Procedure To Replace Rock Guards On Certain D6 Track-Type Tractors {4151, 7152, 7173} Caterpillar


Procedure To Replace Rock Guards On Certain D6 Track-Type Tractors {4151, 7152, 7173}

Usage:

D6T 2B3
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)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

------ WARNING! ------

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 Society
8669 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 Labor
Washington, D.C. 20210

See applicable requirements for your local area.


Required Parts

Table 1
D6K Required Parts 
Qty  Part Number  Description 
435-5599  Bracket As 
435-5600  Bracket As 
382-6539  Guard As 
382-6540  Guard As 
435-5580  Scraper 
459-9051  Scraper 
435-5581  Scraper 
459-9052  Scraper 

Table 2
D6N Required Parts 
Qty  Part Number  Description 
Right-hand side of frame 
478-7835  Scraper 
353-2172  Guard As (RH rear) 
353-2168  Guard As (RH front) 
Left-hand side of frame 
478-7836  Scraper 
353-2173  Guard As (LH rear) 
353-2169  Guard As (LH front) 

Table 3
D6T Required Parts 
Qty  Part Number  Description 
Right-hand side of frame 
285-6673(1)  Guard As 
163-2171(2)(3)  Guard As 
286-0360(4)(5)  Guard As 
163-2174(6)(7)  Guard As 
Left-hand side of frame 
285-6674(1)  Guard As 
163-2172(2)(3)  Guard As 
286-0361(4)(5)  Guard As 
163-2173(6)(7)  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

Table 4
D6K Required Parts 
Item  Qty  Part Number  Description 
382-6539  Guard As 
382-6540  Guard As 
435-5599  Bracket As 
435-5600  Bracket As 
435-5580  Scraper 
b 459-9051  Scraper 
435-5581  Scraper 
b 459-9052  Scraper 

Removal

  1. Disassemble the track roller frame from the machine.

  2. Disassemble all components necessary to provide safe access to the welds securing the damaged components.

  3. Clean areas where the rework will be done. Remove dirt, painting, slag, grease, and oil.


    Illustration 1g06170874


    Illustration 2g06170880

  4. 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.


    Illustration 3g06170885

  5. Remove welds (Red Marks), joining the rock guards to the roller frame, using Arc Gouging or grinding. See Illustration 3.


    Illustration 4g06170887

  6. Remove the parts to be replaced and grind the surface to remove the weld and gouge residues to locate new parts.

Installation



    Illustration 5g06171153

  1. Install bracket (3) and (4), using plate (5a) or (5b), and (6a) or (6b) to locate brackets correctly.


    Illustration 6g06170894

  2. Locate and tack weld guard assembly (1) and guard assembly (2).


    Illustration 7g06170898

  3. Use new brace bars to lock guard assemblies in position.


    Illustration 8g06170915


    Illustration 9g06170917


    Illustration 10g06170919

  4. Weld guard assembly (1) and guard assembly (2). See Illustration 8,9, and 10.

  5. Turn the assembly 180° and repeat Step 4.

  6. Repeat Steps 1 through 5 for the other assembly.

  7. After cooled, remove brace bars, clean, and paint the repaired area. Reassemble the assemblies to the machine.

D6N Procedure

Table 5
D6N Required Parts 
Item  Qty  Part Number  Description 
478-7836  Scraper 
478-7835  Scraper 
353-2172  Guard As (RH rear) 
b 353-2168  Guard As (RH front) 
353-2173  Guard As (LH rear) 
b 353-2169  Guard As (LH front) 

Removal

  1. Disassemble the track roller frame from the machine.

  2. Disassemble all components necessary to provide safe access to the welds securing the damaged components.

  3. Clean areas where the rework will be done. Remove dirt, painting, slag, grease, and oil.


    Illustration 11g06166685


    Illustration 12g06166771

  4. 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.


    Illustration 13g06166700

  5. Remove welds (Red Marks), joining the rock guards to the roller frame, using Arc Gouging or grinding. See Illustration 13.


    Illustration 14g06166702

  6. Remove the parts to be replaced and grind the surface to remove the weld and gouge residues to locate new parts.

Installation



    Illustration 15g06166726

  1. Assemble plate (1) and plate (2) to locate guard assembly (3a) or (3b), and guard assembly (4a) or (4b).


    Illustration 16g06166731

  2. Locate and tack weld guard assembly (3a) or (3b), and guard assembly (4a) or (4b).


    Illustration 17g06166736

  3. Use new brace bars to lock guard assemblies in position.


    Illustration 18g06166777


    Illustration 19g06166756

  4. Weld guard assembly (3a) or (3b), and guard assembly (4a) or (4b). See Illustration 18 and Illustration 19.


    Illustration 20g06166767

  5. Turn the assembly 90° to perform welds in Illustration 20.


    Illustration 21g06166768

  6. Turn the assembly 180° to perform welds in Illustration 21.

  7. Repeat Steps 1 through 6 for the other assembly.

  8. After cooled, remove brace bars, clean, and paint the repaired area. Reassemble the assemblies to the machine.

D6T Procedure

Table 6
D6T Required Parts 
Item  Qty  Part Number  Description 
Right-hand side of frame 
285-6673(1)  Guard As 
b 163-2171(2)(3)  Guard As 
c 286-0360(4)  Guard As 
d 163-2174(5)  Guard As 
Left-hand side of frame 
285-6674(1)  Guard As 
b 163-2172(2)(3)  Guard As 
c 286-0361(4)  Guard As 
d 163-2173(5)  Guard As 
(1) XL/XW SystemOne
(2) XL/XW HD
(3) STD HD
(4) LGP SystemOne
(5) LGP HD

Removal

  1. Disassemble the track roller frame from the machine.

  2. Disassemble all components necessary to provide safe access to the welds securing the damaged components.

  3. Clean areas where the rework will be done. Remove dirt, painting, slag, grease, and oil.


    Illustration 22g06169060


    Illustration 23g06169124

  4. 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.


    Illustration 24g06169204

  5. Remove welds (Red Marks), joining the rock guards to the roller frame, using Arc Gouging or grinding. See Illustration 24


    Illustration 25g06169210

  6. Remove the parts to be replaced and grind the surface to create a clean, smooth area on which to locate the new parts.

Installation



    Illustration 26g06169400

  1. 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).

  2. Tack weld guard assembly (1a), (1b), (1c) , or (1d) and (2a), (2b), (2c) , or (2d) .


    Illustration 27g06169227


    Illustration 28g06169406

  3. Weld guard assembly (1) and guard assembly (2). See Illustration 27 and 28.


    Illustration 29g06169268

  4. Turn the assembly 90° to perform welds in Illustration 29.

  5. Turn the assembly 180° and repeat Step 4.

  6. Repeat Steps 1 through 5 for the other assembly.

  7. After cooled, remove brace bars, clean, and paint the repaired area. Reassemble the assemblies to the machine.

Reference Section

Reference: RESH1841, "General Welding Procedures"

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