- Pipelayer
- PL61 (S/N: 6P21-UP; S3H1-UP; WGS1-UP)
- Track-Type Tractor
- D5R (S/N: D5L1-UP; D5X1-UP)
- D5R2 (S/N: R5A1-UP; WRE1-UP; R5L1-UP; WDZ1-UP)
- D6H Series II (S/N: 8ZJ1-UP; 9KJ1-UP; 8KK1-UP; 8SK1-UP; 9LK1-UP; 9RK1-UP)
- D6K (S/N: 6S61-UP; 7P61-UP; MP71-UP; DHA1-UP; FBH1-UP)
- D6K2 (S/N: EL71-UP; MXK1-UP; MGM1-UP; DFR1-UP; JTR1-UP; RPR1-UP; WMR1-UP; RST1-UP)
- D6N (S/N: MG51-UP; GB61-UP; SC61-UP; PBA1-UP; CBF1-UP; SGG1-UP; CBL1-UP; NJN1-UP; LJR1-UP; PER1-UP; GHS1-UP; P5T1-UP; MLW1-UP)
- D6R (S/N: A6M1-UP; 9BM1-UP; JEN1-UP; 4MN1-UP; 5LN1-UP; DMP1-UP; 4JR1-UP; 4WR1-UP; 5RR1-UP; S6T1-UP; S6Y1-UP)
- D6R Series II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; AGM1-UP; AEP1-UP; BPS1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BRZ1-UP)
- D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; MRT1-UP; EXW1-UP)
- D6R2 (S/N: PPP1-UP; TTT1-UP)
- D6T (S/N: 2D21-UP; CR31-UP; 2B31-UP; MB51-UP; AK71-UP; MH71-UP; CG81-UP; 7C91-UP; SGA1-UP; JHB1-UP; KSB1-UP; ZEB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; JWD1-UP; LBD1-UP; RAD1-UP; LAE1-UP; STE1-UP; DJG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; SNK1-UP; JML1-UP; KJL1-UP; MEL1-UP; SKL1-UP; JNM1-UP; TSM1-UP; WLM1-UP; WRN1-UP; K1R1-UP; KMR1-UP; PLR1-UP; WES1-UP; GCT1-UP; HYT1-UP; SGT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; NDY1-UP; TMY1-UP; HTZ1-UP; SGZ1-UP)
- D5R2 (S/N: R5A1-UP; WRE1-UP; R5L1-UP; WDZ1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Safety Section
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 by reading and understanding 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 instructions of the manufacturer and the safety practices of your employer. Do not touch live electrical parts. See “American National Standard Z49.1, Safety in Welding and Cutting” which is published by the American Welding Society. American Welding Society8669 NW 36 Street #130 Miami, Florida 33166-6672 1-800-443-9353 See “OSHA Safety and Health Standards, 29 CFR 1910” which is available from the U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 See applicable requirements for your local area. |
Required Parts
D6K Required Parts | ||
---|---|---|
Qty | Part Number | Description |
1 | Bracket As | |
1 | Bracket As | |
2 | Guard As | |
2 | Guard As | |
1 | Scraper | |
1 | Scraper | |
1 | Scraper | |
1 | Scraper |
D6N Required Parts | ||
---|---|---|
Qty | Part Number | Description |
Right-hand side of frame | ||
1 | Scraper | |
2 | Guard As (RH rear) | |
2 | Guard As (RH front) | |
Left-hand side of frame | ||
1 | Scraper | |
2 | Guard As (LH rear) | |
2 | Guard As (LH front) |
D6T Required Parts | ||
---|---|---|
Qty | Part Number | Description |
Right-hand side of frame | ||
2 | Guard As | |
2 | Guard As | |
2 | Guard As | |
2 | Guard As | |
Left-hand side of frame | ||
2 | Guard As | |
2 | Guard As | |
2 | Guard As | |
2 | Guard As |
(1) | XL/XW SystemOne |
(2) | XL/XW HD |
(3) | STD HD |
(4) | LGP NON VPAT SystemOne |
(5) | LGP VPAT SystemOne |
(6) | LGP NON VPAT HD |
(7) | LGP VPAT HD |
D6K Procedure
D6K Required Parts | ||||
---|---|---|---|---|
Item | Qty | Part Number | Description | |
1 | 1 | Guard As | ||
2 | 1 | Guard As | ||
3 | 1 | Bracket As | ||
4 | 1 | Bracket As | ||
5 | a | 1 | Scraper | |
b | 1 | Scraper | ||
6 | a | 1 | Scraper | |
b | 1 | Scraper |
Removal
- Disassemble the track roller frame from the machine.
- Disassemble all components necessary to provide safe access to the welds securing the damaged components.
- Clean areas where the rework will be done. Remove dirt, painting, slag, grease, and oil.
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Illustration 1 g06170874 Show/hide tableIllustration 2 g06170880 - Create a brace bar with holes
147 mm (5.80 inch) from the center on both sides. Locate and bolt the brace bar as shown in Illustration 1 (Blue Marks), to avoid welding deformation.Show/hide tableIllustration 3 g06170885 - Remove welds (Red Marks), joining the rock guards to the roller frame, using Arc Gouging or grinding. See Illustration 3.
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Illustration 4 g06170887 - Remove the parts to be replaced and grind the surface to remove the weld and gouge residues to locate new parts.
Installation
- Install bracket (3) and (4), using plate (5a) or (5b), and (6a) or (6b) to locate brackets correctly.
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Illustration 6 g06170894 - Locate and tack weld guard assembly (1) and guard assembly (2).
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Illustration 7 g06170898 - Use new brace bars to lock guard assemblies in position.
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Illustration 8 g06170915 Show/hide tableIllustration 9 g06170917 Show/hide tableIllustration 10 g06170919 - Weld guard assembly (1) and guard assembly (2). See Illustration 8,9, and 10.
- Turn the assembly 180° and repeat Step 4.
- Repeat Steps 1 through 5 for the other assembly.
- After cooled, remove brace bars, clean, and paint the repaired area. Reassemble the assemblies to the machine.
Illustration 5 | g06171153 |
D6N Procedure
D6N Required Parts | ||||
---|---|---|---|---|
Item | Qty | Part Number | Description | |
1 | 1 | Scraper | ||
2 | 1 | Scraper | ||
3 | a | 1 | Guard As (RH rear) | |
b | 1 | Guard As (RH front) | ||
4 | a | 1 | Guard As (LH rear) | |
b | 1 | Guard As (LH front) |
Removal
- Disassemble the track roller frame from the machine.
- Disassemble all components necessary to provide safe access to the welds securing the damaged components.
- Clean areas where the rework will be done. Remove dirt, painting, slag, grease, and oil.
Show/hide table
Illustration 11 g06166685 Show/hide tableIllustration 12 g06166771 - Create 2 brace bars with holes in the ends
317.5 mm (12.5 inch) apart. Locate and bolt the brace bars as shown in Illustration 11 (Blue Marks), to avoid welding deformation.Show/hide tableIllustration 13 g06166700 - Remove welds (Red Marks), joining the rock guards to the roller frame, using Arc Gouging or grinding. See Illustration 13.
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Illustration 14 g06166702 - Remove the parts to be replaced and grind the surface to remove the weld and gouge residues to locate new parts.
Installation
- Assemble plate (1) and plate (2) to locate guard assembly (3a) or (3b), and guard assembly (4a) or (4b).
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Illustration 16 g06166731 - Locate and tack weld guard assembly (3a) or (3b), and guard assembly (4a) or (4b).
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Illustration 17 g06166736 - Use new brace bars to lock guard assemblies in position.
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Illustration 18 g06166777 Show/hide tableIllustration 19 g06166756 - Weld guard assembly (3a) or (3b), and guard assembly (4a) or (4b). See Illustration 18 and Illustration 19.
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Illustration 20 g06166767 - Turn the assembly 90° to perform welds in Illustration 20.
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Illustration 21 g06166768 - Turn the assembly 180° to perform welds in Illustration 21.
- Repeat Steps 1 through 6 for the other assembly.
- After cooled, remove brace bars, clean, and paint the repaired area. Reassemble the assemblies to the machine.
Illustration 15 | g06166726 |
D6T Procedure
D6T Required Parts | ||||
---|---|---|---|---|
Item | Qty | Part Number | Description | |
Right-hand side of frame | ||||
1 | a | 1 | Guard As | |
b | 1 | Guard As | ||
c | 1 | Guard As | ||
d | 1 | Guard As | ||
Left-hand side of frame | ||||
2 | a | 1 | Guard As | |
b | 1 | Guard As | ||
c | 1 | Guard As | ||
d | 1 | Guard As |
(1) | XL/XW SystemOne |
(2) | XL/XW HD |
(3) | STD HD |
(4) | LGP SystemOne |
(5) | LGP HD |
Removal
- Disassemble the track roller frame from the machine.
- Disassemble all components necessary to provide safe access to the welds securing the damaged components.
- Clean areas where the rework will be done. Remove dirt, painting, slag, grease, and oil.
Show/hide table
Illustration 22 g06169060 Show/hide tableIllustration 23 g06169124 - Create 2 brace bars with holes in the ends
168.5 mm (6.60 inch) from center of bars. Locate and bolt the brace bars as shown in Illustration 22 (Blue Marks), to avoid welding deformation.Show/hide tableIllustration 24 g06169204 - Remove welds (Red Marks), joining the rock guards to the roller frame, using Arc Gouging or grinding. See Illustration 24
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Illustration 25 g06169210 - Remove the parts to be replaced and grind the surface to create a clean, smooth area on which to locate the new parts.
Installation
- Locate guard assembly (1a), (1b), (1c) , or (1d) and (2a), (2b), (2c) , or (2d) using dimensions
13 ± 1.5 mm (0.51 ± 0.06 inch) as shown in Illustration 23. Tack weld bars when guards are in position as shown in Illustration 26 (Blue Marks). - Tack weld guard assembly (1a), (1b), (1c) , or (1d) and (2a), (2b), (2c) , or (2d) .
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Illustration 27 g06169227 Show/hide tableIllustration 28 g06169406 - Weld guard assembly (1) and guard assembly (2). See Illustration 27 and 28.
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Illustration 29 g06169268 - Turn the assembly 90° to perform welds in Illustration 29.
- Turn the assembly 180° and repeat Step 4.
- Repeat Steps 1 through 5 for the other assembly.
- After cooled, remove brace bars, clean, and paint the repaired area. Reassemble the assemblies to the machine.
Illustration 26 | g06169400 |
Reference Section
Reference: RESH1841, "General Welding Procedures"