18/4/22, 16:45 SIS 2.

2018/01/22 Repair Of The Main Frame And Radiator Mount {1353, 7050} (REHS1243-05)

SMCS - 1353, 7050 i07187894 

Track-Type Tractor
D10R (S/N: 3KR1-UP; AKT1-UP)
D10T (S/N: RJG1-UP)
D10T2 (S/N: RAB1-UP; JJW1-UP)

Introduction
This Special Instruction provides the information that is necessary to repair some cracks in the main frame.

The following topics are covered in this instruction:

D10R/T Frame Repair

D10R/T Rear Radiator Mount Repair

Refer to the parts list for necessary parts.

After the repair is completed, prepare the machine for service. Refer to the Operation and Maintenance Manual for proper machine preparation.

Do not perform any procedure that is outlined in this publication until you have read the information and you understand the information. Do not
order any parts until you have read the information and you understand the information.

Reference: Service Manual,Parts Book, Operation and Maintenance Manual.

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.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.

Dispose of all fluids according to local regulations and

mandates.

NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components
are filled with fluid, or during any maintenance operation.

Note: Do not coat any fasteners with oil or grease prior to tightening. Instructions are given when lubrication is required.

NOTICE
When a hoist is used to lift any part or assembly, stand clear of
the area. Always make sure the hoist has the correct capacity.
Approximate weights of the components are shown in the chart
which follows.

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D10R Frame Repair

Welding Requirements
The following processes are acceptable:

Gas Metal Arc Welding (GMAW): Use 35 ± 5 CFH of 75 percent argon, 25 percent CO2 mixed shielding gas AWS class ER70S-3 electrode
.

Flux Cored Arc Welding (FCAW).

AWS class E71T-1: Use the gas mixture and flow that is suggested by the manufacturer.

Shielded Metal Arc Welding (SMAW): Use E7018 electrode, direct current electrode positive.

Air Arc Gouging: Direct current electrode positive carbon arc rods (5/16 inch or 3/8 inch diameter).

The following processes are the preferred processes: GMAW, FCAW and E71T-1.

Parts List
Approximate Weights 
Qty  Part Number  Weight 
1  218-3334 Frame Rail  24.6 kg (54.21 lb) 

Table 1

Requirements for Materials

Use low carbon structural steel that is 16 mm (0.63 inch) thick with a minimum yield strength of 290 MPa (42060 psi) to 450 MPa (65270 psi).
This steel is for the replacement window plates and for the replacement of the fender bracket side plates.

Machine Preparation
Prepare the machine for the repair procedure.

Park the machine on level ground.

Lower the attachments to the ground.

Move the implement controls to the HOLD position. On D10R (S/N: 3KR), engage the restraint for the blade control lever and for the ripper
control lever. On D10R (S/N: AKT), D10T (S/N: RJG), and D10T2 (S/N: JJW; RAB), engage the implement control shutoff.

Move the transmission control to the NEUTRAL position.

Engage the parking brake switch.

Stop the engine.

Turn the engine start switch to the OFF position. Remove the key.

Turn the disconnect switch to the OFF position. Remove the key.

Determine the Amount of Cracking D10R Only

Note: This Section is for the D10R only.

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Illustration 1 g00848245
Template for location of the weld
(A) 262 mm (10.3 inch)

(B) 238 mm (9.4 inch)

(C) 35 mm (1.4 inch)

(D) 62 mm (2.4 inch)

(E) 35 mm (1.4 inch)

(F) 67 mm (2.6 inch)

(G) 195 mm (7.7 inch)

(H) 227 mm (8.9 inch)

(R1) 10 mm (0.4 inch) radius (four places)

(R2) 30 mm (1.2 inch) radius (two places)

1. Create a template to determine the location of the weld for the fender bracket. Use Illustration 1 for dimensions of the template.

Illustration 2 g00848215

2. Tack weld a support gusset that rests on the top rail to the top front of the top plate of fender bracket (2).Use the template to determine the
location of the fender bracket weld. Gouge out the fender bracket weld (1) on the outside plate of the fender bracket. Remove the weld
between the outside plate of the fender bracket and the top plate of the fender bracket (2). Remove the fender bracket outside plate.
Note: The support gusset should not be welded to the top rail, only to fender bracket (2).

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3. Scribe two vertical lines on the side plate (3) outside all the [Link] lines will be the sides of a window opening that will be cut in the
side plate. To avoid more vertical welds, the front line must not exceed 40 mm (1.6 inch) from the original location of the fender bracket.
Gouge out the top J-groove weld (4) between the two vertical scribed lines. Do this procedure carefully to minimize the damage to the rail.
Use the air carbon arc down the vertical scribed lines (3) until the entire section of the rail has been cleared. Repeat for the bottom J-groove
weld (5). Use a cutting torch to remove the rest of the window.
Note: If you must remove the fenders and the crossbeam, make a measurement from the bottom of the frame rail to the top of the fender
bracket (REF). Record this dimension for reassembly.

4. Inspect the top rail under the fender bracket top plate. Inspect the inside side plate of the frame. Determine the amount of cracking.

Refer to the following procedures to make the necessary repairs.

The Outside Side Plate Cracked Only D10R Only

Note: This Section is for the D10R only.

1. Use a grinder to remove carbon from the air carbon arc. Restore the J-groove weld joint at the top of the window and the bottom of the
window for each section of the rail. Clean up the sides of the window opening to remove slag or carbon.

2. Create a plate that is approximately 10 mm (0.4 inch) smaller in width and in height in contrast to the existing cut-out. Make 15 degree bevels
on the top of the rail and on the bottom of the plate. Make 30 degree bevels on the sides of the plate.

3. Create two backing strips for the side welds. The backing strips should be 25 mm (1.0 inch) wide and 10 mm (0.4 inch) thick. The length of
the strips is from the bottom of the top rail to the top of the bottom rail.

4. Install the two backing strips along the sides of the window opening. Position the backing strips so that one edge extends 15 mm (0.6 inch)
toward the inside the window opening. Tack weld the strips in place from the outside.

5. Position the window plate in the opening. Leave a 5 mm (0.2 inch) root opening on all sides of the window plate. Weld the full depth of the J-
groove welds on the top and on the bottom. Weld the full depth of the side welds. Grind all welds smooth.

Illustration 3 g00848451

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Side Plate
(A) 262 mm
(10.3 inch)

(B) 238 mm (9.4 inch)

(C) 35 mm (1.4 inch)

(D) 62 mm (2.4 inch)

(E) 35 mm (1.4 inch)

(F) 67 mm (2.6 inch)

(G) 195 mm (7.7 inch)

(H) 227 mm (8.9 inch)

(J) 16 mm (0.63 inch)

(R1) 10 mm (0.4 inch)

radius (four places)

(R2) 30 mm (1.2 inch) radius (two places)

6. Create a fender bracket side plate. Use the dimensions in Illustration 3.

7. Locate the new side plate. Tack weld the plate to the frame and the top plate. Weld the side plate to the top plate of the fender bracket
assembly. Weld a 10 mm (0.4 inch) fillet weld with 2.5 mm (0.10 inch) penetration. Weld the side plate to the frame in the U opening with a
16 mm (0.6 inch) square groove weld.

8. Remove the support gusset that was used to support the top plate of the fender bracket.

9. If the fenders and the crossbeam are removed, use the bolts at the ROPS post to assemble the fenders to the machine. Assemble the
crossbeam assembly. The fenders with the top plate of the fender bracket assembly should be attached to the crossbeam. Position the fender
according to the measurement (REF) that was taken during the disassembly procedure. See Illustration 2.

Both the Outside and the Inside Side Plates Are Cracked D10R Only
Note: This Section is for the D10R only.

1. Use the procedure in the previous section to remove the outside plate. See Illustration 2.
Note: If you must remove the fenders and the crossbeam, make a measurement from the bottom of the frame rail to the top of the fender
bracket (REF). Record this dimension for reassembly.

2. Provide support for the fender crossbeam to hold the crossbeam in place.

3. Gouge out the fender bracket weld on the inside plate of the fender bracket. Use the dimensions in Illustration 3 to determine the location of
the weld. Remove the weld between the inside plate of the fender bracket and the top plate of the fender bracket. Remove the fender bracket
inside the plate.

4. Gouge out the crack on the inside side plate in a V-groove until you break through the entire side plate. Weld the V-groove to the full depth.

5. On the opposite side of the side plate, gouge out the root of the V-groove weld that is deep enough to ensure good welding metal. Weld the
gouged out area to the full depth.

6. Grind both sides smooth.

7. Create a plate that is approximately 10 mm (0.4 inch) smaller in width and in height in contrast to the existing cut-out. Make 15 degree bevels
on the top of the plate and on the bottom of the plate. Make 30 degree bevels on the sides of the plate.

8. Create two backup strips for the side welds. The length of the strips is from the bottom of the top rail to the top of the bottom rail.

9. Install the two backup strips along the sides of the window opening. Position the backup strips so that one edge extends 15 mm (0.6 inch)
toward the inside the window opening. Tack weld the strips in place from the outside.

10. Position the window plate into the opening. Leave a 5 mm (0.2 inch) root opening on all sides of the window plate. Weld the full depth of the
J-groove welds on the top and the bottom. Weld the full depth of the side welds. Grind all welds smooth.

11. Fabricate two new fender bracket side plates. Use the dimensions in Illustration 3. Weld the side plates to the top plate of the fender bracket
assembly with a 10 mm (0.4 inch) fillet weld and 2.5 mm (0.10 inch) penetration.

12. If the fenders and the crossbeam are not removed, weld the side plates to the frame in the "U" opening with a 16 mm (0.6 inch) square
groove weld. If the fenders and the crossbeam are removed, use the bolts at the ROPS post to assemble the fenders to the machine.
Assemble the crossbeam assembly to the fenders. The top plate of the fender bracket assembly should attach to the crossbeam. Position the
fender. Use the measurement (REF) that was taken during disassembly. See Illustration 2.

The Top Rail Is Partially Cracked D10R, D10T, and D10T2

Note: This Section applies to D10R, D10T, and D10T2.

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Illustration 4 g00848361

If the top rail is partially cracked, remove the fenders and crossbeam assembly. Follow the procedures in the previous section to remove the
following components: the fenders, the crossbeam assembly, the fender bracket, and the outside window plate.

1. Gouge out the crack to create a large V-groove that allows full access for the welding gun.

2. Grind the welded area to remove any carbon.

3. Use a dye penetrant to inspect the welded area. Be sure that the crack has been removed completely.

4. Weld the V-groove to the full depth.

5. Grind the weld smooth.

6. Needle peen the welded surface.

7. If the inside plate is not cracked, follow the previous procedure to replace the outside window plate. If the inside plate is cracked, follow the
previous procedure to repair the inside plate.

8. Create a fender bracket side plate. Use the dimensions in Illustration 3.

9. Weld the side plate to the top plate of the fender bracket assembly with a 10 mm (0.4 inch) fillet weld and 2.5 mm (0.10 inch) penetration.

10. Follow the procedures in the previous section to reassemble the fenders and the crossbeam assembly to the machine.

11. Weld the side plate to the frame in the "U" opening with a 16 mm (0.6 inch) square groove weld.

The Top Rail Is Completely Cracked With Possible Separation D10R, D10T, and
D10T2
Note: This Section applies to D10R, D10T, and D10T2.

Illustration 5 g00848362

1. Follow the procedure in the previous sections to remove the fenders and the crossbeam. Support the front end of the main frame with lift
jacks and determine the amount of separation in the frame rail.

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2. Follow the procedure in the previous section to remove the fender bracket. Also, follow the procedure in the previous section to cut a window
opening in the outer plate.

3. If the frame rail has less than 2 mm (0.08 inch) separation, gouge out the crack to create a large V-groove. Remove the material until you
penetrate through the section of the rail. This removal of material will allow full access for the welding gun. Grind the welded area to remove
any carbon. Weld the V-groove to the full depth. On the opposite side of the section of the rail, gouge out enough of the root of the V-groove
weld to ensure good welding metal. Weld the gouged out area to the full depth. Grind all surfaces smooth to create the original geometry.
Needle peen all the welded surfaces.

4. If the frame rail separation is greater than 2 mm (0.08 inch), remove a window plate from the inside plate of the frame to straighten the frame.
The window plate should also remove any cracks that may be on the inside plate. Remove the window plate in a similar manner as the
outside window plate. Make the size of the inside window plate large enough to remove all the separation in the frame rail. Longer openings
may be required to eliminate the separation.

5. Lift the front section of the frame rail that has separated to close the gap in the rail. Weld a temporary weld across the bottom of the rail at the
crack to secure the two rails together. Repeat on the opposite frame rail, if necessary.

6. Start at the top of the rail. Remove the crack within 5 mm (0.20 inch) to 10 mm (0.39 inch) of the bottom of the rail. Create a V-groove weld
that is deep enough to allow full access for the welding gun. Do not go completely through the rail. Grind the surfaces to remove any carbon
that remains from the air carbon arc. Create an opening in the V-groove. Grind the weld flush with the top of the rail.

7. Remove the temporary weld and crack from the bottom by gouging into the new top weld. Use a dye penetrant to inspect the rail. Make sure
that the crack has been removed completely. Make sure that the welded material is secure. Grind the welded area to remove any carbon from
the air carbon arc. Weld the gouged out area and grind the weld flush with the bottom surface. Grind all surfaces smooth to create the original
geometry. Needle peen all the welded surfaces.

8. Follow the previous procedure to replace the window plates.

9. Create two new fender bracket side plates. Use the dimensions in Illustration 3. Weld the side plates to the top plate of the fender bracket
assembly with a 10 mm (0.4 inch) fillet weld and 2.5 mm (0.10 inch) penetration. Follow the procedure in the previous sections to reassemble
the fenders and the crossbeam to the machine. Weld the side plates to the frame in the "U" opening with a 16 mm (0.6 inch) square groove
weld.

The Top Rail Has Multiple Cracks D10R, D10T, and D10T2
Note: This Section applies to D10R, D10T, and D10T2.

1. Follow the procedures in the previous sections to remove the following components: the fenders, the crossbeam, and the fender bracket. Cut
a window opening in the outer plate.

Illustration 6 g00849022
Section of the Rail

(A) 304.8 mm (12 inch) minimum length

2. Remove the window plate from the inside plate of the frame to straighten the frame. Ensure that the piece of rail between the cracks remains
in the original intended position. Remove the window plate in a similar manner as the outside window plate. The inside window plate must be
large enough to remove all the separation in the frame rail. The window plate should also remove any cracks on the inside plate. Longer
openings may be required to eliminate the separation.

3. Lift the front section of the frame rail that has separated. Close the gap in the rail completely. Weld a strap across the upper portion of the
window opening on both the outer plates and the inner plates. This strap will secure the position of the frame rail.

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4. Weld the edges on the failed rail that are cracked in the shape of a square. Cut a 30 degree chamfer on the ends to create an opening at the
V-groove weld. Remove the failed rail. Use 218-3334 Rail to replace the damaged portion of the rail. See length (A) in Illustration 6. Leave a
5 mm (0.2 inch) gap (2) on each end for a root opening. The window opening in the inner plates and in the outer plates should extend past
the cracks. Install backup strips (3) under the 5 mm (0.2 inch) root opening.

5. Weld the V-groove weld to the full depth. Grind the weld flush with the top of the rail. Remove the backup strips. To remove the defects,
gouge out the weld. Grind the welded area to remove any carbon remaining from the air carbon arc. Weld the gouged out area and grind the
weld flush with the bottom surface. Grind all surfaces smooth to create the original geometry of the rail. Needle peen all welded surfaces.

6. Follow the previous procedure to replace the window plates.

7. Create two new fender bracket side plates. Use the dimensions in Illustration 3. Weld the side plates to the top plate of the fender bracket
assembly with a 10 mm (0.4 inch) fillet weld and 2.5 mm (0.10 inch) penetration.

8. Follow the procedures in the previous sections to reassemble the fenders and the crossbeam to the machine.

9. Weld the side plates to the frame in the "U" opening with a 16 mm (0.6 inch) square groove weld.

Rear Radiator Mount Repair D10R, D10T, and D10T2

Note: This Section applies to D10R, D10T, and D10T2.

Welding Requirements
The following processes are acceptable:

Gas Metal Arc Welding (GMAW): Use 35 ± 5 CFH of 75 percent argon, 25 percent CO2 mixed shielding gas AWS class ER70S-3 electrode.

Flux Cored Arc Welding (FCAW).

AWS class E71T-1: Use the gas mixture and flow that is suggested by the manufacturer.

Shielded Metal Arc Welding (SMAW): Use E7018 electrode, direct current electrode positive.

Air Arc Gouging: Direct current electrode positive carbon arc rods (5/16 inch or 3/8 inch diameter).

The following processes are the preferred processes: GMAW, FCAW and E71T-1.

Machine Preparation
Prepare the machine for the repair procedure.

Park the machine on level ground.

Lower the attachments to the ground.

Move the implement controls to the HOLD position. On D10R (S/N: 3KR), engage the restraint for the blade control lever and for the ripper
control lever. On D10R (S/N: AKT), D10T (S/N: RJG), and D10T2 (S/N: JJW; RAB), engage the implement control shutoff.

Move the transmission control to the NEUTRAL position.

Engage the parking brake switch.

Stop the engine.

Turn the engine start switch to the OFF position. Remove the key.

Turn the disconnect switch to the OFF position. Remove the key.

Determine the Amount of Cracking D10R, D10T, and D10T2

Note: This Section is for the D10R, D10T, and D10T2.

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Illustration 7 g00892168
D10R Rear Radiator Support
(1) Fillet Weld

Illustration 8 g06248535
D10T and D10T2 Rear Radiator Support
(1) Groove Weld

Examine the fillet weld for D10R or the groove weld for the D10T and the D10T2 between the radiator mounting bracket and the support plate that
is on the side of the frame. See Illustration 7 for D10R and Illustration 8 for D10T and D10T2.

Refer to the following procedures to make the necessary repairs.

Crack Extends Across Part of the Length of the Weld

1. Gouge out the portion of the weld that is cracked. Use dye penetrant to ensure that the entire crack has been removed.

2. If the weld is removed at either end of the weld, build up a weld dam on the end or use a copper plate to act as a weld dam for the weld.

3. Weld a 16 mm (0.630 inch) fillet weld with 2.5 mm (0.098 inch) penetration for D10R. Weld a 19 mm (0.748 inch) groove weld for D10T and
D10T2. Ensure good penetration into the existing portion of the weld. If a copper plate was used, remove the copper plate from the end of the
weld.

Crack Extends Across the Entire Length of the Weld

1. Gouge out half of the length of the weld. Use dye penetrant to ensure that the entire crack has been removed.

2. Build up a weld dam on the end or use a copper plate to act as a weld dam for the weld.

3. Weld a 16 mm (0.630 inch) fillet weld with 2.5 mm (0.098 inch) penetration for D10R. Weld a 19 mm (0.748 inch)groove weld for D10T and
D10T2. Ensure good penetration into the existing portion of the weld. If a copper plate was used, remove the copper plate from the end of the
weld.

4. Gouge out the second half of the cracked weld, and include some of the weld that was created. Use dye penetrant to ensure that all the crack
has been removed.

5. Build up a weld dam on the end or use a copper plate to act as a weld dam for the weld.

6. Weld a 16 mm (0.630 inch) fillet weld with 2.5 mm (0.098 inch) penetration for D10R. Weld a 19 mm (0.748 inch) groove weld for D10T and
D10T2. Ensure good penetration into the weld that was created previously. If a copper plate was used, remove the copper plate from the end
of the weld.

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PIP-10616642
2022/04/18
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