PIPE AS 2108097 - Caterpillar

Illustration 319 g03217541
Typical view of the inside right-hand radiator support group
(W1) 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) penetration
Illustration 320 g03217777
Typical view of the inside right-hand radiator support group
(W1) 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) penetration
Add reinforcement welds to the right-hand side of the radiator support group in the locations shown in Illustration 319 and Illustration 320.
Illustration 321 g03217579
Typical view of the inside left--hand radiator support group
(W1) 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) penetration
Illustration 322 g03217940
Typical view of the inside left--hand radiator support group
(W1) 6 mm (0.24 inch) fillet weld with 1.5 mm (0.06 inch) penetration
Add reinforcement welds to the right-hand side of the radiator support group in the locations shown in Illustration 321 and Illustration 322.
Grind the welds smooth and paint areas as needed.Procedure to Replace the 521-5887 Shaft
Replace the 521-5887 Shaft by using the following procedure:Note: Shaft replacement is required if cracks are in the parent material of the shaft. Cracks in the weld area only, after excavation, can be repaired using procedures outlined below.
Illustration 323 g01233436
(1) 521-5887 Shaft
Remove damaged shaft (1). Use the method of carbon arc gouging to remove the previous weld.
Illustration 324 g01233483
(A) Maximum radius of 3.0 mm (0.12 inch)
(B) 45° bevel
Prepare the weld joint on the center casting. Remove all the old material from the previous weld. Grind a 45° bevel. Refer to Illustration 324.
Locate shaft (1) by centering the shaft in the machined hole.
Illustration 325 g06056593
(AA) Less than 2 mm (0.08 inch)gap
(BB) 6 mm (0.24 inch) root opening
(1) 521-5887 Shaft
Ensure that the gap between shaft (1) and the casting is less than 2 mm (0.08 inch) and there is a 6 mm (0.24 inch) minimum root opening. Refer to Illustration 325.
Preheat the weld joint. Ensure that the base material is at a minimum temperature between 125° C (257° F) and 300° C (572° F) maximum.
Tack weld the shaft in three places that are separated by approximately 120°.
Illustration 326 g01233509
(1) 521-5887 Shaft
(W1) 40.0 mm (1.57 inch) single bevel groove weld
Illustration 327 g06056493
Stagger weld starts/stops 25 mm (1.0 inch) apart
(C) Weld starts at 6 O'clock
(D) Weld stops at 12 O'clock
(1) 521-5887 Shaft
Complete welding by starting at the bottom 6 O'clock (C) and progressing upward to the top 12 O'clock (D). Refer to Illustration 327.Each weld pass should be consistent with 6 mm (0.24 inch) to 8 mm (0.31 inch) fillet weld volume. Remove slag from each pass prior to welding the next pass.Note: Use a balance welding technique to minimize distortion.
After the groove weld is welded, grind the weld flush. Refer to Illustration 326.
Visually inspect the weld. The weld should be free from cracks, porosity, undercut, and incomplete fusion. Inspect the weld by using an ultrasonic flaw detection unit. Gouge any defects and then repair the defects.Note: This step is necessary to remove any residual hydrogen left in and next to the weld repair before allowing to cool to room temperature.
Final bake. Cover the exposed weld repair area with extra insulating material and raise the temperature to 200°