FILM 8T5054 - Caterpillar

Illustration 1. Dimensions of two new gussets.
Illustration 2. Dimensions of modified 8X-1311 Gusset. Preparation of rear axle mounts for weld procedure:
Clean the EEF assembly of oil, grease, paint and dirt in the area to be repaired. Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed Clean Air Standards requirement.
The EEF must be at a minimum temperature of 16°C (60°F) before and during all cutting and SMAW welding.
SMAW Weld Process
Use AWS E7018 Electrodes for welding procedure.
These are low hydrogen electrodes and must be stored in a electrode oven at 121°C (250°F) when not in use. If the electrodes get damp, scrap or recondition them to manufacturers specifications. Use the direct current electrode positive (DC reverse polarity) polarity setting and remove slag after every pass. The weld pass size shall not exceed two times the electrode diameter.
Alternative FCAW Weld Process
Use AWS E71T-1 Electrodes for welding procedure.
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove slag after every pass. The weld pass size shall not exceed 8 mm (.31 in) fillet volume.
Repair Procedure:
1. Attach the welding ground cable directly to the EEF. Do not allow welding current to travel through the machine bearings or hydraulic cylinders. Protect all hydraulic cylinders, hoses, electrical lines, and machine surfaces from sparks or splatter produced by the welding, chipping and/or grinding operation.
Illustration 3. Location of major components on right side of EEF (Engine End Frame) inside looking out.2. Cut off both 8X-7421 Gussets (3) (not serviced) from inside right and inside left of the EEF. In addition, remove 5G-6973 Lug (not shown) when removing the inside left gusset of the EEF. The lug will be removed when the left 8X-7421 Gusset is removed. Modify both 8X-1311 Gussets (2) as shown in Illustration 2. Care should be taken not to compromise the structural integrity of the modified gussets, the rail assemblies or axle support castings. If damage does occur, these areas should be weld repaired. Grind smooth all the burnt surfaces.3. Make sure the area to be repaired and the surrounding area is a minimum of 16°C (60°F) during the weld procedure. If you find cracking of the weld metal or base metals, preheat as specified and remove the cracked material by carbon arc gouging to a depth necessary to eliminate the cracks. Taper the ends of the arc gouged area to allow for smooth transition to existing sound weld and/or base material. Remove all debris in and around the carbon arc gouged area by chipping and grinding smooth. Visually inspect the carbon arc gouged area for cracks, undercut and porosity. Preheat as specified and reweld the prepared area. Weld repair area shall be free from cracks, porosity, undercut and incomplete fusion.
Illustration 4. Weld location and procedure for the modified 8X-1311 Gussets (2), new gussets (5) and new boss (6). 4. Position and tack one of the new gussets (5) on the right inside of the EEF at the end