HYDRAULIC LINES GROUP 1M8757 - Caterpillar

Weld Procedure
The weld parameters and the weld consumables are summarized in Table 18 and Table 19. The inspection tooling is presented in Table 20 and the machining parameters are presented in Table 21.The parts to be welded must be at a minimum temperature of 16° C (60.8° F) before and during welding. This temperature is required to avoid thermal shock and should not be confused with weld repair preheat requirements.
Remove all oil, grease, dirt, and inspection media from the weld area. Remove the surface oxides within 25.4 mm (1.00 inch) minimum of either side of the weld repair area.
Illustration 42 g02857307
Welded rod - typical example.
Illustration 43 g02857309
Welded rod.
Preheat the rod to 93.3° C (200° F) to avoid the formation of hard heat-affected zones and eliminate tendencies toward quench cracking on cooling.
Weld circumferential beads around the outside edge of the tube assembly and around the inside edge of the weld repair area. The inside edge shall be located at least 50 mm (2.0 inch) from the end of the tube.Note: Since weld distortion is a possibility, minimize the heat into the metal. The weld must be free of voids.
Weld 3.18 mm (0.125 inch) stringer beads longitudinally. Remove slag after every pass. To avoid heat buildup, stagger welds.Note: The weld procedure may also be completed circumferentially.
Welding the rod may contract the inner diameter. The rod internal diameter must meet the specifications presented in Table 12. After welding, measure the rod internal diameter.
Illustration 44 g02857310
TIR shall not exceed 0.05 mm (0.002 inch).
Use a lathe to machine the rod outside diameter. Establish TIR less than or equal to 0.05 mm (0.002 inch).
Complete the rough machining operation with the tooling and parameters specified in Table 21. Leave 1.5 mm (0.06 inch) of material to complete the finish machining.
Illustration 45 g02857312
Blend the welded surface into the original rod material.
Note: Blend the inner portion of the welded area with the original rod material. Attempt to achieve a minimum parting line as shown in Illustration 42 and Illustration 43. Face the end of the rod to remove any excess weld. Machine the inner bore of the rod if any excess weld material remains.
Finish machine the rod. Machine two 0.76 mm (0.030 inch) passes to achieve a 32 micron finish.Note: To achieve the finish, it may be necessary to leave 0.03 mm (0.001 inch) polish allowance.
Illustration 46 g02857314
Machine a 45 degree chamfer.
Machine a 45 degree chamfer in the end of the rod.
Illustration 47 g02857315
Use Tool B, external micrometer, to measure the rod diameter.
Use Tool B to measure the diameter of rod.Note: If the rod internal diameter does not meet the specification, the internal diameter will be too small to allow usage of the 213-5138 Installation Tooling.
Illustration 48 g02857319
Machining tube assembly ID.
If the internal diameter is too small, the internal diameter should be machined to the specifications presented in Table 12. Complete the machining in accordance with the machining parameters described in Table 21.
Reassemble the ejector cylinder. Refer to Table 8 and refer to Disassembly and Assembly Manual, "Ejector Cylinder – Assemble".Salvage Procedure - Thermal