Replacing Ripper Adapters And Adapter Noses {6310, 6808, 6810} Caterpillar

Track-Type Tractor

D10 (S/N: 84W1-UP; 76X1-UP)

D10N (S/N: 2YD1-UP; 3SK1-UP)

D10R (S/N: 3KR1-UP; AKT1-UP)

D10T (S/N: RJG1-UP)

D10T2 (S/N: RAB1-UP; JJW1-UP)

D11N (S/N: 4HK1-UP; 74Z1-UP)

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; DDD1-UP; MDG1-UP; JEL1-UP; RAL1-UP; JNS1-UP)

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)

D5R (S/N: D5L1-UP; D5X1-UP)

D5R2 (S/N: R5A1-UP)

D6G Series 2 (S/N: C6G1-UP; P6G1-UP; 2MJ1-UP; 3SR1-UP; C6X1-UP)

D6G Series II (S/N: BWJ1-UP)

D6K (S/N: DHA1-UP; NCF1-UP; HMG1-UP; FBH1-UP)

D6K2 (S/N: MXK1-UP; DFR1-UP; JTR1-UP; RPR1-UP; RST1-UP)

D6M (S/N: 9ZM1-UP; 2RN1-UP; 3WN1-UP; 4JN1-UP; 5NR1-UP; 5WR1-UP; 6LR1-UP; 2YS1-UP; 4GS1-UP; 4HS1-UP)

D6N (S/N: MG51-UP; GB61-UP; SC61-UP; DJA1-UP; PBA1-UP; CBF1-UP; CCG1-UP; ALH1-UP; JAH1-UP; CBJ1-UP; CCK1-UP; CBL1-UP; AKM1-UP; ALR1-UP; LJR1-UP; PER1-UP; CCS1-UP; GHS1-UP; P5T1-UP; MLW1-UP; ALY1-UP; DJY1-UP)

D6R (S/N: A6M1-UP; EMM1-UP; 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; JEN1-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; S6T1-UP; 1RW1-UP; S6X1-UP; S6Y1-UP; C6Z1-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; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6R2 (S/N: PPP1-UP; SSS1-UP; TTT1-UP)

D6T (S/N: CR31-UP; CG81-UP; SGA1-UP; JHB1-UP; KSB1-UP; JZC1-UP; SMC1-UP; DTD1-UP; JWD1-UP; LBD1-UP; RAD1-UP; LAE1-UP; STE1-UP; DJG1-UP; WCG1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; SNK1-UP; KJL1-UP; MEL1-UP; SKL1-UP; TSM1-UP; KMR1-UP; PLR1-UP; GCT1-UP; SGT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; TMY1-UP; HTZ1-UP; PEZ1-UP)

D7E (S/N: HKA1-UP; TJA1-UP; 47A1-UP; 48A1-UP; 95A1-UP; MDB1-UP; SCG1-UP; SSH1-UP; TAN1-UP; LTW1-UP)

D7R (S/N: R7B1-UP; R7C1-UP; DSH1-UP; R7H1-UP; 9HM1-UP; DLN1-UP; 2EN1-UP; 3DN1-UP; DJR1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; CBZ1-UP; 5KZ1-UP)

D7R Series II (S/N: EEA1-UP; KNA1-UP; AEC1-UP; AFG1-UP; ABJ1-UP; BNM1-UP; BRM1-UP; AGN1-UP; BRP1-UP; ACS1-UP; BPT1-UP; DJT1-UP; ADW1-UP; BNX1-UP)

D8K (S/N: 66V1-UP; 76V1-UP; 77V1-UP)

D8L (S/N: 4FB1-UP; 7YB1-UP; 7JC1-UP; 53Y1-UP)

D8N (S/N: 9TC1-UP; 1XJ1-UP; 5TJ1-UP; 7TK1-UP)

D8R (S/N: JR81-UP; MEJ1-UP; RJM1-UP; 7XM1-UP; 9EM1-UP; T5X1-UP)

D8R Series II (S/N: AKA1-UP; 6YZ1-UP)

D8T (S/N: AW41-UP; MB81-UP; J8B1-UP; FMC1-UP; MLN1-UP; FCT1-UP; KPZ1-UP)

D9H (S/N: 12U1-UP; 90V1-UP; 97V1-UP; 98V1-UP; 99V1-UP)

D9L (S/N: 14Y1-UP)

D9N (S/N: 1JD1-UP; 5FJ1-UP; 6XJ1-UP)

D9R (S/N: JJB1-UP; HWH1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

D9T (S/N: TWG1-UP; RJS1-UP; REX1-UP)

Introduction

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

Safety Section

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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 kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Required Parts

Installation Procedure

Introduction

Illustration 1	g06028814
Pin hole failure

Illustration 2	g06028815
Above pin hole failure

After many hours of operation or when a great deal of tip chatter occurs, ripper shanks may eventually fail from fatigue either through the tip pin hole or just above the pin hole. Refer to Illustrations 1 and 2 the most common type of ripper failures that are repairable.

Illustration 3	g06028816
Failure through lower protector hole

Failures also occur through the lower protector pin hole. Refer to Illustration 3. As with the other two types of failures, the shanks can usually be repaired with an applicable R450, R500, or R550 adapter nose or adapter.

Illustration 4	g06028822
Basic style of ripper adapters

On the R350 and R300 rippers, the failures also occur through the tip pin hole though a larger replacement adapter is available for the R350 size rippers when the lower portion of the unprotected shank becomes heavily worn.

Illustration 4 identifies the basic style of ripper adapters and noses available for a repair.

The R450 full adapter contains all three pin holes and can also be used to upgrade older shanks with old style ripper pin holes without counter-bores. Other non-dozer type machines can also use the same R350 and R300 ripper noses listed in Table 1.

Preparing Shanks For Adapter Replacement

R450, R500, R550 Adapters

1. Trimming shanks for parts replacement and welding the new adapters into place requires care to ensure that upper and lower protector pin holes are properly spaced for mounting protectors and that the adapter nose angles are properly set.
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   Illustration 5	g06028833
   Trim position

2. Place a new adapter on top of the broken shank. With new ripper pins inserted into the lower protector and tip pin holes, line up the adapter with the front edge of the shank. Often, half of the tip pin hole remains and can still be used as a guide. Place a straight edge against the top edge of the adapter. Refer to Illustration 5.
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   Illustration 6	g06028834
   Trim mark

3. Holding the straight edge in place, remove the adapter and mark where the shank will be cut at (C) to accept the new adapter. Refer to Illustration 6.
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   Illustration 7	g06028842
   (E) 9.7 mm (0.38 inch)

4. Draw or mark a second line (D), at dimension (E) or more, below line (C). Refer to Illustration 7. The first torch cut (rough cut) will be on line (D) followed by a second final torch cut (precision cut) at line (C).
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   Illustration 8	g06028860
   (F) Trim line

5. R450 shanks with a cross section of 75 mm (2.95 inch) x 332 mm (13.07 inch) are slightly larger at the fit up position than the 8E-8418 Adapter. In this situation, lay the adapter at the proper location with the front edge lined up and mark the back portion of the shank that will be trimmed away. Refer to Illustration 8.

R300, R350 Adapter Noses

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Illustration 9	g06028872
Trim position

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Illustration 10	g06028878
Trim marks

1. The V-shape of the R300 and R350 noses require marking two angled lines on the ripper shank. Refer to Illustrations 9 and 10. The angled lines are similar to the cut locations (C) and (D) in Illustration 7. If there is an insufficient amount of the lower shank remaining, use two adjustable straight edges clamped together at the correct angle. Refer to angle (A) in Ripper Shank Repair Adapters Table 1, to assist in positioning the adapter nose before marking the shank. See example of device in Illustration 12.

All Adapters

Trim away the marked lower portion of the shank. Pre-heat the area around mark (C) and (D) to at least 149° C (300° F). Refer to Illustrations 7and 10.

Remove heat source and check the shank temperature after one minute. Reheat if the temperature drops more than 10° C (50° F). Make a rough cut on the shank along line (D). While the shank is still hot, make a precision cut on the shank along line (C). Remove all the slag from the cutting operation.

Attaching A New Adapter

R550, R500, R450

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Illustration 11	g06028893
R450, R500, and R550

1. Line up the replacement adapter against the cut shank and verify that the shank has been properly cut so that the hole spacing is correct between the upper and lower protector pin holes (B). Refer to Illustration 11. Verify that the top face of the adapter nose is set at a 140°angle (A) with respect to the front vertical edge of the shank. Refer to Table 1.
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   Illustration 12	g06028927
   Setting adapter nose angle

2. This angle can be checked by using a simple adjustable square gauge and protractor shown in Illustrations 12. The front edge of any adapter should always be even with the front edge of the mating shank. When the adapter and shank are of two different thicknesses, shim the thinner part until the ends are properly centered with each other. Disc grind any irregularities on the cut portion of the shank that would prevent a proper setup. Also Clamp or tack weld the new adapter to the shank to insure that there is no movement or separation during the first weld passes

R300, R350

Illustration 13	g06028937
R300 and R350

Place the new adapter against the bottom of the cut shank and verify that angle (A) between the front vertical edge of the shank and top face of the replacement nose is 135° or 140° as specified in Table 1. Refer to Illustration 13. Clamp or tack weld the new adapter to the shank to insure that there is no movement or separation during the first weld passes.

Welding Sequence

1. Preheat an area at least 76 mm (3 inch) wide of both sections to be joined to 149° C (300° F).

2. Weld with low hydrogen AWS E110-18, 5 mm (0.19 inch) stick electrode, or AWS E110C-G Gas shielded metal cored wire with low diffusible hydrogen levels.
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   Illustration 14	g06028952
   Starting weld passes

3. Starting at the front edges of the ripper shank and adapter (1), apply a single pass weld along the full length of the joint. Return to the front edge with a second pass (2) as shown in Illustration 14.
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   Illustration 15	g06028972
   Weld sequence

4. Turn the shank assembly over and add two weld passes (a), shown in Illustration 15. Continue adding alternating weld passes from side to side.

5. Should the adapter pull away and is no longer parallel, (b), add additional welds to the opposite side (b). As those welds cool and shrink, the adapter will flatten. Continue on with additional alternating passes until there is an excessive amount of weld to the sides and front and rear edge surfaces (c).
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   Illustration 16	g06028975
   Finish grinding

6. The welds should then be ground flush with the existing surfaces using a vertical motion to eliminate any surface imperfections. Refer to Illustration 16 and grind in the direction of the arrows. Round the corners, matching the original profile.
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   Illustration 17	g06029166
   (3) Shank (4) Weld (5) 103-8115 Adapter (A) 90 mm (3.54 inch) (B) 100 mm (3.94 inch)

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   Illustration 18	g06029172
   (3) Shank (4) Weld (5) 8E-8418 Adapter (C) 90 mm (3.54 inch) (D) 74.6 mm (2.94 inch)

7. There will be differences in thickness between some shanks and the adapter replacements. Refer to Illustrations 17 and 18. Add excessive weld as in Step 5, Illustration 15 and then blend between the two sections. Refer to Illustrations 17 and 18. The finished welds should be blended as seen in Illustration 16 and have no cavities or rough surfaces which can cause early failure.