HARNESS AS-WORK TOOL 2940007 - Caterpillar

Illustration 70 g03694242
Depth of grind in corners of Zones (K4) and (K5).
(L) 5.0 mm (0.1969 inch)
Grind cracks at the corners (K4) and (K5) to a depth of (L) 5.0 mm (0.197 inch) maximum. If cracks still appear, proceed with the welding process. Refer to Section "Weld Procedure for Zone K".Additional Crack Grinding in Zone K
If cracks are still present after initial grinding to a depth of 5.0 mm (0.197 inch) grind an extra 5 mm (0.197 inch) without affecting the slot width.The following conditions must be met to continue with the weld procedure. Use the Magnetic Particle Inspection procedure to verify the cracks.
Maximum length of the crack must be less than 108.0 mm (4.251 inch).
The depth of the crack must be less than (M) 10.0 mm (0.394 inch) total depth.If the crack is still present beyond 10.0 mm (0.394 inch) or 108.0 mm (4.251 inch) in length the spindle / front axle cannot be used again. Refer to Illustration 71 to determine crack depth and crack length.
Illustration 71 g03694250
(L) 5.0 mm (0.197 inch)
(M) 10.0 mm (0.394 inch)Weld Procedure for Zone K
Note: The weld procedure and weld parameters in this section are used to repair deep cracks in the corner of the key way in Zone (K.)Weld Parameters
Use the direct current electrode positive polarity (DC reverse polarity) setting and remove the slag after every pass. The weld width must not exceed two times the electrode diameter.The FCAW process will be used with the E90T-1 D-3 (ANSI/AWS A5.29) welding electrode such as the ESAB Dual Shield 150. The weld deposited by these electrodes must have the following mechanical properties listed in Table 11.
Table 11
Tensile Strength 620 MPa (90 KSI)
Yield Strength 540 MPa (78 KSI)
Elongation 17%
Impact Toughness 20 FT LBF @-20F (27J @- 30C)
Welding parameters will vary due to weld position and operator preference but may not vary more than 10%.
Refer to Table 12 for 1.6 mm (1/16 inch) diameter electrode welding parameters.
Table 12
Wire Feed Speed Voltage Approximate Amps
Min 150 IMP 27 190
OPT 250 IMP 30 300
Max 300 IMP 33 365 Note: Use welding grade 100% Carbon-Dioxide Shielding Gas. 45-55 cfh flow rate. 20-25 mm ID gas nozzle.Welding Cracks in Zone K
Pre-heat the area to be welded to 204.4° C (400° F).
Weld the area to be repaired using a pass width of no greater than 8.0 mm (0.315 inch).
The final weld pass must be no greater than 3.0 mm (0.118 inch) above any finished surface. Refer to Illustration 72.
Illustration 72 g03694256
After welding is complete grind, polish, and, needle peen the repaired area.
The repaired area must be finished to the original specifications. This area has critical functionality for the mounting of the steering arm
Illustration 73 g03700380
View of 793 standard spindle / front axle.
Table 13
793
(N) Slot Width 152.76 0.08 mm
(6.014 0.003 inch)
(P) Slot Corner Chamfer 1.1 0.5 mm
(0.043 0.02 inch) X 45°
(R) Slot Fillet Radius 1.2 0.5 mm
(0.047 0.02 inch) X 45°
(S) Slot Depth 7.37 0.25 mm
(0.290 0.010 inch)
Illustration 74 g03700399
View of 797 spindle / front