Reparcion de Boom 336 PDF

Instruccin Especial
Procedure for the Repair of Cracks on Reach Sticks for Certain Excavators{6502}
Procedure for the Repair of Cracks on Reach Sticks for Certain
Excavators{6502}
SMCS - 6502-062
Excavator:
330C (S/N: CYA1-UP; HAA1-UP; MCA1-UP; JAB1-UP; D3C1-UP; JCD1-UP; KDD1-UP;
GAG1-UP; RBH1-UP; JNK1-UP; BTM1-UP; MKM1-UP; CAP1-UP; GKX1-UP; DKY1-
UP; CGZ1-UP)
330D (S/N: RDA1-UP; KAB1-UP; GBC1-UP; PFC1-UP; NBD1-UP; R2D1-UP; GGE1-UP;
NEF1-UP; B6H1-UP; EAH1-UP; LCJ1-UP; THJ1-UP; FFK1-UP; PCK1-UP; JJM1-UP;
LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP; LDR1-UP; HAS1-UP; RAS1-UP; EDX1-UP;
MEY1-UP; T2Y1-UP)
336D (S/N: JBF1-UP; J2F1-UP; PRF1-UP; KDJ1-UP; W3K1-UP; MPL1-UP; MYP1-UP;
DTS1-UP; JBT1-UP; KKT1-UP; M4T1-UP; WET1-UP)
Introduction
This Special Instruction outlines the recommended basic procedures for the repair of cracks on the 3.9 m
(12 ft 10 inch) sticks, the 3.2 m (10 ft 6 inch) sticks, and the 3.2 m (10 ft 6 inch) heavy duty sticks for
certain Excavators. The procedures in this publication are applicable to any of the listed models.
Instructions for making the parts that are needed for this procedure are included in this publication.
Do not perform any of the procedures until you have read the information in this publication.
Understand and perform all of the safety instructions and information. Safety instructions and
information are associated with the removal, handling, repair, and installation of the implements and the
components in the front linkage.
Also, refer to the appropriate Parts Manual, Operation and Maintenance Manual, Disassembly and
Assembly Manual, and Service Manual.
Required Parts
The required parts are defined in each section of this Special Instruction. Use the designs that are
provided in order to fabricate the parts that are needed. All of the plates must be fabricated from ASTM
A572 Grade 42 or Grade 50 steel, or the equivalent steel with a minimum yield strength of 290 MPa
(42000 psi).
Welding Requirements
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Welding quality is critical to the success of the installation procedure. Welds must be smooth and
continuous. Undercutting or overlapping is not acceptable. Grind the ends of the welds to a smooth
radius.
Prepare the metal for welding according to ""Preparing the Metal for Welding" ". Refer to the
illustrations in this special instruction for welding symbols and specifications.
Stick welding SMAW of the casting for the stick is not recommended. The casting has a high carbon
content.
Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to weld the baffle plate
and the reinforcement plates. Basic welding wire ESAB OK tubrod 15.00 with a 1.2 mm (0.05 inch)
diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E71T-5 with
positive polarity. The welding wire must be shielded with CO
2
gas or Argon/CO
2
80/20 gas.
Welding of the gouged grooves requires LB-52 (AWS E7018), or an equivalent electrode. Basic welding
wire ESAB OK tubrod 15.00 with a 1.2 mm (0.05 inch) diameter can also be used.
Personal injury or death can result from fumes, gases and ultraviolet
rays from the weld arc.
Welding can cause fumes, burn skin and produce ultraviolet rays.
Keep your head out of the fumes. Use ventilation, exhaust at the arc, or
both, to keep fumes and gases from your breathing area. Wear eye, ear
and body protection before working.
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 cause death.
Read and understand the manufacturer's instructions and your
employer's safety practices. Do not touch live electrical parts.
See "American National Standard Z49.1, Safety in Welding and
Cutting" published by the American Welding Society.
American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125
See "OSHA Safety and Health Standards, 29 CFR 1910", available
from U.S. Department of Labor.
U.S. Department of Labor
Washington, D.C. 20210
All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300C
(572F). The electrodes must be dried for at least 30 minutes.
Do not weld in windy conditions. Do not weld when temperatures are below 16C (60F).
Penetration characteristics may vary greatly depending on the electrode diameter, shielding gas, welding
current, and plate thickness. Geometry of welded joints, surface conditions, and composition of the base
metal and electrode also affect the welds.
A root pass should be applied before each weld is finished.
Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.
All of the welds to the stick must be in one direction.Weld from the rear of the stick toward the front of
the stick unless the direction of the welds are otherwise specified.
All repair welds should be done in a controlled environment. Controlled environments prevent the rapid
cooldown after the repair. Controlled environments would be inside of a repair shop.
All welds should be done in the horizontal or the flat position in order to make a smooth surface finish.
Make sure that the root cause of the crack in the stick is determined. Eliminate the root cause before
proceeding with the repair.
Make sure that a repair plan is developed in order to prevent losing the alignment of the bores and true
position.
If the repair requires an access hole in the stick, make sure that the backup strips are installed correctly
with the proper gap. Remove the backup strips that are not installed correctly. Gouge out the welded
joint if the backup strips are removed. Repair the welded joint with new backup strips that are properly
installed.
Tack welds that were used during fabrication of the stick at the factory can be removed if the welds are
contributing to the crack. The tack weld on the back side of a backup strip is an example.
Needle peen all of the repaired weld joints in order to achieve the maximum fatigue life.
When possible, grind the surface smooth on the repaired structure. The smooth finish from the grinder
will eliminate stress risers. A smooth transition between the weld and the plate material should be
maintained. A radius of 3 mm (0.12 inch) in the weld toe will provide maximum fatigue life.
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For more welding information, consult the Caterpillar Service Welding Guide, SEBD0512.
Preparing the Metal for Welding
All grease, water, paint, rust, dirt, and scale must be removed before welding. Any of these materials
will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen
embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.
Remove paint, rust, dirt, and scale with a wire brush or by buffing or grinding. Shot blasting all work
areas will also remove foreign material.
Remove any oil or grease that is on the boom with a Caterpillar approved solvent.
Before you do any welding on the boom, remove all foreign material and paint a minimum of 50 mm
(2.0 inch) beyond the area of the weld.
Illustration 1 g01561364
Grind The Weld Toe.
(R) Grind the weld toe smooth.
Personal injury can result from flame cutting or welding on painted
areas.
The effect of gasses from burned paint is a hazard to the person doing
the cutting or welding.
Do not flame cut or weld on painted areas.
Cover all finished bores and threads. Finished bores and threads must be protected from all of the
following items: foreign material, welding, gouging and paint spatters. Do not remove the covers until
the boom is painted.
Preparing the Machine for Servicing
1. Move the machine to level ground. The ground must support the weight of the machine. Personal
injury or death can result if the surface below the machine cannot support the weight of the
machine.
2. Put the machine in the servicing position. The bucket must rest flat on the ground after the boom
is lowered.
3. With the machine in the servicing position, remove the bucket from the stick. Refer to the
Disassembly & Assembly module for machine systems with your machine. Buckets weigh
Be sure all personnel are clear of the equipment while the equipment is
being lowered.
Failure to stay clear of the equipment while the equipment is being
lowered may result in personal injury.
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The servicing position of an Excavator is shown in this illustration. The bucket is flat on the ground. The stick is in a
vertical position.
approximately 2404 kg (5300 lb) to 499 kg (1100 lb).
4. Remove the stick from the boom. Refer to the Disassembly and Assembly module for machine
systems with your machine. Sticks weigh approximately1372 kg (3025 lb) to 1236 kg (2725 lb).
5. Position the boom on the ground. Refer to the Disassembly and Assembly module for machine
systems with your machine.
6. Move the control levers for the boom, the stick, the bucket, swing operation, and the left and right
travel to the full stroke positions. This movement will release any actuator pressure in the
hydraulic lines.
7. Move the hydraulic activation control lever to the UNLOCKED position. This step will release
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Hydraulic oil pressure can remain in the hydraulic systems after the
engine and pump have been stopped. Serious injury can be caused if
this pressure is not released before any service is done on the hydraulic
systems. To prevent possible injury, refer to the section, Testing and
Adjusting, "Hydraulic System Pressure - Release" before any fitting,
hose or component is loosened, tightened, removed or adjusted.
When possible, the bucket or attachment must always be lowered to the
ground before service is started. When it is necessary for the boom to be
in the raised position while tests or adjustments are done, be sure that
the boom, stick and bucket or attachment have correct support.
The swing lock (if equipped) must be engaged before service is started.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
any pressure in the pilot system. For further details on this procedure, refer to the machine
Operation and Maintenance Manual.
8. Slowly loosen the fill/vent plug on the hydraulic tank. This step will relieve the pressure in the
hydraulic tank.
9. Remove the key which starts the machine. Secure the cab.
10. Disconnect all power and ground leads from the batteries in order to avoid possible damage to the
electronic components.
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
Accidental machine starting can cause injury or death to personnel
working on the machine.
To avoid accidental machine starting, turn the battery disconnect
switch to the OFF position and remove the key. If the machine is not
equipped with a battery disconnect switch, disconnect the battery cables
from the battery and tape the battery clamps.
Place a do not operate tag at the battery disconnect switch location to
inform personnel that the machine is being worked on.
NOTICE
Before carrying out arc welding on the machine or on any equipment
attached to the machine, disconnect all power and ground leads from
the batteries in order to avoid possible damage to electronic
components.
Crack Identification
This procedure outlines the recommended basic procedures for the repair of cracks on the 3.9 m (12 ft
10 inch) and the 3.2 m (10 ft 6 inch) reach sticks. The recommendation for repair or replacement of the
stick will depend on the location and the magnitude of the damage. The following seven examples are
the locations of the most common cracks. Refer to Illustration 3.
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Typical Stick
(A) Crack at the joint between the casting for the pivot boss and the side plate
(B) Crack at the joint between the casting for the pivot boss and the side plate that extends into the bottom plate
(C) Crack at the joint between the side plates in the center of the stick
(D) Crack at the joint between the side plates in the center of the stick that extends into the bottom plate
(E) Crack at the joint between the side plates in the bucket end of the stick
(F) Crack at the joint between the side plates in the bucket end of the stick that extends into the bottom plate
(G) Crack at the joint of the stick top plate and the stick cylinder brackets
Note: An air carbon arc torch will be used to gouge out the cracked welds. Be aware of the thickness of
the metal when gouging cracks with an air carbon arc torch. Do not gouge out the metal too deeply.
Procedure for the Repair of a Type A Crack
The following procedure describes the repair for the cracks on the right side plate at the casting for the
pivot boss. This procedure also applies for the left side plate at the casting for the pivot boss also.
1. Position the stick with the cracked side horizontal on suitable repair stands. Sticks weigh
approximately 1372 kg (3025 lb) to 1236 kg (2725 lb).
Table 1
Side plate thickness
Stick Part number Boom end Center
R3.9 236-8391 / 290-9253
14 mm (0.55 inch) 10 mm (0.39 inch)
R3.2 236-8394 / 290-9265
14 mm (0.55 inch) 10 mm (0.39 inch)
R3.2HD 236-8397 / 290-9274
14 mm (0.55 inch)
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Horizontal Position Of A Stick
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2. Use an air carbon arc torch and gouge out 200 mm (7.9 inch) of the weld between the side
plate/pivot boss and the bottom plate (C). Grind a 45 degree bevel for a groove between the side
plate/pivot boss and the bottom plate. Gouge out the crack in the weld on the pivot boss in order to
eliminate the crack. Gouge out 100 mm (4 inch) beyond the end of the crack (B). Grind a 50
degree bevel for a V-groove between the pivot boss and the side plate.
(B) 100 mm (4 inch)
(C) 200 mm (7.9 inch)
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(D) Crack
3. If a crack is created from the inside of the tack weld, repair the crack with the ""Procedure for the
Repair of a Type B Crack" " section of this publication.
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Crack From The Inside Of The Tack Weld
(D) Crack
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4. Weld the V-groove (W1) in the horizontal position. Make the weld between the side plate and the
bottom plate without interruption in the cross section. Grind the weld smooth.
5. Make a root pass in the flat position between the bottom plate and the side plate/pivot boss.
Note: Needle peen after every weld pass. Grind the surface smooth. Clean the surface before each
weld pass.
6. Finish the weld between the bottom plate and the side plate/pivot boss. Grind the weld smooth so
that there is a perpendicular joint between the bottom plate and the side plate/pivot boss.
(E) 3 mm (0.1 inch) minimum
Table 2
Weld Specifications
Item Description
W1
15 mm (0.6 inch) V-groove weld
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7. Make a fillet weld between the bottom plate and the side plate/pivot boss. Refer to illustration 10
for the fillet weld requirements.
weld pass.
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Illustration 11
(G) 300 mm (11.8 inch) radius
(H) 315 mm (12.4 inch) radius
(J) 215 mm (8.5 inch) radius
(K) 12 mm (0.5 inch)
(L) 15 mm (0.6 inch)
(M) 550 mm (21.7 inch)
(N) 132 mm (5.2 inch)
(P) 34.7 mm (1.37 inch)
(R) 252.1 mm (9.93 inch)
(S) 122.7 mm (4.83 inch)
(T) 429 mm (16.9 inch)
(U) 85 mm (3.3 inch) radius
(V) 538.8 mm (21.21 inch)
(W) 222.5 mm (8.76 inch)
(X) 550 mm (21.7 inch)
(Y) 358.5 mm (14.11 inch)
(Z) 368.5 mm (14.51 inch)
8. Fabricate two reinforcement plates. Refer to Illustration 11 for the dimensions.
9. Install a fabricated plate on both sides of the stick. Tack weld the fabricated plate on the stick.
Make sure that the gap between the side plate and the fabricated plate is a maximum of 1 mm
(0.04 inch).
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Illustration 12
(CC) 15 mm (0.6 inch)
Table 3
Weld Specifications
Item Description
W2
10 mm (0.4 inch) fillet weld (two places)
W3
12 mm (0.5 inch) butt weld (2 places)
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10. Weld the fabricated plate on the stick.
Section AA-AA From Illustration 12
(GG) Grind a convex surface in order to remove the existing weld.
(HH) 50 mm (2.0 inch)
(JJ) Grind a radius with a minimum size of 15 mm (0.6 inch).
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Detail BB From Illustration 12
(KK) Join the weld smoothly between the bottom plate and the side plate. Grind the surface after burying a triangular
part.
(LL) 100 mm (3.9 inch)
Table 4
Weld Specifications
Procedure for the Repair of a Type B Crack
The following procedure describes the repair for the cracks on the right side plate at the casting for the
pivot boss that extend into the bottom plate This procedure describes the repair for the left side plate at
the casting for the pivot boss that extend into the bottom plate.
Item Description
W4 10 mm (0.4 inch) by
50 mm (2.0 inch) fillet weld for length DD-EE
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(A) Crack in the bottom plate
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1. Position the stick on repair stands. Position the stick with the bottom plate in a horizontal position.
Sticks weigh approximately 1372 kg (3025 lb) to 1236 kg (2725 lb).
2. Use an air carbon arc torch and gouge out the body of the weld between the bottom plate and the
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3.9 m (12 ft 10 in) stick and 3.2 m (10 ft 6 in) standard stick
(B) 380 mm (15.0 inch)
(C) 180 mm (7.1 inch)
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3.2 m (10 ft 6 in) heavy-duty stick
(B) 400 mm (15.75 inch)
(C) 200 mm (7.87 inch)
side plate on the stick.
Note: Make sure that the side plates for the stick are not damaged by the cut.
a. For the 3.9 m (12 ft 10 in) stick and 3.2 m (10 ft 6 in) standard stick, begin cutting the weld
at a distance of 180 mm (7.1 inch) from the weld for the casting. Gouge out the weld for a
length of 380 mm (15.0 inch).
b. For the 3.2 m (10 ft 6 in) heavy-duty stick, begin cutting the weld at a distance of 200 mm
(7.87 inch) from the weld for the casting. Gouge out the weld for a length of 400 mm (15.75
inch).
3. Make cuts (D) in the bottom plate. Refer to step 2 for the location of the cuts (D). Cuts (D) are
made at the same locations as cut (B) and cut (C). Remove the bottom plate section. Cut a 25
degree bevel on the outside edge of the bottom plate at cuts (D) .
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(D) Bottom plate cut
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Note: Remove bar (E) if the bar prevents access to the crack that is inside of the stick.
4. Reposition the stick on the repair stand. Position the stick with the bottom plate on the repair
stand. Gouge out the crack in the bottom plate from the inside of the stick. Gouge out
approximately 7 mm (0.3 inch) through the thickness of the plate. Gouge out 50 mm (2 inch)
beyond the end of the crack. Grind a 50 degree V-groove. Weld the V-groove in the horizontal
position.
weld pass.
(E) Bar
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(A) Crack in the bottom plate
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5. Use the cut hole in the bottom of the stick and inspect the edge of the pivot boss inside the stick in
order to find any cracks. Position the stick on the side if a crack is found. Gouge out the crack and
the edge of the casting for the pivot boss. Gouge out approximately 7 mm (0.3 inch) through the
thickness of the plate. Gouge out 50 mm (2 inch) beyond the end of the crack. Grind a 50 degree
bevel for a V-groove. Weld the V-groove in the horizontal position.
weld pass.
(A) Crack in the side plate and the casting for the pivot boss
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(F) Gouge
(G) Weld
Note: If the baffle plate within the stick has a crack, repair the baffle plate as follows.
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Baffle plate location (side plate removed for clarification)
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Illustration 25
Typical Baffle Plate In A Stick
(a) Step 6.a
6. Use the cut hole in the bottom of the stick and inspect the fillet weld for the baffle plate inside the
stick in order to find any cracks. Position the stick on the side if a crack is found. Gouge out the
crack and the edge of the pivot boss. Gouge out approximately 7 mm (0.3 inch) through the
thickness of the plate. Gouge out 50 mm (2 inch) beyond the end of the crack. Grind a 50 degree
bevel for a V-groove. Weld the V-groove and the fillet weld for the baffle plate in the horizontal
position. Grind the weld smooth.
Use the procedure that follows in order to remove the cracks in the welds and for the repair weld
of the baffle plate. Refer to Illustration 25.
a. Gouge out the fillet weld for the rear baffle plate and the side plate that is closest to the stick
bucket end.
b. Grind the surfaces for the weld that was removed. Clean the surfaces for the weld that was
removed.
c. Gouge out the crack in the side plate inside the stick for a V-groove weld. Gouge out the
crack to a depth of 10 mm (0.4 inch). Gouge out 50 mm (2 inch) beyond the visible end of
the crack.
d. Weld a root pass. Weld two passes in order to finish the weld. Grind the weld smooth.
e. Weld a 12 mm (0.5 inch) fillet weld.
f. Gouge out the crack in the side plate on the outside of the stick for a V-groove weld. Gouge
out the crack to a depth of 10 mm (0.4 inch).
g. Weld a root pass. Weld two passes in order to finish the weld. Grind the weld smooth.
(b) Step 6.b
(c) Step 6.c
(d) Step 6.d
(e) Step 6.e
(f) Step 6.f
(g) Step 6.g
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7. Position the stick horizontally so that the side with the crack is in a horizontal position. Gouge out
200 mm (7.9 inch) of the weld between the side plate/pivot boss and the bottom plate (H). Grind a
45 degree bevel for a groove between the side plate/pivot boss and the bottom plate. Gouge out
approximately 10 mm (0.4 inch) through the thickness of the weld joint between the side plate and
the pivot boss (J). Gouge out 50 mm (2 inch) beyond the end of the crack. Grind a 50 degree bevel
for a V-groove. Weld the V-groove and the fillet weld for the baffle plate in the horizontal
position. Grind the weld smooth.
weld pass.
(H) Gouge length of 200 mm (7.9 inch)
(J) Gouge depth of 10 mm (0.4 inch)
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8. Position the stick with the bottom plate in a horizontal position. Position the stick with the bottom
plate facing upward. Gouge out approximately 10 mm (0.4 inch) through the thickness of the
bottom plate at the casting for the pivot boss (J). Gouge out 50 mm (2 inch) beyond the end of the
crack. Grind a 50 degree bevel for a V-groove. Weld the V-groove and the fillet weld for the
baffle plate in the horizontal position. Grind the weld smooth.
weld pass.
9. Build up the edges of the side plates with weld beads if the side plates are damaged. Clamp a brass
plate or a copper plate on the inside of the side plate in order to build up the edge with welds.
Grind the welded edge smooth and straight.
(J) Gouge depth of 10 mm (0.4 inch)
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10. Grind a 25 degree bevel (K) on the edge of the bottom plate for the stick. Grind a 45 degree bevel
(L) that is 6 mm (0.24 inch) deep on the side plate.
11. Fabricate two backup strips. The backup strips are positioned on the parent material of the stick
bottom plate in order to provide a base for the fillet welds between the bottom plate and the
replacement plate. A backup strip is to be positioned at both weld seams between the bottom plate
and the replacement plate.
(K) 25 degree bevel
(L) 45 degree bevel
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Backup Strip
(M) 305.0 mm (12.00 inch)
(N) 25.0 mm (1.00 inch)
(P) 10.0 mm (0.39 inch)
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12. Fabricate a new bottom plate for the stick in order to replace the plate that was previously
removed. Refer to figure 31 for the dimensions of the plate. Use the dimensions and the shape of
the plate that was removed as a reference to fabricate the new bottom plate.
Illustration 31
Plate dimensions are given in millimeters.
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Alignment Of The Backup Strip
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13. Use clamps in order to make sure that the backup strips are flush with the bottom plate. Make sure
that there is less than a 0.5 mm (0.02 inch) gap between the backup strip and the parent material of
the bottom plate in the center section. Misalignment of the backup strip will severely reduce the
life of the structure. Refer to Illustration 32.
Note: Tack weld the backup strips with three 3 mm (0.12 inch) fillet welds that are 20 mm (0.8
inch) long on the V-groove side of the backup strip. Do not tack weld 50 mm (2.0 inch) from the
ends of the backup strip. Remove the clamps used to prepare the backup strips for tack welding.
Tack weld locations for backup strips (viewed from inside of stick)
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14. Position the replacement plate so that there is a 3 mm (0.12 inch) gap between the bottom plate
and the replacement plate for each weld. The gap must be flush. Clamp the replacement plate to
the stick in order to begin welding.
15. Tack weld the replacement plate with the bottom plate for the stick and side plates. Use a steel
runoff plate in order to create a weld dam at the edge of the weld. Tack weld the plate securely in
the root of the seam with high-quality welds. Remove the clamps.
16. Finish the cross weld. Allow the welded area to cool between passes. The weld in the root is
continuous over the tack weld. No stops are allowed. Make sure that the tie in welds for both of
the top plates and the bottom plates are good.
weld pass.
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17. Position the stick so that the side is horizontal. Remove all of the clamps. make a root pass in the
flat position between the side plates and the bottom plate.
weld pass.
18. Finish the weld between the replacement plate and the side plates. Grind the weld smooth so that
there is a perpendicular joint between the replacement plate and the side plate.
Illustration 35
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19. Make a fillet weld between the bottom plate and the side plate. Refer to illustration 37 for the fillet
weld requirements.
weld pass.
20. Grind the cross welds on the bottom plate flush when all welds are completed. The joint for the
bottom plate cross weld should not be visible.
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Illustration 38
(G) 300 mm (11.8 inch) radius
(H) 315 mm (12.4 inch) radius
(J) 215 mm (8.5 inch) radius
(K) 12 mm (0.5 inch)
(L) 15 mm (0.6 inch)
(M) 550 mm (21.7 inch)
(N) 132 mm (5.2 inch)
(P) 34.7 mm (1.37 inch)
(R) 252.1 mm (9.93 inch)
(S) 122.7 mm (4.83 inch)
(T) 429 mm (16.9 inch)
(U) 85 mm (3.3 inch) radius
(V) 538.8 mm (21.21 inch)
(W) 222.5 mm (8.76 inch)
(X) 550 mm (21.7 inch)
(Y) 358.5 mm (14.11 inch)
(Z) 368.5 mm (14.51 inch)
21. Fabricate two reinforcement plates. Refer to Illustration 38 for the dimensions.
22. Install a fabricated plate on both sides of the stick. Tack weld the fabricated plate on the stick.
Make sure that the gap between the side plate and the fabricated plate is a maximum of 1 mm
(0.04 inch).
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Illustration 39
(CC) 15 mm (0.6 inch)
Table 5
Weld Specifications
Item Description
W2
10 mm (0.4 inch) fillet weld (two places)
W3
12 mm (0.5 inch) butt weld (2 places)
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23. Weld the fabricated plate on the stick.
Section AA-AA From Illustration 39
(GG) Grind a convex surface in order to remove the existing weld.
(HH) 50 mm (2.0 inch)
(JJ) Grind a radius with a minimum size of 15 mm (0.6 inch).
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Detail BB From Illustration 41
(KK) Join the weld smoothly between the bottom plate and the side plate. Grind the surface after burying a triangular
part.
(LL) 100 mm (3.9 inch)
Table 6
Weld Specifications
24. Fabricate a reinforcement plate for the bottom plate. Refer to illustration 42 for the dimensions of
the reinforcement plate.
Item Description
W4 10 mm (0.4 inch) by
50 mm (2.0 inch) fillet weld for length DD-EE
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Illustration 42
Reinforcement plate (dimensions given in millimeters)
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25. Install the fabricated reinforcement plate on the bottom plate as shown in illustration 43.
26. Clamp the reinforcement plate to the stick bottom.
27. Weld the reinforcement plate to the stick bottom plate. Grind all weld surfaces smooth.
Procedure for the Repair of a Type C Crack
Illustration 43
Typical example of a stick bottom reinforcement plate.
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Illustration 44
This procedure describes the repair for cracks in the weld seam between the side plates in the center of
the stick on the right side or the left side of the stick.
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Typical location of a Type C crack in side plate weld seam.
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1. Position the stick on repair stands so that the crack is in a horizontal position.
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2. Use an air carbon arc torch and gouge out the weld between the bottom plate and the side plates
100 mm (3.9 inch) from both sides of the side plate weld joint. Gouge out the crack in the side
plate weld joint in order to eliminate the crack. Extend the gouge 100 mm (3.9 inch) past the end
of the crack.
Note: Gouge out the crack completely and do not disturb the backup strip behind the side plates.
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3. Grind a 45 degree groove in the side plate at the side plate to bottom plate joint. Grind a 25 degree
bevel on the side plates at the side plate joint. Make a root pass in the flat position between the
side plate and the bottom plate. Make a body weld in the V-groove between the side plates
without interruption. Grind the surface of the side plate joint weld smooth.
Weld seam at bottom plate and side plates
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Weld seam at side plates
weld pass.
4. Finish the weld between the bottom plate and the side plates. Grind the weld smooth so that there
is a perpendicular joint between the bottom plate and side plates.
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weld requirements.
weld pass.
Procedure for the Repair of a Type D Crack
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This procedure describes the repair for cracks in the weld seam between the side plates in the center of
the stick on either the right side of the stick or the left side of the stick that extends into the bottom plate.
Type D crack
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1. Position the stick so that the bottom plate for the stick is up. Cut the weld between the bottom
plate and the side plates a distance of 200 mm (7.87 inch) from the seam of the side plates toward
the bucket end of the stick. Cut the weld between the bottom plate and the side plates a distance of
300 mm (11.81 inch) from the seam of the side plates toward the boom end of the stick.
Note: Make sure that the side plates on the stick are not damaged when removing the welds.
2. Make cuts across the bottom plate in order to remove the section with the crack. Grind a 25 degree
bevel on the remaining bottom plates in preparation for welding the replacement bottom plate
section.
Cut locations for bottom plate removal.
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3. Position the stick on repair stands so that the crack on the inside of the stick is in a horizontal
position and facing upward. Remove the backup strip.
Note: If necessary, remove the distance bar between side plates. Add another distance bar on the
appropriate position in order to prevent the stick from becoming distorted. Weld the distance bar
after the inside crack repair. The distance from each weld is to be at least 10 mm (0.39 inch).
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Backup strip
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4. Gouge out the crack that is located on the inside of the stick on the side plate weld seam. Gouge
out approximately 7 mm (0.28 inch) through the thickness of the plate. Gouge out 50 mm (1.97
inch) beyond the end of the crack. Grind a 50 degree bevel in the gouge. Weld the V-groove in a
horizontal position. Grind the weld flush.
Gouge on inside of weld seam (50 degrees, 7 mm (0.28 inch) deep)
Ver imagen
Gouge on outside of weld seam (50 degrees, 10 mm (0.39 inch) deep)
5. Position the stick so that the crack on the outside of the stick at the side plate weld seam is in a
horizontal position. Gouge out approximately 10 mm (0.39 inch) through the thickness of the
plate. Gouge out 50 mm (1.97 inch) beyond the end of the crack. Grind a 50 degree bevel in the
gouge. Weld the V-groove in a horizontal position. Grind the weld flush.
Ver imagen
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(K) 25 degree bevel
(L) 45 degree bevel
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Backup Strip
(M) 305.0 mm (12.00 inch)
(N) 25.0 mm (1.00 inch)
(P) 10.0 mm (0.39 inch)
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Illustration 62
Plate dimensions are given in millimeters.
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Ver imagen
ends of the backup strip. Remove the clamps used to prepare the backup strips for tack welding.
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weld pass.
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14. Position the stick so that the side is horizontal. Remove all of the clamps. Make a root pass in the
flat position between the side plates and the bottom plate.
weld pass.
15. Finish the weld between the replacement plate and the side plates. Grind the weld smooth so that
there is a perpendicular joint between the replacement plate and the side plate.
Illustration 66
Ver imagen
Ver imagen
weld requirements.
weld pass.
17. Grind the cross weld flush when all of the welds are completed. The joint for the cross weld
should not be visible.
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19. Install the fabricated reinforcement plate on the bottom plate as shown in illustration 70
Illustration 69
Fabricated reinforcement plate for the bottom plate (All dimensions given in millimeters.)
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Illustration 70
Typical example of a stick bottom plate reinforcement plate.
20. Weld the reinforcement plate as shown in illustration 71. Grind the welds smooth.
Procedure for the Repair of a Type E Crack
The following procedure describes the repair for the cracks in the weld seam between the side plates at
the bucket end of the stick on the right side or the left side.
Ver imagen
Illustration 71
Ver imagen
Type E crack
1. Position the stick on the repair stands so that the crack is in a horizontal position.
2. Use an air carbon arc torch and gouge out the weld between the bottom plate and the side plates
100 mm (3.9 inch) from both sides of the side plate weld joint. Gouge out the crack in the weld
between the side plates in order to eliminate the crack. Gouge out 100 mm (4 inch) beyond the
end of the crack.
Note: Gouge out the crack completely and do not disturb the backup strip behind the side plates.
Ver imagen
Ver imagen
3. Grind a 50 degree groove in the side plate at the side plate to bottom plate joint. Grind a 25 degree
bevel on the side plates at the side plate joint. Make a body weld in the V-groove between the side
plates without interruption. Grind the surface of the side plate joint weld smooth.
Weld seam at bottom plate and side plates
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Weld seam at side plates
4. Make a root pass in the flat position between the side plates and the bottom plate.
weld pass.
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Illustration 76
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6. Make a fillet weld between the bottom plate and the side plate. Refer to illustration 78 and 79 for
Ver imagen
R3.2/R3.9 Stick
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HD3.2 Stick
the fillet weld requirements.
weld pass.
Procedure for the Repair of a Type F Crack
The following procedure describes the repair for the cracks in the weld seam between the side plates at
the bucket end of the stick on the right side or the left side that extends into the bottom plate.
1. Position the stick on the repair stands so that the crack is in a horizontal position.
Ver imagen
Ver imagen
Note: If a wear plate is attached to the bottom plate, remove the wear plate.
2. Use an air carbon arc torch and gouge out the weld between the bottom plate and the side plates a
distance of 100 mm (3.94 inch) from the seam of the side plates toward the bucket end of the
stick. Gouge out the weld between the bottom plate and the side plates a distance of 300 mm
(11.81 inch) from the seam of the side plates toward the boom end of the stick.
Note: Make sure that the side plates on the stick are not damaged when removing the welds.
3. Make cuts across the bottom plate in order to remove the section with the crack. Grind a 25 degree
bevel on the remaining bottom plates in preparation for welding the replacement bottom plate
section.
Ver imagen
4. Position the stick so that the side is horizontal. Remove the backup strip from the crack location.
5. Gouge out the crack that is located on the inside of the stick on the side plate weld seam. Gouge
out approximately 7 mm (0.28 inch) through the thickness of the plate. Gouge out 50 mm (1.97
inch) beyond the end of the crack. Grind a 50 degree bevel in the gouge. Weld the V-groove in a
Ver imagen
Gouge on inside of weld seam (50 degrees, 7 mm (0.28 inch) deep)
horizontal position. Grind the weld flush.
6. Position the stick so that the crack on the outside of the stick at the side plate weld seam is in a
horizontal position facing upward. Gouge out approximately 10 mm (0.39 inch) through the
thickness of the plate. Gouge out 50 mm (1.97 inch) beyond the end of the crack. Grind a 50
degree bevel in the gouge. Weld the V-groove in a horizontal position. Grind the weld flush.
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Gouge on outside of weld seam (50 degrees, 10 mm (0.39 inch) deep)
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(K) 25 degree bevel
(L) 45 degree bevel
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Backup Strip
(M) 305.0 mm (12.00 inch)
(N) 25.0 mm (1.00 inch)
(P) 10.0 mm (0.39 inch)
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Illustration 88
Plate dimensions given in millimeters
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ends of the backup strip. Remove the clamps that were used to prepare the backup strips for tack
welding.
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weld pass.
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15. Make a root pass in the flat position between the side plates and the replacement plate.
weld pass.
Illustration 92
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R3.2/R3.9 Stick
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HD3.2 Stick
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17. Make a fillet weld between the replacement plate and the side plate. Refer to illustration 94,
illustration 95, and illustration 96 for the fillet weld requirements.
weld pass.
18. Grind the cross weld flush when all of the welds are completed. The joint for the cross weld
should not be visible.
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Illustration 97
Fabricated reinforcement plate for the bottom plate (All dimensions given in millimeters.)
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20. Install the fabricated plate on the bottom plate as shown in illustration 98. Grind the welds
smooth.
Procedure for the Repair of a Type G Crack
Illustration 98
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This procedure describes the repair of cracks at the joint of the stick top plate and the stick cylinder
brackets.
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1. Position the stick so that the top plate for the stick is up.
2. Gouge out the cracks as shown in illustration 101 on the bracket weld in order to eliminate the
crack.
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3. Weld the gouge in the stick bracket as shown in illustration 102.
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Unacceptable finish weld
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4. Grind the weld smooth as shown in illustration 104
5. Fabricate two reinforcement plates for the cylinder bracket. Refer to illustration 105 for the
dimensions of the reinforcement plate. The recommendation of this material is higher than another
plate. ASTM A572 Grade 65 or Grade 70, or the equivalent steel with a minimum yield strength
of 450MPa is the best material for this plate. If you cannot get this material, minimum yield
strength of 290MPa is needed at least.
Acceptable finish weld
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6. Install a fabricated plate on both brackets of the stick cylinder. Adjust the gap to less than 1 mm
(0.039 inch) between the stick and the reinforcement plate. Tack weld the fabricated plate on the
bracket.
7. Put two bars on the plate to prevent the plate from leaning.
Illustration 105
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Illustration 106
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Tack weld
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8. Weld the fabricated plate on the bracket.
Bar
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9. Connect smoothly each weld by grinding at point B and near the area as shown in illustration 110
Illustration 109
Welding specification
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10. Grind the weld smooth as shown in illustration 111and 112.
(B) After grinding
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Before grinding
11. Remove the bar and finish paint.
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After grinding
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After grinding
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After paint
Copyright 1993 - 2013 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
Mon Nov 18 22:42:13 EST 2013

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