DISC 1218845 - Caterpillar

Illustration 6 g06304832
Position the Boom with the cracked side horizontal on suitable repair stands. Refer to Illustration 6.
Illustration 7 g06304835
(A) 120 mm (4.7 inch)
(B) 650 mm (25.6 inch)
(C) 670 mm (26.4 inch)
(D) 40 mm (1.6 inch)
Use an air carbon arc torch to make a 515 mm (20.3 inch) diameter hole. Refer to Illustration 7.
Illustration 8 g06305084
(A) Top
(B) Baffle
(C) Gouging
(D) Crack (in red)
(E) Bevel
(F) Dress Weld
Remove crack (D) completely by using gouging (C) and grinding. Make bevel weld (E) and clean around baffle plate (B). Fill out bevel by weld and apply weld toe control by dress weld (F). Refer to Illustration 8.Note: Ensure strong support if putting boom upside down when repairing inner fillet welding seam between top plate and baffle plate at PT2.Note: Put PT3 pin in the ear plate to avoid deformationNote: Suggested gouging depth is 6.5 1.5 mm (0.26 0.06 inch).Note: If a great deal of smoke is produced during gouging removal, prepare a vacuum cleaner for smoke removal.
Illustration 9 g06305244
(1) Baffle Plate
(A) 178 mm (7 inch)
(B) 184 mm (7.2 inch)
Set baffle plate (1) on top plate and weld around the perimeter. Grind plate (1) as needed to achieve a good fit to the boom. Refer to Illustration 9.
Illustration 10 g06305260
(2) Backing Plate
(A) Side
(B) Bevel
(C) 520 mm (20.5 inch)
(D) Tack Weld
Bevel around hole (25° angle) by grinding. Install backing plate (2) with a tack weld. Weld on bottom baffle and bottom inside. Refer to Illustration 9.
Illustration 11 g06305552
If a weld crack is found on stick cylinder bracket and top plate, remove crack. Refer to Steps 2 through 4, gouging and grinding from inside and outside. Use of flux-tab is acceptable. Refer to Illustration .
Illustration 12 g06305571
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(4) Plate
(A) Before grinding
(B) After grinding
Weld round plate (3) and apply surface treatment by grinding for weld joint. A maximum 0.8 mm (0.03 inch) grinding undercut is permitted . Test fit plate (3) to the boom, adjust plate width by grinding. Refer to Illustration 12.
Illustration 13 g06305617
(4) Plate
Illustration 14 g06305667
(4) Plate
(A) Top
(B) Side
(C) 25 mm (0.98 inch)
(D) Notch
Test fit plate (4) to the boom. Grind the width of the plate to achieve a good fit. Weld all around plate (4) and perform grinding detail A. Weld from point (B) to point (C) and from point (D) to point (E) , not permit notch of top plate, Refer to Illustrations 13 and 14.
Illustration 15 g06305705
(5) 117-5604 Stud
(6) 423-2484 Bar
(A) 14.25 mm (0.56 inch) hole
(B) 20 mm (0.79 inch)
(C) 22 mm (0.87 inch)
(D) 22 mm (0.87 inch)
(E) 22 mm (0.87 inch)
(F) 22 mm (0.87 inch)
(G) 297 2 mm (11.7 0.09 inch)
(H) 17 2 mm (0.7 0.08 inch)
(J) 95 5 mm (3.7 0.2 inch)
(K) 48° 5°
(L) 491 2 mm (19.3 0.08 inch)
(M) 541 2 mm (21.3 0.08 inch)
(N) 658 5 mm (25.9 0.2 inch)
Fabricate a reinforcement plate that can be used on the Boom. Refer to Illustration 15.Note: The reinforcement plate must be fabricated from ASTM A572 Grade 42 or Grade 50 steel, or the equivalent steel with