SUPPORT 0858577 - Caterpillar

Position fabricated baffle (4) and weld the baffle according to Illustration 13.
Illustration 14 g01390172
(5) Fabricated backup strips (6) Fabricated top plate (J) 2 mm (0.08 inch) Maximum (K) 25° + 5° − 2°
Position fabricated backup strips (5) at locations "E" and "F". Refer to Illustration 14. Tack weld inside chamfer. Those weld points MUST be fully re-melted.
Position fabricated top plate (5) and weld the top plate according to Illustration 14. The longitudinal welds must be continuous and free of starts and stops. For the transverse weld, reweld the butt joint at both ends of plate after gouging 4 mm (0.16 inch) mini from back side of beveled plates or use flux-tab before welding (instead of gouging).
Grind the edge of the plate flat and chamfer 0.5 mm (0.02 inch) to 3 mm (0.12 inch) for both corners. Allow to cool slowly using a heated cover.Rework at the Center Boss Assembly
Illustration 15 g01390174
(C) 150 mm (6 inch)
Use air arc gouging to gouge the weld from "A" to "B". Refer to Illustration 15.
Illustration 16 g01390175
(D) 25° + 5° − 2° (E) 2 mm (0.08 inch) Maximum
Check if there is a chamfer on the edge of the side plate that was just gouged. If there is no chamfer, chamfer that side plate. Refer to Illustration 16. Always weld in the horizontal position. Preheat at 200 °C (392 °F). Control the interpass temperature from 150 °C (302 °F) to 250 °C (482 °F).
Illustration 17 g01390176
(F) 3 mm (0.12 inch) Minimum
Reweld the butt end. Refer to Illustration 17. Grind the new weld flat and smooth. Avoid any sharp edges. Do not decrease the weld width under 14 mm (0.55 inch). Repeat the same procedure on the other side of the stick. Allow to cool slowly using a heated cover.Rework at the Stick Cylinder Bracket
Illustration 18 g01390177
(1) Stick Cylinder Bracket (Old design) (2) Stick Cylinder Bracket (New design)
Determine if the stick cylinder bracket is old design (1). If the stick cylinder bracket is the old design, use the rework procedure that follows. If the stick cylinder bracket is new design (2), stop the rework procedure here. Refer to Illustration 18.Note: The interpass temperature should not exceed 250 °C (482 °F).
Illustration 19 g01390193
(1) Stick Cylinder Bracket (Old design) (7) Fabricated lug (F) 30 mm (1.2 inch) (G) 12 mm (0.5 inch) (I) 5 mm (0.2 inch) Minimum (J) 30 mm (1.2 inch) (K) 12 mm (0.5 inch)
Illustration 20 g01390196
Sequence of the Alternative Passes
Position fabricated lug (7) onto stick cylinder bracket (1). Weld the fabricated lug to the stick cylinder bracket from "A" to "C" according to Illustration 19. Start with a first pass and gouge a 4 mm (0.2 inch) mini from the back side of the joint to remove any inclusions. Continue welding the next passes.Note: Alternating the passes in the same sequence that is shown in Illustration 20 is very important.
Grind the weld so that the surface is completely flat. Weld "Area C" from "A" to "E" according to Illustration 19.Note: Following the procedure that is indicated by Illustration 19 is