PLATE-MOLDB 4D5820 - Caterpillar

Introduction
This Special Instruction provides the necessary information required to fabricate reinforcing plates and repair any cracks occurring on the stick nose of either the medium or long stick machines listed above.Do not perform any procedure outlined in this publication or order any parts until you have read and understood the information contained within.Reference: Service Manual, Parts Manual and Caterpillar Service Welding Guide, SEBD0512.Welding Requirements
Weld quality is critical to the success of this installation. Welds should be as smooth and continuous as possible.All electrodes must be completely dry. Dry electrodes at 300°C (572.0°F) for a minimum of one-half hour.Do not weld in areas where there is air movement or in temperatures below 15.5°C (60°F).Use AWS E7016 electrodes or their equivalent.Cleaning Procedure
All foreign material such as grease, water, paint, rust, dirt and scale must be removed before welding. These materials discharge gas when they come into contact with heat. This gas can cause porosity (very small bubbles) in the weld deposit. Water or rust can cause a condition known as "hydrogen embrittlement", resulting in cracks in the weld deposit.Remove all oil and grease with solvent. Remove paint, rust, dirt and scale with a wire brush or by blasting with glass beads.Cracks
No cracks are permissible, external or internal. If external cracks are suspected, the part should be thoroughly cleaned and Magnafluxed.X-Ray or Ultrasonic methods are ideal to check for internal cracks. However, these methods are more involved and require a special shop to perform the checks.If the cracks are repairable, they should be cut or ground out approximately 6 mm (.25 in) deeper than the original crack whenever possible. Fill the hole with weld.To ensure a good weld, the material around the weld area should be heated to 230 28°C (450 82°F) during the welding process on the part being repaired.Repair
Medium Stick
Reinforcing Plate (1)1. Fabricate two reinforcing plates (1) using 1E1883, ASTEM A36 steel or equivalent, 9 mm (.35 in) thick.2. Use a dye penetrant crack detection process to check for possible cracks.3. Grind out all cracks thoroughly.4. Use a torch and wire brush to thoroughly remove all moisture, oil and paint film from the immediate and adjacent areas of the ground out crack.5. Weld the ground out portions. Use AWS E7016 electrodes.6. Grind the weld area smooth.
Reinforcing Plate (1) Installation7. Tack weld two reinforcing plates (1) to the stick side plates. Keep a clearance of 1 mm (.04 in) or less between the stick plate and the reinforcing plate.8. Use a torch and wire brush to clean the reinforcing plates and the area of the stick being repaired. Be sure that the weld area is free of moisture, oil and dirt before welding.9. Weld reinforcing plates (1) to the stick nose. Weld the gaps between bosses and plates. Refer to sections A-A, B-B and detail C. Extend the welds 30 mm (1.2 in) as shown in detail C to join the existing welds between the side plates and the upper and lower plate.10. Dress the ends of the