CONTROLLER 4606428 - Caterpillar

The Following Welding Processes are Acceptable for this Repair
Table 2
Shielded Metal Arc Welding (SMAW)
Use E7018 Electrode    
   
Direct Current Electrode Positive    Repair Procedure
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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Follow all safety procedures typical of radiator guard removal. Refer to the D&A Module, "Radiator Guard - Remove" for your particular machine for the proper procedures. This module is located in the service manual for your machine.
Remove the radiator guard for the repair procedure.
Clean the radiator guard thoroughly and inspect the guard for cracks.
Illustration 1 g00796518
If the guard is cracked all the way from the front corner of the casting back into the bore for the lift cylinder yoke, the radiator guard is not repairable. See Illustration 1. Salvage the radiator guard and install a new guard.
Illustration 2 g00793084
Crack in the corner of the guard
Illustration 3 g00793116
Air arc gouging
Use air arc gouging to burn out the crack. Burn approximately 1/2 way through the radiator guard. Use a grinder to clean out the groove. Remove the slag and the carbon with the grinder.
Illustration 4 g00793119
Welding the groove
Use a weaving technique to weld the groove in layers.
Illustration 5 g00793125
Grind the weld to the original profile.
Illustration 6 g00793132
Back side of the guard
Turn over the radiator guard and remove the crack from the back side of the guard. Use air arc gouging to remove the crack completely.
Illustration 7 g00793145
Weld the crack.
Weld the groove in layers by using a weaving technique.
Illustration 8 g00793146
Grind the weld.
Use a grinder on the welded area to remove carbon and slag. Use a dye penetrant to check the crack in order to make sure that the crack is completely removed.
Follow all safety procedures typical of radiator guard installation. Refer to the D&A Module, "Radiator Guard - Install" for your particular machine for the proper procedures. This module is located in the service manual for your machine.
Reinstall the radiator guard.