Length Guards

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Illustration 48	g01665393

1. Use the dimensions in Illustration 48 to make Plate (17) for the Std full length guards.
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   Illustration 49	g01666814

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   Illustration 50	g01666816

2. Locate Plate (17) with the correct dimensions. Refer to Illustration 49 and Illustration 50.

   Note: Grind the weld or the plate cutting to keep up a good fit. The good fit will prevent an excessive gap.

3. Weld Plate (17) in 16 locations on the full length guard. Refer to Illustration 50.

4. Check the quality of the weldments. Defects are not permitted in the weld. Any defects should be ground out to be smooth.