Relocation of the Fumes Disposal Tube{1317} Caterpillar

Track-Type Tractor:

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)

Introduction

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

This Special Instruction does not apply to any D6R Series II Track-Type Tractor with the VPAT attachment.

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.

Parts List

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

ReferenceRefer to Special Instructions, REHS1841, "General Welding Procedures" for additional welding instructions.

ReferenceGuide, SEBD0512-01, "Service Welding Guide".

ReferenceRefer to Disassembly and Assembly, RENR4261 for more information on removing the bottom guards.

ReferenceRefer to Disassembly and Assembly, RENR4276 for more information on removing the bottom guards.

Procedure

1. Remove the front bottom guard and remove the middle bottom guard.

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Illustration 1	g01433855
(1) 5P-0597 Hose Clamp (2) 220-4293 Hose (3) 5P-4325 Clip (4) 8T-4136 Bolt (5) 8T-4121 Hard Washer

2. Remove clamp (1), hose (2), clip (3), bolt (4) and washer (5). Discard the components that were removed.

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Illustration 2	g01433862

3. Clean area (6) and remove the paint on the inside left frame rail.

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Illustration 3	g01433872
(7) 286-2562 Plate (A) 105 mm (4.1 inch) (B) 100 mm (3.9 inch) (C) 40 mm (1.6 inch)

4. Weld plate (7) onto the left hand side frame rail. Use the dimensions in Illustration 3 in order for the tube to drain forward.

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Illustration 4	g01433919
(7) 286-2562 Plate (8) 9U-7068 Tapered Cap/Plug

5. Cover the threaded holes in plate (7) with plugs (8). Covering the threads will protect the threads against paint. Paint plate (7) in order to prevent corrosion. Remove plugs (8) from plate (7) .

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Illustration 5	g01433971
(7) 286-2562 Plate (9) 4S-1962 Clip (10) 308-7067 Tube (11) 8T-4195 Bolt (12) 8T-4121 Hard Washer

6. Install tube (10) to plate (7). Use two clips (9), two bolts (11) and two washers (12) in order to install the tube to the plate.

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Illustration 6	g01434031
(13) 9M-0164 Hose Clamp (14) 230-9796 Duct As

7. Install the 50.80 mm (2.0 inch) side of duct (14) to the engine. Use hose clamp (13) in order to secure duct (14) .

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Illustration 7	g01434191
(10) 308-7067 Tube (14) 230-9796 Duct As (15) 2S-3440 Hose Clamp

8. Secure the 25.4 mm (1.0 inch) side of duct (14) to tube (10). Use clamp (15) in order to secure duct (14) to tube (10) .

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Illustration 8	g01434206
(14) 230-9796 Duct As (16) Hydraulic tilt line (17) 9X-8250 Clip (18) 8T-4133 Nut (19) 6V-1889 Clip (20) 8T-4136 Bolt (21) 8T-4121 Hard Washer

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Illustration 9	g01434222
(14) 230-9796 Duct As (16) Hydraulic tilt line (17) 9X-8250 Clip (18) 8T-4133 Nut (19) 6V-1889 Clip (20) 8T-4136 Bolt (21) 8T-4121 Hard Washer

9. Secure duct (14) to hydraulic tilt line (16). Use clip (17), clip (19), two washers (21), bolt (20) and nut (18) in order to secure duct (14) .

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Illustration 10	g01434234
(14) 230-9796 Duct As (22) 6V-1889 Clip (23) 8T-4136 Bolt (24) 8T-4133 Nut (25) Hydraulic lift line (26) 8T-4121 Hard Washer (27) 184-7211 Clip

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Illustration 11	g01434242
Refer to Illustration 10 for the components of area (28) .

10. Secure duct (14) to hydraulic lift line (25). Use clip (22), clip (27), two washers (26), bolt (23) and nut (24) in order to secure duct (14) .

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Illustration 12	g01434398
(14) 230-9796 Duct As (29) 8T-4136 Bolt (30) Hydraulic lift line (31) 6V-1889 Clip (32) 8T-4121 Hard Washer (33) 114-9223 Spacer (34) 8T-4133 Nut (35) 184-7211 Clip

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Illustration 13	g01447053
Refer to Illustration 12 for the components of area (36) .

11. Paint spacer (33) in order to prevent corrosion. Secure duct (14) to hydraulic lift line (30). Use clip (31), clip (35), spacer (33), two washers (32), bolt (29) and nut (34) in order to secure duct (14) .

12. Install the front bottom guard and install the middle bottom guard.