HOUSING 0933473 - Caterpillar

Illustration 13 g06041643
(10) Location 04 - Location where the crack observed in the field
Illustration 14 g06041647
Welding requirement in the failed locations as per the drawing
Illustration 15 g06041631
Location 04 - Weld crack observed weld connecting car body leg plate to car body bottom plate - curvature location weld
Schematic representation of Location 4 weld rework
(H) Groove depth 6.0 mm (0.24 inch)
(W1) Groove weld
(W2) Fillet weld size 10.0 mm (0.39 inch)Note: For vertical weld, during rework at the site, perform the welding in a vertical up position.
Remove the existing cracked weld.
Make a bevel groove preparation on the failed location as shown in Illustration 15. Extreme care should be taken while creating the bevel groove since excess base material removal will deteriorate the structure and make sure that the bevel groove depth should be restricted to 6.0 mm (0.24 inch).
Use a pencil grinder for bevel groove preparation.
Fill the groove with weld metal and make a 10.0 mm (0.39 inch) fillet weld above the groove weld.
Perform the welding in 2G, 3G & 2F, 3F position (horizontal & vertical up position).
Illustration 16 g06041659
(11) Frame assembly – undercarriage rear side – LHS
(12) Frame assembly – undercarriage rear side - RHS
Illustration 17 g06041663
(13) Location 05 - Weld crack observed in frame assembly - undercarriage rear side - LHS and RHS
Illustration 18 g06041689
Welding requirement in the failed locations as per the drawing
Illustration 19 g06041627
Location 05 - Weld crack observed Frame assembly – undercarriage rear side – LHS & RHS - overhead weld
Schematic representation of Location 05 weld rework
(H) Groove depth 6.0 mm (0.24 inch)
(W1) Groove weld
(W2) Fillet weld size 10.0 mm (0.39 inch)
Gouge out the existing cracked or damaged weld.
Remove the weld near the cracked location minimum 50.0 mm (1.97 inch) on both side.
Make a bevel groove preparation on the failed location as shown in Illustration 19. However extreme care should be taken while creating the bevel groove since excess base material removal will deteriorate the structure and make sure that the bevel groove depth should be restricted to 6.0 mm (0.24 inch).
Use a pencil grinder for bevel groove preparation.
Fill the groove with weld metal and make a 10.0 mm (0.39 inch) fillet weld above the groove weld.
Perform welding in 4G and 4F position (overhead position).Note: Final inspection required after completing all the weld reworks
The final capping weld must not exceed 2.0 mm (0.08 inch)with good wetting profiles on the toes of the weld.
Use suitable grinding/finishing equipment to smooth the surface of the built up area to the original profile (matching with the adjacent area).
Make sure that all the weld start - stop and tie-in location should be eliminated at the corner location. The weld start - stop and tie – in should be merged smoothly with suitable grinding / finishing equipment and it should be free from any weld defects like crater and lack of sidewall fusion etc.
Check for visual weld defect inspection. If any defects are noticed, grind the defective location and reweld the defect location.
Check that the reworked area is free from external defects and check with DP test for defect