TURBO GP-BASIC 6I3539 - Caterpillar

Illustration 18 g06089886
After grinding smooth
Grind the weld surface to get a smoother section transition while maintaining a minimum thickness of 18 mm (for 390F) or 16 mm (for 390D). Finish the grinding with a flat grinding disk.No grinding marks over 0.5 mm are allowed. Large marks may stress the weld. Grinding must be done with the grinder moving in the same direction as the weld to have the grinding marks on the longitudinal side of the stick.
Perform a visual inspection on the repair. After, perform penetrant testing and ultrasonic testing to validate the repair. Use straight and angled beams during ultrasonic testing.
Proceed to "Repair Instruction 3"Repair Instruction 3
Fabricate a reinforcement plate. Refer to Illustration 19 for 390D and Illustration 20 for 390F.
Illustration 19 g06089436
Reinforcement plate (390D)
Illustration 20 g06089439
Reinforcement plate (390F)
Remove any oil, paint, or dirt from all surfaces of the reinforcement plate.
Illustration 21 g06089901
Remove hardware or bosses weld gauging and grinding.
Illustration 22 g06089450
Plate fit up
(17) Fit up point
(18) Slot wedge
(19) Welded block ()
Fit the reinforcement plate onto the stick.Note: The maximum allowable gap at fit up point (17) is 1.0 mm. To reduce the gap, temporarily weld blocks (19) on the thicker plate. Then drive a slot wedge (18) in the clearance between the blocks and the doubling plate after each tack welding.
Tack weld (5 mm x 5 mm) in the order of (#1), (#1'), (#2), (#2'), (#3), and (#3').
Tack weld (5 mm x 5 mm) (#4).
After 1 second, hit the slot wedge with a hammer to decrease the gap.
Tack weld (5 mm x 5 mm) (#5) and (#5').
After 1 second, hit the slot wedge with a hammer to decrease the gap.
Tack weld (5 mm x 5 mm) (#6) and (#6').
After 1 second, hit the slot wedge with a hammer to decrease the gap.
Hit the reinforcement plate with copper hammer soon after tacking at (#7) and (#7') to decrease the gap.
Extend all the tack welds to 5 mm x 20 mm to prevent weld cracking.
Illustration 23 g06091161
Weld locations and sizes
(5a) Refer to Step 5.a
(5b) Refer to Step 5.b
(5c) Refer to Step 5.c
(5d) Refer to Step 5.d
Illustration 24 g06090057
Add weld onto the reinforcement plate. At points (a), (b), (e), and (f) fillet weld down smoothly to fit the shape of the plate. Refer to Illustrations 23 and 24. Remove the slag after making welds.Note: There is a 20 mm weld gap (21) at point (g) for ventilation.
The weld size for (#1) through (#5) is 5 mm x 5 mm.
The weld size for (#6) through (#8) is 10 mm x 40 mm for D series and 10 mm x 45 mm for F series.
The weld size for (#9) through (#12) is 12 mm x 12 mm.
The weld size for (#13) through (#16) is 12 mm x 12 mm.
Illustration 25 g06089466
Illustration 26 g06090089
(22) Weld start point; make tail weld (c)- (b) and (e)- (d)
( 23) After welding
(24) After grinding (side view)
(25) After grinding (top view)
Illustration 27 g06090092
(26) Weld start point; make tail weld
(27) After welding
(28) After grinding (top view); make an edge while grinding
(29) After grinding (side view)
Finish the corner areas