EDGE AS 1982925 - Caterpillar

Personal injury can result from flame cutting or welding on painted areas.The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.Do not flame cut or weld on painted areas.
Rework Procedure
Remove the boom.
Remove the hydraulic lines and all the components that limit access to the repair area.Note: The components that remain installed on the machine must be protected from high temperatures and damage due to repair projections that occur during the repair procedure.
Illustration 1 g06156879
Install temporary bars
Install 2 temporary bars. Use tack welds at locations (1) on the side plate.
Illustration 2 g06156890
Doubling and tube with crack identified
(2) Tube
(3) Doubling
(4) Crack
(5) 25 mm (0.98 inch) extended gouging
Illustration 3 g06159927
Doubling and tube with the crack identified (case 1 and case 2)
(2) Tube
(3) Doubling
(4) Crack
Determine if the crack is type case 1 or case 2.Note: Case 1 is a crack that is both on the tube (2) side and the doubling (3) side. Case 2 is a crack that is either on the tube (2) side or the doubling (3) side.
Illustration 4 g06158167
Doubling and tube with gouging
(5) Gouging
Gouge and remove the crack completely. Extend the gouging (5) by 25 mm (0.98 inch) on each of the crack ends.Note: Do not remove all the welding.Note: Grind the bevel portion so that the surface is not rough after gouging.Note: Clean up the surface close to the crack portion to remove water, oil, and paint with a wire brush and gas jet.
Illustration 5 g06158193
Welding at crack
Apply welding on the crack portion at locations A and B. Grind the surface flat.
Illustration 6 g06158255
Corner welding
Apply welding at the corner.
Illustration 7 g06223638
Location for excess welding
Illustration 8 g06223656
Location for excess welding
Continually apply 1 pass of excess welding (6) on the gouging portion between positions C and D. Refer to red line in Illustration 7 for the welding location.Note: Tube side weld toe must be R5mm minimum and 40 degrees maximum.
Illustration 9 g06224736
Grinding on the weld toe
Illustration 10 g06223629
Weld toe grinding
Apply grinding on the weld toe of tube side and doubling side between positions C and D.Note: Grind a minimum R 5 mm (0.197 inch) shape on the weld toe.Note: A maximum 0.8 mm (0.032 inch) undercut (7) is allowed on weld toe grinding.
Remove the temporary bars. Completely remove the welding by grinding.
Apply painting on the reworked portion.
Reassemble all the components that have been removed from the machine in step 2.
Reinstall the Boom.