SERVICE GP- 2316614 - Caterpillar

Illustration 1.
Typical fuel and hydraulic tank bracket. Field Repair Of Cracks
The following procedure is for the field repair of tank mount weld cracks and to enhance the fatigue life of the tank mount welds.
1. Visually inspect for fractures and use 4C-4736 or 9U-6335 Liquid Penetrant Kit on surfaces where cracks are suspected.2. Clean the area to be welded of oil, grease, paint and dirt.3. Protect all machined surfaces from sparks or splatter produced by welding, chipping and/or grinding operations.4. Attach the welding ground directly to the frame.5. Remove any cracks with the grinding or carbon arc gouging method. Cut past the suspected end of the crack by approximately 2 inches. Through section cracks should be removed with a grinder to prevent blowing through the casting. Cracks must be completely removed to sound metal prior to welding. Verify that the crack has been completely removed. The weld groove preparation shall include an approximate 90° angle at the root for good penetration and to minimize root defects. The side walls shall be angled at approximately 45° slope. Weld repair the prepared groove by using passes that do not exceed two times the electrode diameter. If the alternate process is selected, the welding pass size should not exceed (.31 in) fillet weld volume. Slag each pass to avoid the possibility of slag inclusions.6. Clean and inspect the weld repair as in Step 1. The weld is to be free from cracks, porosity, undercut and incomplete fusion.
Illustration 2.
5 mm (.2 in) toe radius weld.7. Weld a minimum of 5 mm (.2 in) radius weld around the toe of the existing weld as shown in Illustration 2.8. Use a small grinder to blend the toe of this weld to create a smooth transition from the weld to the rail.Adaptable To: Effective with 776D (5ER108), 784C (2PZ1), 771D (6YS1), 775D (8AS1), 069D (9SS180), 073D (1GW123), 769D (5SS1), 773D (7CS1), 777D (3PR950), 777D (2YW99), 785B (6HK709), 785C (1HW1), 785C HAA (5AZ90), 789B (7EK553), 789C (2BW1), 793C (4AR80) and adaptable to earlier modelsWelding Operator Requirements
All repair welding operators must be qualified for fillet and/or groove welding as outlined in the current ANSI/AWS D1.1 or D14.3 qualifications, or Caterpillar Manufacturing Practices MC1000-105. The qualification will be for the SMAW (Shielded Metal Arc Welding) process in the vertical welding positions. The alternate process for this repair is FCAW (Flux Cored Arc Welding). The welding operator must also have used the welding process within the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications.
Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill.
Read and understand the manufacturer's instructions and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye,