GEAR A. 0655353 - Caterpillar

The welding parameters will vary with the position of the weld and with different electrode manufacturers.Weld Inspection
The weld should not have any of the conditions that follow:
Cracks
Porosity
Undercut
Incomplete FusionIn order to verify the quality of the weld, refer to "American National Standards Institiute (ANSI)/American Welding Society (AWS) Specification D14.3" and ISO 6520.Manufacture of Replacement Gussets
Fabricate the following components from either ASTM A572 grade 50 structural steel or ASTM A656 grade 50 structural steel.
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Manufacture two sets of gussets (3) and (4) for each machine that is being reworked.
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Development View
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Gusset (3)
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Gusset (4) Fabricate gusset (3) from 6 mm (0.24 inch) thick structural steel. Refer to Illustration 5, Illustration 6 and Table 7.Fabricate gusset (4) from 6 mm (0.24 inch) thick structural steel. Refer to Illustration 5, Illustration 7 and Table 7.
Table 7
Dimensions for the Gussets    
A    
6 .5 mm (0.24 0.02 inch)    
B    
135 1 mm (5.32 0.04 inch)    
C    
126 1 mm (5.00 0.04 inch)    
D    
32 1 mm (1.26 0.04 inch)    
E    
95 1 mm (3.74 0.04 inch)    
F    
120 1 mm (4.72 0.04 inch) Radius    
G    
221 1 mm (8.70 0.04 inch)    
H    
204 1 mm (8.03 0.04 inch)    
I     90° 1°    
J    
125 1 mm (4.92 0.04 inch)    
K     6 mm × 45°    Installation Procedure for Replacement Gussets
When you install the fabricated components to your machine, please note that you must tailor the fit of the fabricated components in order to conform to any deformation of the body that may have occurred because of use of the machine.
On one side of the body perform the following.
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Remove the old gussets (1) and (2) .
Inspect the area of the old gussets for cracks. Gouge out any cracks and weld the gouges. Grind the filled cracks flat with the surrounding body.
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Typical example on the left side of the body
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Position gussets (3) and (4) to the body and weld the gussets in place. Refer to Illustration 9, Illustration 10 and Table 8. For information on welding, refer to ""Weld Specifications and Qualifications"".
Table 8
Information for Welding the Gussets    
L    
6 mm (0.24 inch) Weld    
M    
5 mm (0.20 inch) Fillet Weld    
N     90°    
O    
10 2 mm (0.40 0.08 inch)    
P    
6 mm (0.24 inch) Fillet Weld    
Repeat the procedure for the gussets on the other side of the body.
Paint the gussets and all surrounding bare metal.