BRAKE-PARKING 2303366 - Caterpillar

Introduction
This Special Instruction provides the necessary information required to repair high hour fatigue cracks in front frame axle pads on the machines listed above.Do not perform any procedure outlined in this publication, or order any parts until you read and understand the information contained within.Reference: Service Manual.Weld Specifications
SMAW (Stick) E7018 OR EquivalentGMAW-CO2 (MIG) ER705-3 OR EquivalentFCAW (Gas Shield) E71T-1 OR Equivalent.Weld Procedure
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 the 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, 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.
Repair Procedure
1. Clean the surface of the area to be welded so that it is free from oil, grease, paint, rust or scale. These materials displace hydrogen gas when in contact with intense heat. The gas causes weld porosity and weld deposit cracking.Remove oil and grease with solvent and allow to dry. Remove paint, rust, dirt and scale with a wire wheel/brush or with a fiber flap wheel.2. Maintain the frame at a temperature of 10°C (50°F) or above.3. Arc gouge the crack until the debris is completely removed. Extend the gouging to 6 mm (.24 in) beyond the end of each crack. A minimum backwall thickness of 5 mm (.20 in) is to be maintained to prevent burn through.4. Grind the gouged area to remove any burning debris and prepare the weld area such that a V-groove of 45-60° included angle is formed.5. Weld the repair area using appropriate process and filler metal chosen. Refer to Weld Specifications. The welds are preferred to be done in the flat position if possible.6. Remove the slag and clean the weld after each patch.7. Grind the repaired area smooth and flush with the surface. Make sure it is free of porosity, undercuts or cracks.
Avoid high grinding pressures that can cause excessive heat and discoloration of the weld material.
Gusset (1).
Gusset (2). (K) Follow profile of cast surface from L to M.8. Using the dimensions shown in the illustrations, fabricate two gussets (1) and two gussets (2). Use 20 mm (.8 in) thick steel plate.
Top View.
Right Side View.
Front View.9. Using the following weld chart and dimensions provided in the illustrations, locate and weld 4 gussets (1) and (2) on each side of the machine.