COUPLING AS-REFRIGERANT 4160625 - Caterpillar

Repair Procedure
1. Remove all oil, grease, paint and inspection decals from the area. Remove surface oxides from the area for repair.2. Protect all machined from sparks or spatter produced by air carbon arc cutting, flame cutting, welding and grinding processes.3. Repairs should be made with the roller frame assembly at a temperature of 20°C (68°F) with protection from drafts, especially in cold weather.4. Use the air carbon arc or flame cutting process to remove plates (1), (2) and (3). Save the plates for later use. After the plates are removed, remove the broken tube section from the box assembly. 5. Grind the box assembly area smooth. Eliminate any rough edges which may become a stress point during fabrication. 6. Weld a lifting eye to the top of the box assembly as shown. This is used to hoist the box assembly onto the fixture.
Lifting eye installed.7. Clean the four bogie bores in the box assembly with a die grinder and a metal surfacing disc.
Inner ring in position.8. Install Rings "B" (part of FT2256 Tooling) in the inner bores and place the box assembly onto the fixture. 9. Carefully align the bogie bores with the bores in the fixture as shown.10. Slide the shaft (part of FT2256 Tooling) through the bogie and fixture bores as shown. 11. Install Rings "A" (part of FT2256 Tooling) onto each end of the shaft and into the bogie bores.
Remaining rings installed.12. Level the face of the box section, using the adjustable screw on the fixture.Place the appropriate tube assembly onto the fixture and slide it against the face of the box section.Fit the top and bottom of the tube flush, in alignment with the top and bottom of the box assembly. 13. After alignment, scribe a line around the O.D. of the tube onto the face of the box assembly.
O.D. of the tube assembly scribed on face of box assembly.14. Lift the box assembly into a vertical position
Box assembly rotated.15. Place 7T1428 Ring (4) in the center of the scribed circle and place tack welds on the I.D. of the ring to the box assembly. For the D8N, place the 7T4212 Shaft in the center of the scribed circle and place tack welds on the O.D. of the shaft to the box assembly. The D8N uses the 7T4212 Shaft instead of a ring. 16. Make a 10 mm (.4 in) fillet weld on the I.D. of the ring. For the D8N, make a 8 mm (.3 in) bevel groove weld on the O.D. of the 7T4212 Shaft. The D8N weld should not extend beyond the O.D. of the shaft by 1 mm (.04 in) maximum. This dimension will provide for the stop tube clearance.
D8N Only17. Lower the box assembly back onto the fixture and slide the tube back against the face of the box assembly.18. Align the sides of the bulkhead with the arms on the box assembly.
Align bulkhead and box assembly.19. Tack weld the tube to the box assembly using an alternating sequence