PLATE 5354877 - Caterpillar

TECHNICAL INFORMATION BULLETIN August 08, 2005
Track-Type Tractors D8R Series II (6YZ1-Up), (AKA1-Up)
D8R (7XM1-Up), (9EM-Up)
D7R Series II (ABJ1-Up), (AGN1-Up), (AEC1-Up), (AFG1-Up), (ADW1-Up), (ACS1-Up), (EEA1-Up), (BNX1-Up), (BPT1-Up), (BRM1-Up), (BNM1-Up), (BRP1-Up)
Component Code(s) 7155SUBJECT: D8R Track-Type Tractor Radiator Guard As Cracks at the Gusset Toe
PROBLEM:
On some D8R and D8R Series II Track-Type Tractors, the radiator guard side sheets have cracked at the toe of the gussets across the radiator opening at the upper corners. Cracks have occurred at both the right side and the left side gussets.
SOLUTION:
The following is a procedure to repair the cracks in the radiator guard side sheets at the gusset toe. The addition of weld around the toe of the gusset and dressing the toe of the weld will improve the weld joint.
Suitable Welding Procedures
Preferred Methods for this Repair
Process Shielding Gas Wire Specifications Current Flow
Gas Metal Arc Welding (GMAW) Use 35 -+ 5 CFH of 75% Argon 25% CO2 Mixed Shielding Gas AWS Class ER70S-3
Flux Cored Arc Welding (FCAW) AWS Class
E71T-1
Acceptable Methods for this Repair
Shielded Metal Arc Welding (SMAW) E7018 Electrode Direct Current Electrode Positive
1. Inspect both sides of the radiator guard for cracks at location (A). Refer to "Cracks at the Bottom of the Gusset" if plate (2), inner side sheet, is cracked but plate (1), outer side sheet, is not cracked. Refer to "Cracks on Both Plates" if both plates are cracked.
Cracks at the Bottom of the Gusset
1. Remove the radiator guard doors.
2. Use an air arc gouge to remove the depth of the crack (3). Take care to not cut all the way through the plate (2). If the crack is all the way through plate (2), see procedure for "Cracks in Both Plates" and replace a section of plate (2) where cracked. Grind the area to remove the slag and any paint.
3. Use dye penetrate to ensure that the entire crack has been removed.
4. Weld the groove
5. Grind the weld flush with the plate (2). Make sure to not leave any low spots or high spots on the surface of the plate.
6. Start 50 mm away from the end of the gusset (4), weld around the end of the gusset (4), and back up the other side 50 mm (From point (A) to point (B) in one continuous weld). Do not start a weld or stop a weld near the end of the gusset (4).
7. Dress the toe of weld (5) to make it concave. Section view (C) shows weld (5) prior to the dressing procedure. Section view (D) shows weld (5) after it has been dressed.
Cracks on Both Plates
1. Remove the radiator guard doors.
2. Lay out the position of window (6) that extends from plate (1) to 50 mm past the gusset (4) and from the toe of gusset (4) down 125 mm. Use a torch or plasma to cut out the window (6). Make sure that any crack (7) in plate (2) is fully removed.
3. Use an air arc gouge to remove the inside of the crack (7) that is in plate (1). Make sure to remove at least two