Replacement of the Equalizer Bar Saddle {7206} Caterpillar

Track-Type Tractor

D5M (S/N: 6GN1-UP; 3CR1-UP; 3DR1-UP; 4BR1-UP; 7LR1-UP; 4JS1-UP; 5ES1-UP; 5FS1-UP; 6AS1-UP)

D5N (S/N: AKD1-UP; AGG1-UP; CFH1-UP; CKT1-UP)

D6R (S/N: 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; DMP1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; 1RW1-UP)

D6R Series II (S/N: BNC1-UP; AFD1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6T (S/N: JHB1-UP; KSB1-UP; ZEB1-UP; ZJB1-UP; JZC1-UP; SMC1-UP; DTD1-UP; JWD1-UP; LBD1-UP; RAD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; SNK1-UP; KJL1-UP; SKL1-UP; TSM1-UP; WLM1-UP; WRN1-UP; KMR1-UP; WES1-UP; GCT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; TMY1-UP; HTZ1-UP; PEZ1-UP)

Introduction

This special instruction provides the procedure to replace the equalizer bar saddle for the equalizer bar. The procedure includes the method of replacing the equalizer bar saddle. Replacement includes removal of the old equalizer bar saddle, bracing the frame assembly, preparation of the frame and installation of the new equalizer bar saddle.

Refer to the necessary parts list.

After installation of the equalizer bar saddle is complete, prepare the machine for service. Follow the procedure in the Operation and Maintenance Manual for your machine.

Safety

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

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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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; read and understand 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 manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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When a hoist is used to lift any part or assembly, stand clear of the area under the part being raised. Always make sure that the hoist has adequate lifting capacity and the wire cable is not damaged. Failure to follow this instruction could lead to injury or death. Approximate weights of the components are shown in the table which follows.

Weights

The weights that are listed are approximate.

Parts List

Some of the following parts will need to be fabricated. Dimensions will follow later in this Special Instruction.

Processes for Welding

Use the following electrodes: low hydrogen E7018 electrode, E70S-3 (dual shield) solid wire and E71T-1 flux cored wire.

All electrodes must be completely dry.

Do not weld in areas if there is a strong movement of air or in temperatures of less than 16 deg C (61 deg F).

The following welding processes are acceptable for this procedure:

• Gas metal arc welding (GMAW)Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The AWS Class ER70S-3 is a welding process that can be used with the following welders: Lincoln L-50 and Hobart HB-25 or comparable equipment.

• Flux cored arc welding (FCAW)Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The FCAW process is called the AWS Class E71T-1 process.

• Shielded metal arc welding (SMAW)Use E7018 electrodes in this DCEP process.

• Air arc gouging (DCEP)Use 5/16 inch diameter rods for carbon arc.

References

Reference: Refer to Special Instructions, REHS1841, "General Welding Procedures" for additional welding instructions.

Reference: Guide, SEBD0512-01, "Service Welding Guide".

Replacement of the Equalizer Bar Saddle

Note: Replacement of the equalizer bar saddle is a labor-intensive procedure. Use this procedure only if repair procedures are not an option.

Note: The illustrations in this procedure may look different from your machine. These illustrations are of a D6T case and frame assembly.

Preparation

Refer to the appropriate Disassembly and Assembly modules for information on removing and installing various components.

1. Remove the engine, the torque converter, all the wiring harnesses, and all the hoses from the engine compartment.

2. Remove the two track roller frames and the equalizer bar.

3. Securely cover all opening to hose and cover all openings in the operator station in order to control the contamination.

Removal Procedure

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Illustration 1	g01427910
(A) Scribed lines (AA) Weld two Tools (AA) across the top of the case and frame assembly. Weld one Tool (AA) into position above the equalizer bar saddle. Weld one Tool (AA) near the front of the equalizer bar saddle. In order to anchor the Tools, weld longitudinally in the center of the top side plate. (W1) 8 mm (0.3 inch) Fillet weld

1. Weld two Tools (AA) to one side of the case and frame assembly with weld (W1) in order to align the case and frame assembly before the new equalizer bar saddle is welded into position. Scribe the position of the free ends of Tools (AA) on the case and frame assembly. Scribed lines (A) provide a reference for realignment of Tooling (AA) prior to welding the new equalizer bar saddle.
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   Illustration 2	g01427911
   (A) Scribed lines (AA) Weld Tool (AA) across the bottom of the case and frame assembly. (W2) 8 mm (0.3 inch) Fillet weld

2. Weld Tooling (AA) to one side of the case and frame assembly with weld (W2) in order to align the case and frame assembly before the new equalizer bar saddle is welded. Scribe the position of the free end of Tooling (AA) on the case and frame assembly. The scribed lines (A) provide a reference for realignment of Tooling (AA) prior to welding the new equalizer bar saddle to the case and frame assembly.
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   Illustration 3	g01428441

3. Mark the location of the support for the belly guard that is located behind the equalizer bar saddle. The marks are used in order to provide alignment of the supports during the reinstallation of the supports for the belly guard.

4. Repeat Step 3 for the other side.

5. Remove the two supports for the belly guard.
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   Illustration 4	g01428100

6. Install Tooling (BB) to the equalizer bar saddle with pin (DD), bolt (EE), washer (FF) two bolts (GG), and two washers (HH). Tighten the bolts.
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   Illustration 5	g01428440
   (W3) 10 mm (0.4 inch) Fillet weld, two places (W4) 10 mm (0.4 inch) Fillet weld

7. Position Tooling (CC) against Tooling (BB) and the inside of the case and frame assembly. Weld Tooling (CC) to the case and frame assembly with weld (W3).

8. Weld one Tool (CC) to Tool (BB) with weld (W4) on the same side of the case and frame assembly as Tools (AA) are welded to the case and frame assembly.
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   Illustration 6	g01429119
   (B) No welds in this area (W5) 10 mm (0.4 inch) Fillet weld

9. Position Tooling (CC) against Tooling (BB) and the inside of the case and frame assembly. Weld Tooling (CC) to the case and frame assembly with weld (W5).

10. Do not weld the second Tool (CC) to Tool (BB) in order to allow for removal of the equalizer bar saddle.

11. Install a suitable lifting device to the equalizer bar saddle. The weight of the equalizer bar saddle is 105 kg (230 lb).
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    Illustration 7	g01428448

    Note: Use of an insulator is required on the lifting devices when air arc gouging is used to remove the metal from the welds.

12. Use air arc gouging to remove the welds from under the ends of the equalizer bar saddle and the side plates of the case and frame assembly. Use air arc gouging in order to remove the remaining welds around the equalizer bar saddle.

13. Repeat Step 12 for the other side of the case and frame assembly.

14. Remove pin (DD), bolt (EE), washer (FF) two bolts (GG), and two washers (HH). See Step 6.

15. Lower the old equalizer bar saddle from the case and frame assembly. It may be necessary to spread the side plates of the case and frame assembly slightly in order to remove the equalizer bar saddle.

16. Grind the side plates of the case and frame assembly smooth and flat.

Preparation of the Equalizer Bar Saddle for Installation

In order to achieve proper weld penetration, a chamfer must be ground into the replacement equalizer bar saddle. Due to the differences in the construction of the standard case and frame assembly and the "VPAT" case and frame assembly with solid side plates, the chamfers are different.

Illustration 8	g01428463
Standard Machine Preparation of the equalizer bar saddle for installation to a standard case and frame assembly

For a standard case and frame assembly, grind a 2 mm (0.08 inch) by 2 mm (0.08 inch) chamfer between point "AA" and point "AB" on both ends of the equalizer bar saddle.

Illustration 9	g01428464
"VPAT" machines Preparation of the equalizer bar saddle for installation to a case and frame assembly with solid side plates

For a "VPAT" case and frame assembly with solid side plates, grind a 2 mm (0.08 inch) by 2 mm (0.08 inch) chamfer all around on both ends of the equalizer bar saddle.

Installation Procedure of the Equalizer Bar Saddle

Note: The illustrations in this procedure may look different from your machine. These illustrations are of a D6T case and frame assembly.

Note: In order to install the new equalizer bar saddle, it may be necessary to slightly spread the side plates of the case and frame assembly.

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Illustration 10	g01428476

1. Lift a new equalizer bar saddle (1) into position against Tooling (BB).
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   Illustration 11	g01428479

2. Install pin (DD) through tooling (BB) and equalizer bar saddle (1). Install bolt (EE), washer (FF) two bolts (GG), and two washers (HH). Tighten the bolts.
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   Illustration 12	g01428498
   (A) 828 mm (32.6 inch) Reference (B) 977 mm (38.5 inch) Reference (C) 1010 mm (39.8 inch) Reference (C) 770 mm (30.3 inch)

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   Illustration 13	g01428482
   (W6) 8 mm (0.3 inch) Fillet weld

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   Illustration 14	g01428483
   (W7) 8 mm (0.3 inch) Fillet weld

3. Align the side plate of the case and frame assembly and Tooling (AA) to scribed lines (A) created in Step 1 of the "Installation Procedure of the Equalizer Bar Saddle". Verify with the reference dimensions provided in Illustration 12. Weld Tooling (AA) to the side plate in three places with welds (W6) and weld (W7).
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   Illustration 15	g01428587

   Note: Do not start welds or stop welds in the corners.

4. Tack weld equalizer bar saddle (1) into position. Place the tack welds in the center of the straight sections as indicated by the arrows.

5. Repeat Step 4 for the other side of the case and frame assembly.

   Note: For Standard Machine use Steps 6 through Step 11.

   Note: For "VPAT" Machines use Step 12 through Step 17.

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   Illustration 16	g01448386
   Standard Machine Welds for the standard case and frame assembly (W8) 6 mm (0.24 inch) Square groove weld (W9) 6 mm (0.24 inch) Square groove weld (W10) 6 mm (0.24 inch) Fillet weld with 2.5 mm (0.1 inch) weld penetration

   Note: Do not start welds or stop welds in the corners.

6. Finish weld equalizer bar saddle (1) to the case and frame assembly with weld (W10) from point "ABA" to point "ACA" at the bottom of the equalizer bar saddle.

7. Finish weld equalizer bar saddle (1) to the case and frame assembly with weld (W8) from point "ACA" to point "AAA" over the top of the equalizer bar saddle.

8. Repeat Step 6 and Step 7 for the other side of the case and frame assembly.

9. Remove pin (DD), bolt (EE), washer (FF) two bolts (GG), and two washers (HH). See Step 2 "Installation Procedure of the Equalizer Bar Saddle".

10. Finish weld equalizer bar saddle (1) to the case and frame assembly with weld (W9) from point "AAA" to point "ABA".

11. Repeat Step 11 for the other side of the case and frame assembly.
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    Illustration 17	g01447759
    "VPAT" Machines Welds for the case and frame assembly with solid side plates (W11) 12 mm (0.48 inch) Fillet weld with 2.5 mm (0.1 inch) weld penetration (W12) 12 mm (0.48 inch) Fillet weld with 2.5 mm (0.1 inch) weld penetration (W13) 12 mm (0.48 inch) Fillet weld with 2.5 mm (0.1 inch) penetration

    Note: Do not start welds or stop welds in the corners.

12. Finish weld equalizer bar saddle (1) to the case and frame assembly with weld (W13) from point "AEA" to point "AFA" at the bottom of the equalizer bar saddle.

13. Finish weld equalizer bar saddle (1) to the case and frame assembly with weld (W11) from point "AFA" to point "ADA" over the top of the equalizer bar saddle.

14. Repeat Step 12 thru Step 13 for the other side of the equalizer bar saddle and the case and frame assembly.

15. Remove pin (DD), bolt (EE), washer (FF) two bolts (GG), and two washers (HH). See Step 2 "Installation Procedure of the Equalizer Bar Saddle".

16. Finish weld equalizer bar saddle (1) to the case and frame assembly with weld (W12) from point "ADA" to point "AEA" at the bottom of the equalizer bar saddle.

17. Repeat Step 16 for the other side of the equalizer bar saddle and the case and frame assembly.
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    Illustration 18	g01428607

18. Remove the welds on the ends of Tooling (AA) on the side plates of the case and frame assembly by air arc gouging. Remove the welds on the ends of Tooling (CC) on the side plates of the case and frame assembly by air arc gouging.

19. Grind the side plates of the case and frame assembly smooth and flat.
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    Illustration 19	g01428614
    (W14) 6 mm (0.24 inch) Fillet weld with 1.5 mm (0.06 inch) weld penetration, 2 places

20. Position the supports for the belly guard to the original locations for the supports as marked in Step 3 of the "Removal Procedure". Weld the supports for the belly guards with weld (W14).

21. Repeat step 20 for the other side of the case and frame assembly.

22. Grind all welds and blend all welds.

23. Paint all the areas where welding and grinding has occurred.

Fabricated Tooling

Tooling "AA"

Note: Three Tools (AA) are required.

Illustration 20	g01428244
Tooling (AA) ( A) 50 mm (2 inch) (B) 1050 mm (41.3 inch) (C) 25 mm (1 inch)

Tool Assembly "BB"

Note: One Tool (BB) is required.

Illustration 21	g01428118
Plate (1) ( A) 152.4 mm (6 inch) (B) 920 mm (36 inch) (C) 25 mm (1 inch)

Illustration 22	g01428119
Plate (2) ( A) 152.4 mm (6 inch) (B) 240 mm (9.5 inch) (C) 50 mm (2 inch) Cold Finished Steel

Illustration 23	g01428121
Tooling (BB) ( A) 70.50 ± .25 mm (2.776 ± 0.010 inch) Diameter (B) 26.00 ± .25 mm (1.024 ± 0.010 inch) diameter (C) 54.42 mm (2.142 inch) (D) 11.0 +.3 / −.1 mm (0.433 + 0.012 / −0.040 inch) diameter, 2 holes (E) 95.25 mm (3.750 inch) (F) 120 mm (4.7 inch) (G) 460 mm (18.1 inch) (H) 95.25 mm (3.750 inch) (W1) 6 mm (0.24 inch) Fillet weld

Tool Assembly "CC"

Note: Two Tool Assemblies (CC) are required.

Illustration 24	g01428123
Plate (3) ( A) 130 mm (5 inch) (B) 235 mm (9.3 inch) (C) 25 mm (1 inch)

Illustration 25	g01428125
Plate (4) ( A) 130 mm (5 inch) (B) 50 mm (2 inch) (C) 25 mm (1 inch)

Illustration 26	g01428126
Tool (CC) ( A) 10 mm (0.3 inch) (W1) 10 mm (0.3 inch) Fillet weld