TUBE AS 4159561 - Caterpillar

The Top Rail Has Multiple Cracks D10R, D10T, and D10T2
Note: This Section applies to D10R, D10T, and D10T2.
Follow the procedures in the previous sections to remove the following components: the fenders, the crossbeam, and the fender bracket. Cut a window opening in the outer plate.
Illustration 6 g00849022
Section of the Rail
(A) 304.8 mm (12 inch) minimum length
Remove the window plate from the inside plate of the frame to straighten the frame. Ensure that the piece of rail between the cracks remains in the original intended position. Remove the window plate in a similar manner as the outside window plate. The inside window plate must be large enough to remove all the separation in the frame rail. The window plate should also remove any cracks on the inside plate. Longer openings may be required to eliminate the separation.
Lift the front section of the frame rail that has separated. Close the gap in the rail completely. Weld a strap across the upper portion of the window opening on both the outer plates and the inner plates. This strap will secure the position of the frame rail.
Weld the edges on the failed rail that are cracked in the shape of a square. Cut a 30 degree chamfer on the ends to create an opening at the V-groove weld. Remove the failed rail. Use 218-3334 Rail to replace the damaged portion of the rail. See length (A) in Illustration 6. Leave a 5 mm (0.2 inch) gap (2) on each end for a root opening. The window opening in the inner plates and in the outer plates should extend past the cracks. Install backup strips (3) under the 5 mm (0.2 inch) root opening.
Weld the V-groove weld to the full depth. Grind the weld flush with the top of the rail. Remove the backup strips. To remove the defects, gouge out the weld. Grind the welded area to remove any carbon remaining from the air carbon arc. Weld the gouged out area and grind the weld flush with the bottom surface. Grind all surfaces smooth to create the original geometry of the rail. Needle peen all welded surfaces.
Follow the previous procedure to replace the window plates.
Create two new fender bracket side plates. Use the dimensions in Illustration 3. Weld the side plates to the top plate of the fender bracket assembly with a 10 mm (0.4 inch) fillet weld and 2.5 mm (0.10 inch) penetration.
Follow the procedures in the previous sections to reassemble the fenders and the crossbeam to the machine.
Weld the side plates to the frame in the "U" opening with a 16 mm (0.6 inch) square groove weld.Rear Radiator Mount Repair D10R, D10T, and D10T2
Note: This Section applies to D10R, D10T, and D10T2.Welding Requirements
The following processes are acceptable:
Gas