REPLACING REAR CRANKSHAFT COUNTERWEIGHT BOLT CAT 777D 1. BACKGROUND To maintain road condition in the field, grader have high working load. To maximize productivity of the grader good quality maintenance must be perform. Regarding to crack issue on front frame and artic hitch 16M Grader, we propose to replace add plate into the front frame and artic hitch of 16M Grader. This improvement will perform by internal labor align with PM schedule (artic hitch bearing replacement), “Front Frame and Artic Hitch Top plate crack 2. DATA REVIEW 2.1. Program Objective ‘As we know Trakindo has released service letter before to repair and replace plate on artic hitch if, ‘crack found (after fail only) but the program expired and not all Grader completed to perform the improvement, This program is proactive action by TC! to reduce the downtime related to crack issue on front frame and artic hitch2.2. Parts Needed and Scenario for Execution ‘The scenario is order additional plate for front frame and artic hitch that needed for one unit 16M Grader then fabricate the plates as per sample by Fab Shop for Cat 16M Grader that needs to perform the program, See below for additional plate for front frame and artic hitch 16M Grader need to purchase to Trakindo. The plates have been redesigned to provide better frame assembly service life. The new plates require less complicated welding techniques for installation. (Quantity Part Number Description, Unit Price (RUP)| Total Price 2 [sw-61e2 Plate Centre ShiftLHRH | Rp 1,941,540 Rp 2,882,080 1 [455-9757 [Bottom Plate Fp 7,077,680 Ro 7,077,680 2 [78-7100 Fish Plate IH Rear RP 6,155,510 | Rp 12,311,020 2 [a74-7151___Fish Plate RH Rear Rp 6,534,280 Rp 13,068,560 2 [374-7152 __ Fish Plate LH Front Fp 4,883,900 Rp 9,767,600 2 [74-713 Fish Plate RH Front Rp 4,888,020 Ro 9,777,240 1 [a2i-111__Top Plate Rp 10,941,710 | Ro 10,941,710 1 [617-6058 Plate Cover Pin Rp 1,977,370 | Ro 1.927.370 ‘Also wrapper plate fabrication by fabshop to support the top plate 3. SUMMARY Regarding to crack issue on front frame and artic hitch 16M Grader, we propose to replace add plate into the front frame and artic hitch of 16M Grader. This program is proactive action by TCI to reduce the downtime related to crack issue on front frame and artic hitch.Media Search - REBE8413 - PRODUCT SUPPORT PROGRAM FOR REWORKING T... Page | of 5 CATERPILLAR’ Service Information System [Shutdown SIS Previous Sereen < Proguct: No EQUIPMENT SELEC Model: NO EQUIPHENT SELECTED Configuration: NO EQUIPMENT SELECTED Service Letter PRODUCT SUPPORT PROGRAM FOR REWORKING THE ARTICULATION HITCH ON CERTAIN 16M MOTOR GRADERS Media Number -REBES413-02 Publication Date -10/08/2012 Date Updated -07/10/2013 CONFIDENTIAL REBES413-02 CATERPILLAR” 10Aug2012 (Revised 070ct2013) v-417 8-332 D-387 0-384 After Failure PRODUCT SUPPORT PROGRAM FOR REWORKING THE ARTICULATION HITCH ON CERTAIN 16M MOTOR GRADERS Only nosh PS52269 Nome: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52269" as the Part Number and Caterpillar: Confidential Yellow sweb/techdoc/techdoc print page.jsp?returnurl=/sisweb/sisweb/... 3/15/2018Media Search - REBE8413 - PRODUCT SUPPORT PROGRAM FOR REWORKING T... Page 2 of 5 "7755" as the Group Number. Description Code and use "Z @ "96" as the Warranty Claim as the SIMS Description Code. Nove The information this service letter may not be valid ‘min: ram. Do not perform work outlined in this Service Letter after the termination without first contacting your Caterpillar product analyst. nore his Revised Service Letter repla: es have been made to Affec n Required, and Service Claim Allowances @ 21NOV2012 oduct, Parts TERMINATION DATE 31Aug2014 PROBLEM The existing rear frame can crack in the top plate at the articulation joint on certain 16M Motor G ders operating in harsh applications. These cracks typically occur at higher hours and can propagate to the outer edge of the plate, resulting in fr. AFFECTED PRODUCT [Moder identification Nanber Fe jp5100100-00866 JR9H00100-00801 PARTS NEEDED Part Number Description Qty 2 192150 SEAL-LIP Caterpillar: Confidential Yellow veb/sisweb/techdoc/techdoc print page.jsp?returnurl=/sisweb/sisweb/... 3/15/2018Media Search - REBE8413 - PRODUCT SUPPORT PROGRAM FOR REWORKING T... Page 3 of 5 2 3K6454 .IP TYPE 10 455477 1 aK746 1 4K7462 2 4K7463 1 5K3489 SHIM-PACK 1 8K3492 SHIM-PACK 1 5K3494 RING" SLEEVE 1 5K3496 BEARING-SLEEVE 1 5K3929 BEARING AS-RLR 10 5K9090 10 6v8397 25 eve3se 10 759108 4 10 4 9x8257 WASHER-HARD 4 1187313 BOLT-HEX HEAD 2 1693257 NUT-WELD 2 2796632 WASHER-HARD 2 3196699 BOLT=HEX HEAD 2 3434081 BOLT-SHOULDER 4176056 SHIM 1 4176058 PLATE 1 4211181 PLATE AS Confidential Yellow Caterpillar: https://127.0.0./sisweb/sisweb/techdoc/techdoc print page.jsp?returnurl=/sisweb/sisweb/... 3/15/2018Media Search - REBE8413 - PRODUCT SUPPORT PROGRAM FOR REWORKING T... Page 4 of 5 In order to allow equitable parts avail 1 participating dealers, ase limit your initial parts ord not exceed 1% 0 This i ality to to dealership population. 1 orde: commendation only, and the ultimate responsibility for ering the 1 number of parts needed to satisfy the program lies n the ACTION REQUIRED If a crack is discovered in top plate of the articulation hitch weldment on the rear frame, apply Special Instruction REHS7191 rocedure to Repair Cracks and Improve the culation Kitch on Certain 16M Motor Graders" to replace the top plate. SERVICE CLAIM ALLOWANCES Product emu/age caterpillar Dealer Suggested |] customer suggested whichever comes first abor abor jabor Farts & Parte Bre’ ses Brat 0-16000 hra, 00.08 00.08 0.08 0.08 0.08 0.0% 0-48 mo 6001-24000 hrs, | 33.08 50.08 0.08 0.08 50.08 50.08 49-72 mo NOTE: This is a 150.0-hour job PARTS DISPOSITION Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Caterpillar: https://127.0.0.l/sisweb/s Confidential Yellow sweb/techdoc/techdoc print page.jsp?returnurl=/sisweb/sisweb/... 3/15/2018Media Search - REBE8413 - PRODUCT SUPPORT PROGRAM FOR REWORKING T... Page 5 of 5 cspuraht 1203-2018 cateeplar i hu Mar 35 16:01:02 UTC-+0800 2018 Caterpillar: Confidential Yellow https://127.0.0./sisweb/sisweb/techdoc/techdoc print page.jsp?returnurl=/sisweb/sisweb/... 3/15/2018Wrapper Plate Fabrication Fabricate new wrapper plates according to specifications Wrapper Plate Fabrication Fabricate new wrapper plates according to specifications RIGHT WRAPPER PLATE Te TEE Psat. ae ese ects ses sm tS Bea'sWrapper Plate Fabrication *+ When marking out the wrapper pate profiles, ello additonal material to final profi dimension forthe recite gin (0 vwinove arin Zin OF bse atrial owls fw ected acy, cabo wd ross residue Note: Carefully inspect and remove defects or surface cracks by grinding. + Wrapper plates must st both Mush and verte onthe rear ame; grinding the plates slong the edge inthe vicnty ofthe bends may be required to remove end ‘pucker fom the patos pucker pucker Welding Important notes to understand priate welding: + Preheat areas to be welded to 100 DegC: Top plate, Wrapper plates. any bracing and run outstrips + Tack wed the top plat tothe wrapper plates ‘+ Atemporay brace on the side of the wrapper plates opposite the top plate may be required to lim weld distortion Syne, + Install metal sips at ocations "XX", to allow filet welds to un out + Max weldinterpass temp, 200 Dege + When welding Sonen inner incapper Mile. Start 261 from end and overlap weld without ting and continue vweling. star poeUse material strips to allow um out wees. Grind fash hen ecg i completed TIG Dressing Upper Wrapper Plate Welds TIG dress the upper wrapper plate welds (Typ, two locations) 4. Start the TIG dressing on the outer face, working towards the inzide face Stop point 2, Ensure a continuous TIG dressing, start and stop TIG dressing in the center of the fillet a = Stop point IG dressings shown in purpleTIG Dressing Procedure Note: The fatigue performance is contrlled by the profi of the weld tos. Ths applies to fabricated stuctures that have filet woded attachments to highly stressed members. The fatigue performance can be improved by altering the original ‘Neleod toe profile. This ean be achieved by using several post we weatmant options, Ths procedure deceribes a ‘method of using an electric ac to reduce adverse profes and stress risers, This creates a seamless transition from one ‘compenentt the next component spar ea mat bec pg 208 ange (ri uy stand cles ao, na ocr ttn nich ete 5mm 006i donee TIG Dressing Procedure oa sommes id J oon =. min apn cetera tig 8 mpm gna ng ete ‘ete Ora uate Saeed Sema oo athonbe oim otae \ Sees ‘aceon a at de cans tt ma Sia St cups ‘ele ad atean ens ae enved Tan mana eee Styne nao ee ont 2 Retwea 24pm aon sect, Ree ote ess at Eee ini nese pad ese 2 Rain tango ton tes CHK Adee a (Soe Mel eran on cr soe al opr caer “ Seburrdiaie ite weanTIG Dressing Procedure Pte omen cpg Metnacttt Sin nie Malan Sal aan meme eee te 5. Sua teaeang ingens pewernoesr a cand dpa oan tt Te Fo us a Tapes bse ase ‘operate tug sa the ‘Wows atomed abut peo soowsSom beamsMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 1 of 29 CATERPILLAR’ Sorvice Information System Previous Screen Welcome: j210mbe Product: NO EQUIPMENT SELECTED Model: No EQUIPMENT SELECT: Configuration: NO EQUIPMENT <0 Special Instruction Procedure to Repair Cracks and Improve the Articulation Hitch on Certain 16M Motor Graders {7050, 7051} Media Number -REHS7191-03 Publication Date 14/09/2035 Date Updated -14/09/2015 io6268254 Procedure to Repair Cracks and Improve the Articulation Hitch on Certain 16M Motor Graders{7050, 7051} SMCS - 7050; 7051 Motor Grader: 16M (S/N: B9H1- Introduction Reference16M Motor Grader Machine System Disassembly and Assembly, KENR6018 ReferenceReuse And Salvage Guidelines, SEBF8401, "Dimensions for Articulated Joints and Steering Cylinder Bores for Motor Graders’. ReferenceSpecial Instructions, REHS7152, and Seals on Certain 16M Motor Graders” "Procedure To Install Articulation Cylinder Pin Joint Bushings ‘The 284-6069 Frame As is cracking at the articulation hitch. The top frame cracks at the articulation pin retainer plate bolt holes. Then the cracks propagate to the outer edge of the plate. In cases of excessive cracking of the frame assembly replacement of the top plate is required. This procedure applies to both circumstances. This procedure applies to the repair and or prevention of fatigue cracking associated with the 16M Motor Grader articulation frame. Note: The area of the rework must be clear of fuel tanks, all lines, all harness, all tubes, and all valves. This rework procedure generates many sparks, therefore provide protection from these sparks. Separating the front and rear frames is required to perform this rework, Do not perform any procedure until you read the information and you understand the information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 2 of 29 Specifications for Cables, Chains, and Lifting Devices Use approved cables, chains, and lifting devices in order to lift components. Refer to the weight provided by the manufacturer in order to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit, Note: The lifting devices that are shown in this publication are not Caterpillar parts. lustration L 200629745 Lift angles fr lifting sings (A) The load capacity is 100% of the working load limit forthe sling. (B) The load capacity is 86% ofthe working load limit forthe sling (©) The load capacity i 70% ofthe working load limit forthe sting (D) The load capacity is $0% of the working load limit for the sling Welding Specifications and QualificationsMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 3 of 29 WARNING 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 instruction 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, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting” published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CER 1910, available from U.S. Dept. of Labor, Washington D.C. 20210. Note: Personal breathing protection should be wom by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection. Qualifications Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW), Flux Cored Are Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to AWS D1.1 Structural welding code-steel or equivalent nationally or Internationally recognized code or standard for guidance on welder qualification testing requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months. Proper Welding Procedure on Machines and Engines with Electronic Controls Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow: 1. Turn off the engine. Put the key start switch in the OFF position. 2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery. 3. Connect the ground cable for the welder directly to the actual machine component that will be welded Attach the clamp for the ground cable as close as possible to the area that is being welded. This procedure will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components, Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 4 of 29 4. Protect the wiring hamesses from the welding spatter. Cleaning The area to be welded shall be clean, dry, and free of the following contaminants: + Oi * Grease * Paint + Dirt + Rust + Any fluids or moisture Initial Bake and Preheat Heat the repair area to a temperature of 100° C (212° F). Heating this area will remove all grease and thoroughly bake out any oil that may have been absorbed by the part or into the crack The minimum preheat temperature should be established at a distance that is at least equal to the thickness of the thickest member, but not less than 75 mm (2.95 inch) in all directions from the point of welding. Ensure that the full material volume surrounding the joint is heated. Heat the side opposite of the side which is to be welded. Measure the surface temperature next to the joint. The temperature may only be checked on the heated side. The heat source should be removed and sufficient time allowed for temperature equalization before measurement, ‘The interpass temperature should be checked in order to verify that the minimum preheat temperature has been maintained. The minimum preheat temperature should be maintained prior to initiating the arc for each pass. Preheat and interpass temperature can be measured with temperature indicating crayons, infrared thermometers, or thermocouples. Refer to Illustration 2 through 4.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 5 of 29 Mlustration 2 202028619 ‘Temperature indicating crayon Ilustration 3 202028621 ‘Thermometer Ilustration 4 202028622 ‘Type "K" thermocouple wires.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 6 of 29 Required Tooling The following tools are needed, and these tools are in addition to the normal supplies in the shop: + The Welding equipment and electrodes that are shown above + Oxy/Acetylene torch + Electrodes for Carbon arc gouging 6.35 mm (0.25 inch) in diameter Welding Electrodes and Parameters Flux Cored Welding Electrode for the FCAW Process Use Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSV/AS.20) welding electrode and the ‘manufacturer shielding gases that are specified (typically 75% argon and 25% carbon dioxide). The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical properties: Table 1 Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSVAWS A5.20 E7IT-1 8" Tensile Strength 480 MPa 70000 psi Yield Strength 400 MPa (58000 psi) Elongation 22% Impact Toughness 273 @ -18 °C (20 ftlb @ -0°F) The tables that follow show the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode diameters. Table 2 Welding Current for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch) Wire Feed Rate Voltage || Amperage 7620 mm (300 inch) Per Minute to || 24t0 28 |] 190 to 240 10,160 mm (400 inch) Per Minute Table 3 ‘Welding Current for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch) Wire Feed Rate Voltage _|| AmperageMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 7 of 29 5080 mm (200 inch) Per Minute to || 23 to 27 _|| 180 to 220 6350 mm (250 inch) Per Minute Note: The settings listed above are recommendations-based on experience welding in the horizontal, vertical- up, and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode manufacturers. Higher parameters than specified are acceptable to use for welding in the flat position. Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is, trapped in the weld. The maximum size weld per pass should be equivalent to that of a 8.0 mm (.32 inch) fillet weld. Low Hydrogen Electrodes for the SMAW Process An alternative process, or when wind conditions are a factor use SMAW and low hydrogen electrodes that mect the following minimum mechanical properties. Table 4 Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSVAWS ASL E7018" Tensile Suength 480 MPa (70000 psi) Yield Strength 400 MPa (58000 psi) Elongation 22% Impact Toughness 273 @ -29 °C (20 ft b @ -20 °F) Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the specifications provided by the manufacturer. The table that follows shows the settings for the welding current based on electrode diameter. Table 5 Welding Current for Low Hydrogen Electrodes Diameter Amperage Rating 3.2 mm (1/8 inch) 105-155 4.0 mm (5/32 inch) 130-200 4.8 mm (3/16 inch) 200-275 Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 8 of 29 Weld Inspection and Acceptance Criteria Table 6 1S0 6520 Defect Defect Name Reference Number | Remarks Defect Limit Cracks - 1011, 1012, 1013, Longitudinal, 1014, 1023, 1024, Transverse 1031, 1033, 1034, Radiating, Crater, | 1045, 1046, 1047, || Not Permitted Disconnected, 1051, 1053, 1054, Branching 1061, 1063, 1064 Crack - Transverse} 1991 Hard Surfacing Welds Only Permitted Crack- Transverse} 1991 Joining Welds Not Permitted Maximum Diameter for a Single Pore L mm (0.040 inch) Maximum Pores in Any 300 min (11.81 inch) Length of |] 6 2011, 2012, 2014, Porosity ce Weld Maximum Number of Pores in Any 50mm (2.0 inch) of Weld Length | for Welds Less Than 300 mm (11.81 inch) in Length . Maximum Length of Cluster in Any Clustered Porosity | 2013 yeu 3 mm (0.120 inch) Maximum Height or Width 3mm (0.120 inch) Blongated Cavities 915 Maximum Length for Any Single Discontinuity 25 mm (1.00 inch) Maximum Length in Any Weld _|[ 10% of Weld Length Maximum Dimension of Any ; Single Cavity 3mm (0.120 inch) Elongated Cavities | 4916 10% of Weld Length Not to Exceed 25 mm (1.00 inch) Maximum Total Length of Affected Area in Any Weld Shrinkage Cavities 2021, 2024, 2025 |] Maximum Diameter or Length 1 mm (0.040 inch) Slag or Flux 3011, 3012, 3014, Inclusions 3021, 3022, 3024 _ || Maximum Height or Width Imm (0.040 inch)Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on C... Page 9 of 29 Maximum Length for Any Single Discontinuity 25 mm (1.00 inch) Maximum Length in Any Weld __ || 10% of Weld Length Maximum Height or Width Imm (0,040 inch) Oxide Inclusions | 3031, 303 3033. || Maximum Length for Any Single Discontinuity 25 mm (1.00 inch) Maximum Length in Any Weld 10% of Weld Length Puckering (Oxide Inclusion - 3034 Not Permitted Aluminum) ‘Metallic Inclusion | 3041, 3042, 3043 || - Not Permitted Visual (Breaking the Surface) Not Permitted ‘Subsurface Maximum Height or Width Imm (0.040 inch) Lack of Fusion 4011, 4012, 4013 Subsurface Maximum Length for Any Single Discontinuity 25 mm (1.00 inch) Maximum Length in Any Weld 10% of Weld Length 10% of Nominal Penetration Not to Maximum Reduced Penetration enet Exceed Lack of Penetration} 495 4991 ‘Imm (0.040 inch) Maximum Allowed Total Length of Reduced Penetration 10% of Weld Length Undercut 5011, 5012, 5013, |] Maximum Depth Measured From ndercul 5014, 5015 Plate Surface - Any Length 0.5 mm (0.020 inch) Any Length, - Weld Face Width 5 mm (0,20 inch) or Less 1 mm (0.040 inch) Weld Face Width Over Excess Weld Metal - Smm (0.20 inch) But Less Than Groove Weld 10 mm (0.40 inch) 1.5 mm (0.060 inch) 502 Reinforcement (Convexity) Weld Face Width Over (10 mm) (0.40 inch) But Less Than 20 mm (0.80 inch) 2mm (0.080 inch) Weld Face Width Over 20 mm (0.80 inch) But Less Than 30 mm (1.20 inch) 3 mm (0.120 inch)Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 10 of 29 Weld Face Width 30 mm (1.20 inch) and Over 4 mm (0.160 inch) Excess Weld Metal - Filllet Weld Convexity 503 Convexity Affects Weld Toe Angle, Reducing Fatigue Life 90 Degrees Weld Toe Angles of 135 Degrees and More Are Better Defect Limits Expressed as Minimum Toe Angles Allowed Excess Penetration 5041, 5042, 5043 Without Drawing Limitation 2 mm (0,080 inch) (Any Length) With "Melt - Thru" and "Flush" Weld Symbols 1 mm (0.040 inch) (Any Length) With "Melt - Thru" and "Grind Flush" Symbols Not Permitted (After Grinding) Incorrect Weld Toe ‘When 1E2995 Applies (Expressed 505 as a Toe Radius Rather Than a Toe [3 mm (0.120 inch) Angle) Minimum Radius Overlap 5061, 5062 Expressed as Minimum Toe Angle} 99 peorees Fillet Weld Leg Size - Undersize Applies to Bither Weld Leg Measured Independent of the Other Maximum Undersize 1 mm (0.040 inch) Maximum Length of Undersize Weld 10% of Total Weld Length If At Least 10% of Total Weld Length is at Least 1 mm (0.040 inch) Over Nominal Size, Otherwise, No Undersize Length is Permitted Fillet Weld Leg Size - Oversize Applies to Bither Weld Leg Measured Independent of the Other Maximum Oversize +25% (max 3 mm (0.120 inch))Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 11 of 29 Conformance to Design - Fillet Weld Leg Sizes May be Oversized (Within Defect Limitations or Beyond) Without Correction Provided the Excess Does not Interfere with Satisfactory End Use of the Component (‘e., Distortion, Fit-Up Interference, etc.) Fillet Weld - Linear Length when specified at less than the length of the joint Weld Size < 6.5 mm (0.256 inch) 6.5 mm (0.256 inch) Weld Size > 6.5 mm (0.256 inch) + 12.5 mm (0.492 inch) Fillet Weld Throat Nominal Size (0.7 x Leg Size) Not Inclusive of Penetration Beyond the Weld Root Not Permitted 2 mm (0.080 inch) Size Underine [5213 MAX - and Not to - ; Exceed 20% of Weld Crater Only - Maximum Speuified Throat, Not Undersize : Inclusive of Penetration Beyond the Weld Root (0.7 x Leg Size) Careful Consideration Needs to be Given When Plate Mismatch is |] Not Permitted Incompletely Filled | 551 Apparent Groove Weld 5 _———<$_—<—<— — Weld Depth Must be Maintained as, a Minimum Root Concavity on Maximum Depth measured From Open Root Groove | 515, 5013 Plate Surface or Tube Inner Surface Watts Pan Length 0.5 mm (0.020 inch) Measured in Terms of Excess Weld Metal (Fillet Weld Convexity) or |] Overlap on Groove Welds, Lack of Fusion, or Insufficient Throat Excess Weld Metal on Fillet Welds, Defect Limits Expressed as 90 Degrees Poor Restart (Tie - aa Me- | sii, sim Minimum Toe Angles Allowed Overlap on Groove Welds, Defect Limits Expressed as Minimum Toe |] 90 Degrees Angles Allowed Lack of Fusion - Visual Maximum Length Per Restart 3 mm (0.120 inch)Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 12 of 29 Insufficient Weld Throat Not Permitted Stray Arc Strike 601 ~ Not Permitted SMAW, SAW, FCAW, GMAW _|| Not Permitted Silicon Residue Slag Residue ols GTAW Permitted Unless Removal Specified by Drawing Note Total Maximum Combined Length of All Imperfections in a Weld, 1% Expressed as a Percent of Total Combined Weld Length Discontinuities (No Single Type of Imperfection Can Exceed the Limits for That || ~ Single Type of Imperfection) Prepare the Machine for Rework 1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel. Place the transmission direction control switch in the NEUTRAL position, Engage the parking brake. Lower the work tools to the ground. Stop the engine and put chocks in front of the wheels and behind the wheels. 2. Remove the pressure from all of the systems. Do not assume that the pressure is removed from the circuit if the brake pedal has no resistance. 3. Refer to 16M Motor Grader Machine Systems Disassembly and Assembly, KENR6018 for information on exposing and disconnecting the articulation hitch. 4. Cover the engine and components with a tarp to protect the engine from sparks and slag. 5. Remove the cab and the fuel tanks when you perform this rework procedure. This rework generates sparks and slag. Protect all components of this machine from these sparks and slag Tooling Required for This Rework Table 7 Required Tools Description ay Air Arc Gouge 1 GTAW "(TIG)" 1 Are Welder 1 178 mm (7 inch) Pneumatic Grinder !Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 13 of 29 Assorted sanding Pads 178 mm (7 inch) Pneumatic Grinder Pneumatic die grinder with a 25 mm (1 inch) barrel attachment and with 36 grit and 80 grit sanding cylinders 1/2 by 1 inch, and 3/8 by 1/2 tungsten carbide burr tools 1 237-5181 RESPIRATOR 1 Tarp - Magnetic Drill 1 Optional Parts Required for this Rework Table 8 Parts List Item [Qty | Part Number Part Name 1 4 118-7313 Bolt 2 2 169-3257 Weld Nut 3 2 13-2150 Lip Type Seal 4 2 87-4223, Hard Washer 5 1 421-1181 Plate As 6 2 343-4081 Special Bolt 1 2 319-6699 Bolts 8 2 3K-6454 Lip Type Seal 9 10 4.5477" O-Ring Seal 10 1 SK-3495 Collar WL 1 5K-3489 Shim Pack 12 1 5K-3492 Shim Pack 13 1 5K-3494 Bushing 14 1 5K-3496 Bushing 15 1 5K-3929 Roller Bearing As 16 10 5K-9090 O-Ring Seal 17 10 || 6v-8397 O-Ring SealMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on.. 18 | 25 || ov-s308 O-Ring Seal 19 10 73-9108 O-Ring Seal 20 10 9X-7383 O-Ring Seal 21 4 9X-8257 Washer 22 1 417-6058 Plate 23 | 20 417-6056 Shim am |4 7K-9204° Lip Type Seal \ Required to connect the hydraulic lines when correcting the machine. ® Articulation dust seals that require replacement when splitting the machine. 16M Rear Frame Repair 2. After removal of the top plate clean the area with a sander, Mustration 5 ‘Top view of the rear frame assembly 203067137 . Gouge the welds that hold the existing plate assembly to the frame assembly. Th Page 14 of 29 remove the top plate, Do not remove material from the vertical plates. Removing that material would cause the height of the new plate to be altered.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on.. lvstration 6 View of the top of the plate 203072423 3. Push the new plate against the divider plate. FWD Mstration 7 View of the top of the plate 203072445, Page 15 of 29 4. Place square vertically at the arrows. Then place a square over the edge of the plate and position the plate even with the next plate down. Check the other side with the square also. 5. Make a visual observation to verify that plate (5) is correctly positioned on the articulation hitch.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 16 of 29 lustration 8 203074458, ‘View of the top of the new plate 6. Tack weld the plate at points indicated by the arrows.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 17 of 29 lustration 9 203067217 ‘Top view A-A rotated 90°, Refer to Illustration 10 AA r = } : ax 20 [7 Ilustration 10 120306 View of the top right side of the articulation hitchMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 18 of 29 (A) Maintain 140 mm ($.5 inch) between the two plates and maintain parallelism (B) Minimum dimension of 65.5 mm (2.58 inch) between the boss's in two places, 7. Tack weld plate (5) into position. ustration 11 (©) 50 min (1.97 inch) (D) 150 mm (5.91 inch) 203834824 8. Finish weld the wrapper plate into position, Alternate the areas that are being welded to minimize heat distortion. Note: A continuous weld should extend along length (C), around the end of the wrapper plate and along length (D). The weld size and penetration must be maintained along the end and backside of the wrapper plate. TIG Dressing Procedure Note: The fatigue performance is controlled by the profile of the weld toe. This applies to fabricated structures that have fillet welded attachments to highly stressed members. The fatigue performance can be improved by altering the original welded toe profile. This can be achieved by using several post weld treatment options. This procedure describes a method of using an electric arc to reduce adverse profiles and stress risers. This creates a seamless transition from one component to the next component. Table 9 Required Equipment Tool DescriptionMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on.. Page 19 of 29 GTAW (TIG) Power supply and a torch. ‘The power supply must be capable of producing 200 amps (min. 60% duty cycle) with a hand control or a foot control Shielding Gas 00% Argon and flow meter Lanthanated or Ceriated or ‘Thoriated Tungsten Electrode 2.4: mm (0.09 inch diameter) If needed: ER70S-2 filler metal 1.5 mm (0.06 inch diameter) Grinder Pneumatic or electric with carbon steel wire wheel attachment Grinding Wheel Aluminum Oxide Radius gauges 270 3X DIAMETER i —+| lw TO 1/2X DIAMETER ustration 12 203667539 2.4 mm (0.09 inch) Tungsten Electrode Preparation (A) Serrations or Grinding MarksMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 20 of 29 1, Cleanliness and tungsten electrode preparation are the first steps in order to ensure that a proper TIG dressing is achieved. All contaminants must be removed from the fillet weld and the surrounding base metal. All rust, dirt, oil, scale, and silicate islands must be removed. This can be accomplished quickly via a grinder with a carbon steel wire attachment. 2. Prepare a 2.4 mm (0.09 inch) tungsten electrode. Refer to the dimensions that are shown in Illustration 12. The serrations should run parallel to each other. 3. Adjust the shielding gas flow rate to 15 CFH. Adjust the current control to approximately 200 amps. If a ramp down control is present on the power source, utilize the ramp down control to ensure that proper crater fill control is achieved. 4. A number of different techniques exist for TIG dressing. This is due to the variation of the contour of the fillet weld toe, The contour of the fillet weld toe must be reshaped. Use a stringer or weave manipulation of the torch in order to achieve a smooth radius of the weld. A minimum radius of 5.0 mm (0.20 inch) must exist between the base material and the weld metal. ~ 070 25" WORK ANGLE ‘x lustration 13 202585257 Stringer Technique Note: Use a 10 to 15 degree push angle for the stringer technique. 5. Illustration 13 represents the stringer technique of welding. The center of the arc needs to be 0.0 - 2.0 mm (0.0 - 0.08 inch) from the weld toe into the base material.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 21 of 29 0 TO 45° WORK ANGLE 3mm WEAVE lvstration 14 202585296 ‘Weave Technique Note: Use a 10 to 15 degree push angle for the weave technique. 6. Illustration 14 represents the weave technique of welding. Mustration 15 1202585300 7. Illustration 15 represents a cross section view of a proper TIG dressed fillet weldMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 22 of 29 lustration 16 202585301 Mlustration 17 202585303 8, Illustration 16 and Illustration 17 are examples of expected results.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 23 of 29 Ilvstration 18 203834064 100 min (3.49 inch) lustration 19 203834073 (A) SO mm (1.97 inch) 9. Once TIG dressing is completed, the arca needs to be cleaned and painted in order to prevent pitting due to corrosion Note: Poorly shaped fillet welds with 70 degree to 90 degree transition angles will require several overlapping TIG dressing runs. Overlapping of the TIG dressing runs is required in order to stabilize the weld toe transition area. Note: TIG dressing can be conducted in the vertical position as long as the TIG dressing is performed in a downhill progression. Note: Some undercuts will require the addition of filler metal. This can be accomplished by hand feeding ER70S-2 1.5 mm (0.06 inch diameter) into the weld pool. You then repeat the TIG dressing in order to achieve the desired toe radius and the desired profile. Inspect using a radius gage to ensure a5 mm (0.20 inch) minimum radius. TIG dressing along the top hitch plate should be executed along the weld toe of the wrapper plate to top hitch plate joint as shown in Illustrations 18 and Illustration 19. Start the TIG dressing 100 mm (3.94 inch) from the end of the plate on the front side, Run a continuous TIG dressing around the edge of the plate and 50 mm (1.97 inch) along the back side. Start and stop the TIG dressing in the center of the fillet weld, The TIG dressing should be carried out on the left and right side of the hitch Reassembly ProcedureMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 24 of 29 Ilvstration 20 203073918, Some holes are not shown in this view (C) View of two holes that need to be line bored to $7.205 + 0.03 mm (2.252, + 0.001 inch). (D) View of hole that needs to be line bored 120.68 + 0.05 mm (4.751 + 0,002 inch). 1. Line bore one hole (D). Refer to Reuse and Salvage Guidelines, SEBF8401, "Dimensions for Articulated Joints and Steering Cylinder Bores for Motor Graders" 2. Line bore two holes (C). Refer to Reuse and Salvage Guidelines, SEBF8401, "Dimensions for Articulated Joints and Steering Cylinder Bores for Motor Graders’.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 25 of 29 {L | T | a t ‘o | © + Wo oo ustration 21 0388 View of the location of new holes and bosses on the reworked top plate (£) 34.6 mm (1.36 inch) in two places (&) 85.5 mm (3.37 inch) in two places }) 110 mm (4.3 inch) in two places (A) 112.5 mm (4.43 inch) in two places (D) 69.5 mm (2.74 inch) in two places (K) 102.6 mm (4,046 inch) in two places. (L) 149.7 mm (5.89 inch) in two places (OM 191 mm (7.5 inch) in three places (Datum (®) DatumMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 26 of 29 (R) Drill wo holes 9.5 mm (0.37 inch)-A diameter holes, Maintain perpendicularty of S mm (0.196 inch) 5) Drill and tap four through holes with a M16x2 thread (1) Line bore the top set of two holes 120.68 +: 0.05 mm (4.75117 4 0.00197 inch) Dall wo 10.5 holes and tap using a 12 x 1.75 - 611 tap 3. Use a mag drill to machine the holes into plate (5). Locate the holes off datum (N) and datum (P) XO ee FWD Mlustration 22 203067141 (2) 169-3257 Weld Nut 4, Attach one weld nut (2) to the top side of plate assembly (5) in two places.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 27 of 29 Ilustration 23 203879101 ‘Top pin ofthe articulation joint. Bolt plate to the upper articulation pin using two washers (4) and two bolts (7). Install four bolts (1) and four washers (21). Pre-torque bolts (1) to one half the standard torque value. a Measure gap between the newly installed top plate (5) and plate (22) 7. Install shims (23) as needed and install two bolts (6) . . Final torque bolts (1) to the standard torque. 2 Assemble the machine per 16M Motor Grader Machine System Disassembly and Assembly, KENR6O18.Media Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 28 of 29 Mlustration 24 (203879103, ‘The parts that are called out in this graphic are listed in Table 8 (2) 118-7313 Bolt ira ip Type Seal (4) 279-6632 WasherMedia Search - REHS7191 - Procedure to Repair Cracks and Improve the Articulation Hitch on... Page 29 of 29 (6) 343-4081 Special Bolt (1) 319-6699 Bolt (8) 3K-6454 Lip Type Seal (10) 5K-3495 Collar (11) SK-3489 Shim Pack (12) 5K-3492 Shim Pack (13) 5K-3494 Bushing (14) 5K-3496 Bushing (45) SK-3929 Roller Bearing As (21) 9X-8257 Washer = 2036 casera ‘Thu Mar 24 15:26:31 UTC#0800 2016 ‘AllBlants Reserves j210mbeMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page | of 37 CATERPILLAR’ Service Information System Welcome: j210mbe < Procuct: seue Model: No EQUIPMENT SELEC Configuration: NO EQUIPMENT SELECTED I Instruction Procedure For The 16M Motor Grader Front Frame and Centershift Bracket{7050} Media Number -REHS8792-01 Publication Date 13/10/2014 Date Updated -13/10/2014 ios907811, Repair Procedure For The 16M Motor Grader Front Frame and Centershift Bracket{7050} SMCS - 7050 Motor Grader: 16M (S/N: B9H1-UP; R9H1-UP) Introduction ‘This Special Instruction provides information on the areas of the frame assembly that should be inspected for cracks. The following areas are covered in this Special Instruction: general, inspection, centershift repair, TIG dressing procedure and weld quality criteria. The supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for each standard machine. Read the entire Special Instruction. Understand the information before you perform any procedures. ‘Understand the information before you order any parts. a ITT Do not attempt to assemble this machine until you read and you understand the assembly instructions. Safety Improper assembly procedures could result in injury or death.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 2 of 37 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. a ITT 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, car 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 749.1, 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 aT ‘When a hoist is used to lift any part or assembly, stand clear of the area under the part being raised. Always make sure that the hoist has adequate lifting capacity and the wire cable is not damaged.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 3 of 37 Failure to follow this instruction could lead to injury or death. Approximate weights of the components are shown in the table which follows. Processes for Welding Do not weld in areas if there is a strong movement of air or in temperatures of less than 16 deg C (61 deg F). ‘The following welding processes are acceptable for this procedure: + Gas metal are welding (GMAW) Use 35 + 5 cu ft per hour of shielding gas (75% argon and 25% carbon dioxide). The AWS Class ER70S-3 is a welding process that can be used with the following welders: Lincoln L-S0 and Hobart HB-25. Comparable equipment may be used, + Flux cored are welding (FCAW) Use 35 + 5 cu ft per hour of shielding gas (75% argon and 25% carbon dioxide). The FCAW process is called the AWS Class E71T-1 process. Table 1 Weld Specifications Weld Description WI |[ 14 mm (55 inch) fillet weld W2 || 5 mm (020 inch) fillet weld W312 mm (0.47 inch) fillet weld W4 |) 3 mm (0.12 inch) fillet weld References ReferenceRefer to Operation and Maintenance Manual, 2BU7696, "Welding on Machines and Engines with Electronic Controls" for additional welding instructions. ReferenceRefer to Special Instructions, REHS1841, "General Welding Procedures” for additional welding instructions, ReferenceGuide, SEBD0512, "Service Welding Guide". ReferenceRefer to Disassembly and Assembly, KENR6018 when you need to remove any components to repair the front frame.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 4 of 37 Specifications for Cables, Chains, and Lifting Devices Use approved cables, chains, and lifting devices in order to lift components. Refer to the weight from the manufacturer in order to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit, Note: The lifting devices that are shown in this publication are not Caterpillar parts. lustration L 200629745 Lift angles fr lifting sings (A) The load capacity is 100% of the working load limit forthe sling. (B) The load capacity is 86% ofthe working load limit forthe sling (©) The load capacity i 70% ofthe working load limit forthe sting (D) The load capacity is $0% of the working load limit for the sling Replacement PartsMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 5 of 37 lusteation 2 203664115 Bottom side of frame Table 2 Replacement Parts Item |/Qty [Part Number _ | Description 1 4 9R-3761 Boss 2 1 455-9757 Plate Welder Qualification and Safety 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. a ITTMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 6 of 37 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. S. Department of Labor Washington, D.C. 20210 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. ReferenceSpecial Instruction, REHS1841, "General Welding Procedure: All welders must be qualified for the material, process, and position in accordance with Caterpillar Service Manual, SEBDO512, "Service Welding Guide" or the specific requirements and rules as outlined in a recognized national or international specification standard applicable to the product being manufactured, Personal protection equipment should be worn in accordance with local safety policies. The welder must alsoMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 7 of 37 be familiar with both the air Carbon Arc Gouging (CAC-A) and grinding processes. The welder must know how to use the processes safely Cleaning Clean oil, grease, paint, dirt, and all other contaminants from the area to be repaired. Clean the area that is repaired by grinding, sanding, and rotary steel wire wheel. Area to be cleaned should extend at least 152.4 mm (5.99 inch) on all sides of the crack. Care should be taken when cleaning so that minimal base material thickness is affected Initial Bake and Preheat Heat the repair area to a temperature of 100° C (212° F). Heating this area will remove all grease and thoroughly bake out any oil that may have been absorbed by the part or into the crack. The minimum preheat temperature should be established at a distance that is at least equal to the thickness of the thickest member, but not less than 75 mm (2.95 inch) in all directions from the point of welding. Ensure that the full material volume surrounding the joint is heated. Heat the side opposite of the side which is to be welded, Measure the surface temperature next to the joint. The temperature may only be checked on the heated side. The heat source should be removed and sufficient time allowed for temperature equalization before measurement, ‘The interpass temperature should be checked in order to verify that the minimum preheat temperature has been maintained. The minimum preheat temperature should be maintained prior to initiating the arc for each pass. Preheat and interpass temperature can be measured with temperature indicating crayons, infrared thermometers, or thermocouples. Refer to Illustration 3 through 5 Ilustration 3 202028619 ‘Temperature indicating crayonMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 8 of 37 Ilustration 4 202028621 ‘Thermometer lustration 5 202028622 ‘Type "K" thermocouple wires. Inspection and RepairMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Cent... Page 9 of 37 Mustration 6 20366 ‘View of front covers 1. Remove front covers (A), (B), (C) and (D) 2. Remove the blade lift arms, refer to Disassembly and Assembly, KENR6018. Move or disconnect hydraulic and electrical lines as needed to access the centershift area for inspection and repair. Cap and cover all hydraulic and electrical lines to protect from debris and contamination. Cover the cab with weld blankets to protect the surfaces from slag and sparks.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 10 of 37 Mustration 7 20366 ‘View of right sear inspectionMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 11 of 37 lustration 8 20366 ‘View of right rear inspection (old style fish plate) 3. Starting on the machine right side, inspect the atea behind the centershift plate, refer to Illustration 7 and Illustration 8, Focus on the vertical weld seams and the four weld intersections. Look for any signs of cracking (cracked paint, visible rust seam, etc.). Magnetic particle or dye penetrant tests may be used to confirm a crack is present. Ensure that the frame top and bottom plates are inspected next to any of the weld intersections to ensure that no cracks are present. Pay particular attention to areas where weld terminations are present. Note: If your frame is equipped with the old style fish plates, see Illustration 8, these will be need replaced with the improved square style fish plates shown in Illustration 7. Refer to Special Instruction, REHS4249, "Front Frame Inspection and Crack Repair For 16M Motor Graders" If a crack is found in the vicinity of either of the rear weld intersections (locations (E) or (F), Illustration 7 or locations (G) or (H), Ilustration 8), the rear vertical weld seam (between locations (E) and (F), Ilustration 7), or in the top or bottom frame plates, refer to Special Instruction, REHS4249, "Front Frame Inspection and Crack Repair For 16M Motor Graders” to repair the cracks and replace the fish. plates. Steps 24 through 29 in the Section "Crack Repair in bottom Plate” should be omitted. An improved bottom plate and weld procedure will be referenced later in this Special Instruction. If any cracking is present in the front vertical weld seam and there is no cracking present in either the top or bottom frame plates, the damaged weld can be gouged out and rewelded. The crack must be fully excavated to find the root, Multiple weld passes may be required to complete the repair. The final repair should be blended into the adjacent material. The weld starts and stops must be blended into the adjacent weld such that they are not readily visible. If no cracks are found, using a sanding disc, blend any weld terminations located in the areas shown in Ilustration 7. Take care not to gouge the weld or remove any excessive weld material. Also, take care not to gouge or remove any of the base, parent material. The final blended weld should look like a continuous, smooth weld with no discernable starts or stops.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 12 of 37 Mlustration 9 20366 Inspection between centershift plates 4, Looking between the centershift plates on the right side of the machine, inspect for any signs of cracking at the intersections of the welds at the top and bottom corners of the centershift plates. Inspect the top and bottom plates near the welds to ensure that no cracking is present. The vertical welds between the centershift plates should also be inspected for any cracks. If any deficiencies are found, refer to Special Instruction, REHS4249, "Front Frame Inspection and Crack Repair For 16M Motor Graders". Again, steps 24 through 29 in the Section “Crack Repair in bottom Plate” should be omitted. An improved bottom plate and weld procedure will be referenced later in this Special Instruction, If any visible or abrupt weld starts or stops are present, using a sanding disc, blend any weld terminations located in the areas shown in Illustration 9. Take care not to gouge the weld or remove any excessive weld material. Also, take care not to gouge or remove any of the base, parent material. The final blended weld should look like a continuous, smooth weld with no discernable starts or stops.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 13 of 37 Mlustration 10 20366 ‘View of right front inspectionMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 14 of 37 lvstration 11 20366 ‘View of right front inspection (old style fish plate) 5. On the right side of the machine, inspect the area in front of the centershift plate as shown in Ilustration 10 and Illustration 11. Focus on the vertical weld seams and the four weld intersections. Look for any signs of cracking (cracked paint, visible rust seam, etc.). Magnetic particle or dye penetrant tests may be used to confirm a crack is present. Ensure that the frame top and bottom plates are inspected next to any of the weld intersections to ensure that no cracks are present, Pay particular attention to areas where weld terminations are present. Note: If your frame is equipped with the old style fish plates, see Illustration 11, replace fish plates with the improved square style fish plates shown in 10. Refer to Special Instruction, REHS4249, "Front Frame Inspection and Crack Repair For 16M Motor Graders" If a crack is found in the vicinity of either of the front weld intersections (locations (J) or (K), Illustration 10 or locations (L) or (M), Illustration 11), the front vertical weld seam (between k (J) and (K), Illustration 10), or bottom frame plates, refer to Special Instruction, REHS4249, Frame Inspection and Crack Repair For 16M Motor Graders" to repair the cracks and replace the fish plates. Steps 24 through 29 in the Section "Crack Repair in bottom Plate" should be omitted. An improved bottom plate and weld procedure will be referenced later in this Special Instruction, If any cracking is present in the rear vertical weld seam and there is no cracking present in either the top or bottom frame plates, the damaged weld can be gouged out and rewelded. The crack must be fully excavated to find the root, Multiple weld passes may be required to complete the repair. The final repair should be blended into the adjacent material. The weld starts and stops must be blended into the adjacent weld such that they are not readily visible. If no cracks are found, using a sanding disc, blend any weld terminations located in the areas shown in Ilustration 10. Take care not to gouge the weld or remove any excessive weld material. Also, take care not to gouge or remove any of the base, parent material. The final blended weld should look like a continuous, smooth weld with no discernable starts or stops. 6. Following the same procedure, inspect the left side of the frame in the centershift area. Working from the rear of the machine to the front, identify and repair any cracks. Bottom Reinforcement Plate Installation A bottom reinforcement plate has been designed to improve the weld fatigue life of the centershift welds. Ifa bottom reinforcement plate is already installed on the frame, removing the existing bottom plate and installing anew one will not improve the overall centershift life, Inspect the welds on the existing reinforcement plate and the adjacent base material to ensure that no cracking is present. Ensure that no weld discontinuities exist. Blend the existing weld starts and stops into the adjacent weld material. The finished weld should be smooth and uniform in appearance with no visible starts or stops. Once the existing bottom reinforcement plate welds are inspected, repaired, and blended properly, skip to "" TIG Dressing Procedure” " Section. If the frame does not already have a bottom plate, refer to the following procedure to install the bottom reinforcement plate.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 15 of 37 Mustration 12 20366 1. Remove hardware from the bottom of the frame, see Illustration 12. Take care not to gouge the bottom plate. All weld material must be removed and area blend smooth and flush with the frame bottom plate of the frame.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 16 of 37 lustration 13, 203666273 2. Remove all paint from the area where the bottom plate will be welded as shown in Illustration 13. In order to position new reinforcement plate (2) on bottom of the frame, it has to be fed through the centershifi bracket from the front side of the centershift bracket. The rear of plate (2) can be identified by the slots that are cut out. Use two people to position th plate, the weight of plate (2) is approximately 80 kg (175 Ib). 3 203666398 Ulustration 14Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 17 of 37 lvstration 15 203666387, 4, Use a crane or C-clamps to secure plate (2) in position. The plate should follow the contour of the frame. Try to locate the new plate by minimizing gap between reinforcement plate and bottom of frame. Ilustration 14 shows a crane and strap used to hold plate in position. [lustration 15 shows clamps on rear section of plate to hold in position. With the cab and hydraulic and electrical components installed on the machine, clamps may need to be positioned on the lower flange of the frame and a bar used across the bottom to provide clamping force on the reinforcement plate.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 18 of 37 Ilvstration 16 203666779 Centering of bottom plate 5. Center plate (2) on the bottom of the frame. Measure from the outside of the frame to the edge of the plate, there should be approximately 62 mm (2.44 inch) (A) on either side of the plate. ustration 17 20366 ‘View of gap inspection area 6. Inspect the fit-up of the plate. Pay particular attention to the area shown in Illustration 17. All gaps should be 5 mm (0.20 inch) or less. If any gaps exist that exceed 2 mm (0.08 inch), the weld must be oversized to compensate. The leg length of the fillet weld must be oversized by the amount of the gap; for example, if the nominal weld is 14 mm (0.55 inch) and a 4 mm (0.16 inch) gap exists, the leg length of the fillet weld in that area must be increased to 18 mm (0.71 inch).Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 19 of 37 20366 Mlustration 18 View of tack welded plate 7. Once plate (2) is properly located for best fit-up and centered, tack into position starting at the rear. Tack welds should be 15 mm (0.59 inch) to 20 mm (0.79 inch) in length and spaced out approximately every 150 mm (5.90 inch).Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 20 of 37 | ~________ p —_____+| -—_____— ¢ —_____+| He \ E FWD j{-———— F ——_> + s —___-| Llustration 19 20366 View of weld locations on the bottom ofthe frame (2) Reinforcement plate {B) 1060 mm (41.73 ined) (©) 1010 mm (39.76 inch) (©) 450 mm (17.72 inch) {500 mm (19.69 inch) (&) 825 mm (32.48 inch) 875 mm (34.45 inch) (8 75 mm (2.95 inch) (W1) 14 mm (0.55 inch) fillet weld (W2) S mm (0.20 inch) fillet weld 8. Mark out the perimeter weld as shown in Illustration 19. Once plate (2) is marked, finish weld the plate. Blend all starts and stops. Ensure transitions between the two sizes of fillet welds are smooth, W2.- 5 mm (0.20 inch) fillet weld * (AR) to (AS) © (AT) to (AU) » (AV) to (AX)Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 21 of 37 © (AZ) to (AY) WI - 14 mm (0.55 inch) fillet weld © (AY) to (AR) © (AX) to (AZ) © (AU) to (AV) © (AS) to (AT) Note: The 14 mm (0.55 inch) fillet weld (W1) should be made in a minimum of three stringer passes. 2 wa LEN Ww rae D (2) Reinforcement plateMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 22 of 37 (W3) 12 mm (0.47 inch) fillet weld 9. Weld (W3) the three slots at the rear of plate (2). Blend welds as needed to ensure a smooth and uniform final weld, After completing all the welds, inspect the welds according to ""Weld Quality Criteria" " TIG Dressing Procedure Note: The fatigue performance is controlled by the profile of the weld toe. This applies to fabricated structures that have fillet welded attachments to highly stressed members. The fatigue performance can be improved by altering the original welded toe profile. This can be achieved by using several post weld treatment options. This procedure describes a method of using an electric arc to reduce adverse profiles and stress risers. This creates a seamless transition from one component to the next component, Table 3 Required Equipment ‘Tool Description GTAW (TIG) Power supply and a torch. The power supply must be capable of producing 200 amps (min. 60% duty cycle) with a hand control or a foot control. Shielding Gas 100% Argon and flow meter Lanthanated or Ceriated or Thoriated Tungsten Electrode 2.4 mm (0.09 inch diameter) If needed: ER70S-2 filler metal 1.5 mm (0.06 inch diameter) Grinder Pneumatic or electric with carbon steel wire wheel attachment Grinding Wheel Aluminum Oxide Radius gaugesMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 23 of 37 2T03K VE DIAMETER th —+| Ls TO 1/2X DIAMETER Mlustration 21 203667539 2.4 mm (0.09 inch) Tungsten Electrode Preparation ) Sertations or Grinding Marks Cleanliness and tungsten electrode preparation are the first steps in order to ensure that a proper TIG Gressing is achieved. All contaminants must be removed from the fillet weld and the surrounding base metal. All rust, dirt, oil, scale, and silicate islands must be removed. This can be accomplished quickly via a grinder with a carbon steel wire attachment. Prepare a 2.4 mm (0.09 inch) tungsten electrode. Refer to the dimensions that are shown in Illustration 21. The serrations should run parallel to each other. Adjust the shielding gas flow rate to 15 CFH. Adjust the current control to approximately 200 amps. If aramp down control is present on the power source, utilize the ramp down control to ensure that proper crater fill control is achieved. A number of different techniques exist for TIG dressing. This is due to the variation of the contour of the fillet weld toe, The contour of the fillet weld toe must be reshaped. Use a stringer or weave manipulation of the torch in order to achieve a smooth radius of the weld. A minimum radius of 5.0 mm (0.20 inch) must exist between the base material and the weld metal.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 24 of 37 (070 25" WORK ANGLE Lo lvstration 22 202585257 Stringer Technique Note: Use a 10 to 15 degree push angle for the stringer technique. 5. Illustration 22 represents the stringer technique of welding. The center of the arc needs to be 0.0 - 2.0 mm (0.0 0.08 inch) from the weld toe into the base material. 0 TO 45° WORK ANGLE 3mm WEAVE Ilustration 23 202585296, ‘Weave Technique Note: Use a 10 to 15 degree push angle for the weave technique. 6. Ilustration 23 represents the weave technique of weldingMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 25 of 37 lvstration 24 202585300 7. Ilustration 24 represents a cross section view of a proper TIG dressed fillet weld. lustration 25 202585301 Mostration 26 202585303 8, Illustration 25 and Illustration 26 are examples of expected results. 9. Once TIG dressing is completed, the area needs to be cleaned and painted in order to prevent pitting due to corrosion.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 26 of 37 Note: Poorly shaped fillet welds with 70 degree to 90 degree transition angles will require several overlapping TIG dressing runs. Overlapping of the ‘TIG dressing runs is required in order to stabilize the weld toe transition area. Note: TIG dressing can be conducted in the vertical position as long as the TIG dressing is performed in a downhill progression. Note: Some undercuts will require the addition of filler metal. This can be accomplished by hand feeding ER70S-2 1.5 mm (0.06 inch diameter) into the weld pool. You then repeat the TIG dressing in order to achieve the desired toe radius and the desired profile. Inspect using a radius gage to ensure a5 mm (0.20 inch) minimum radius. lustration 27 20366 (B) 75 mm (2.95 inch)Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 27 of 37 lvstration 28 203667708 Detailed view of TIG toe dressing 10. TIG dressing needs to be applied to the front and rear ends of plate (2) as shown in Ilustration 27. It must extend 75 mm (2.95 inch) (B) past the radii. The TIG dressing is to be applied at the weld toe on the main bottom plate of the frame as shown in Ilustration 28. Note: If the frame had a previous bottom plate installed, perform a similar TIG dress procedure on that plate concentrating on the radii at the front and rear edges of the plate.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 28 of 37 Mustration 29 20366 (B) 75 mm (2.95 inch) ‘Mustration 30 203667722 (L) Fish plateMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 29 of 37 11. Apply a TIG dressing to the toe of the vertical fish plate weld and extend the TIG dressing 75 mm (2.95 inch) along the side plate to frame top plate and side plate to frame bottom plate welds, see Illustration 29, TIG dressing should be applied continuously from location (C) to (D), (D) to (E), and (E) to ). ‘Then (G) to (H), (H) to (J), and (J) to (K). Also, see Illustration 30 for detailed location of the TIG dressing. Ensure prior to TIG dressing that the weld start and stops in this area are adequately blend ground; the weld should look uniform in appearance with no visible starts or stops. The TIG dressing should be continuous to provide a maximum benefit to the fatigue resistance of the weld. Both the right and left sides of the frame should be TIG dressed in these areas for a total of four locations. Mlustration 31 203667735 ‘TIG dress on rear vertical seam of rear centershift plateMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 30 of 37 Ilustration 32 203667747 Details of Rear Centershift Plate TIG Dressing (B) 75 mm (2.95 inch) Mustration 33 203667748, Details of Rear Centershift Plate TIG Dressing mS Mlustration 34 203667749 Front Centershift Plate TIG DressingMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 31 of 37 12, Mlvstration 35 203667750 Details of Front Centershift Plate TIG Dressing Apply a TIG dressing to the welds on the front and rear of the centershift plates. Ensure that all weld starts and stops are blended prior to TIG dressing. Properly blended welds should be uniform in appearance without readily visible starts or stops. For the rear centershift plate, the TIG dressing should ‘extend the entire length of the rear vertical seam. It will wrap around the top and bottom of the centershift plate and 75 mm (2.95 inch) down the other side on both ends. The front centershift plate is similar except that the vertical weld on the forward side of the plate will receive the TIG dressing for the entire length of the weld and it will wrap around to the rear side of the plate.Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 32 of 37 i 4 | ; LM Li t | Yt we) | P ——_> FWD |-——— rk ———_-| Ilustation 36 20366 (Boss 40 4:5 mm (1.57 4 0.20 inch) (Mp 316 + 5 mm (12.44 + 0.20 inch) (N) 477.5 mm £ 5 mm (18.799 inch £0.20 inch) (P) 852 mm + 5 mm (33.54 inch + 0.20 inch) (R) 1032.5 mm_+ § mm (40.649 inch + 0.20 inch) (W4) 3 mm (0.12 inch) fillet weld 13. Weld four bosses (4) as shown in Illustration 36. 14. After final inspection of all welds, paint frame as required for corrosion protection, Reinstall lift arms, reassemble electrical and hydraulic components as required and reinstall front covers. Refer to Disassembly and Assembly, KENR6018. Weld Quality Criteria Table 4 ISO 6520 Defect Defect Name Reference Number || Remarks Defect Limit Cracks - 1011, 1012, 1013, ff. Not Permitted Longitudinal, 1014, 1023, 1024,Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 33 of 37 Transverse, 1031, 1033, 1034, Radiating, Crater, | 1045, 1046, 1047, Disconnected, 1051, 1053, 1054, Branching 1061, 1063, 1064 Crack - Transverse 1991 Hard Surfacing Welds Only Permitted Crack - Transverse} 1991 Joining Welds Not Permitted Porosity 2011, 2012, 2014, 2017 Maximum Diameter for a Single Pore 1 mm (0.040 inch) Maximum Pores in Any 300 mm (11.81 inch) Length of Weld Maximum Number of Pores in Any 50 mm (2.0 inch) of Weld Length for Welds Less Than 300 mm (11.81 inch) in Length Maximum Length of Cluster in Any Clustered Porosity 2013 Weld 3mm (0.120 inch) Maximum Height or Width 4 mm (0,120 inch) Elongated Cavities | 5915 Maximum Length for Any Single Discontinuity 25 mm (1.00 inch) Maximum Length in Any Weld 10% of Weld Length Maximum Dimension of Any 44mm (0.120 ine) Single Cavity Blongated Cavities | 4916 Maximum Total Length of Affected ‘Area in Any Weld 10% of Weld Length Not to Exceed 25 mm (1.00 inch) Shrinkage Cavities 2021, 2024, 2025 Maximum Diameter or Length 1 mm (0.040 inch) Slag or Flux Inclusions 3011, 3012, 3014, 3021, 3022, 3024 Maximum Height or Width 1 mm (0.040 inch) Maximum Length for Any Single Discontinuity 25 mm (1.00 inch) Maximum Length in Any Weld 10% of Weld Length Oxide Inclusions 3031, 3032, 3033 Maximum Height or Width 1 mm (0.040 inch) Maximum Length for Any Single Discontinuity 25 mm (1.00 inch)Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 34 of 37 Maximum Length in Any Weld 10% of Weld Length Puckering (Oxide Inclusion - 3034 - Not Permitted Aluminum) Metallic Inclusion |] 3041, 3042, 3043 |] - Not Permitted Lack of Fusion 4011, 4012, 4013, Visual (Breaking the Surface) Not Permitted Subsurface Maximum Height or Width 1 mm (0,040 inch) Subsurface Maximum Length for Any Single Discontinuity 25 mm (1.00 inch) Maximum Length in Any Weld 10% of Weld Length Lack of Penetration 402, 4021 Maximum Reduced Penetration 10% of Nominal Penetration Not to Exceed 1 mm (0,040 inch) Maximum Allowed Total Length of Reduced Penetration 10% of Weld Length ‘Undereut 5011, 5012, 5013, 5014, 5015 Maximum Depth Measured From Plate Surface - Any Length 0.5 mm (0,020 inch) Excess Weld Metal - Groove Weld Reinforcement (Convexity) 502 Any Length Weld Face Width 5mm (0,20 inch) or Less 1mm (0.040 inch) Weld Face Width Over 5 mm (0,20 inch) But Less Than 10 mm (0.40 inch) 1.5 mm (0.060 inch) Weld Face Width Over (10 mm) (0.40 inch) But Less Than 20 mm (0.80 inch) 2mm (0.080 inch) Weld Face Width Over 20 mm (0.80 inch) But Less Than 30 mm (1.20 inch) 3 mm (0.120 inch) Weld Face Width 30 mm (1.20 inch) and Over 4:mm (0,160 inch) Excess Weld Metal - Fillet Weld Convexity 503 Convexity Affects Weld Toe Angle, Reducing Fatigue Life 90 Degrees Weld Toe Angles of 135 Degrees and More Are Better Defect Limits Expressed as Minimum Toe Angles AllowedMedia Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 35 of 37 Excess Penetration 5041, 5042, 5043 Without Drawing Limitation 2 mm (0.080 inch) (Any Length) With "Melt - Thru” and "Flush" Weld Symbols 1 mm (0.040 inch) (Any Length) With "Melt - Thru” and "Grind Flush" Symbols Not Permitted (After Grinding) Incorrect Weld Toe When 1E2995 Applies (Expressed 505 as a Toe Radius Rather Than a Toe |] 3 mm (0.120 inch) Angle) Minimum Radius Overlap 5061, 5062 Expressed as Minimum Toe Angle | 99 peprees Fillet Weld Leg Size - Undersize Applies to Either Weld Leg Measured Independent of the Other Maximum Undersize 1 mm (0.040 inch) Maximum Length of Undersize Weld 10% of Total Weld Length If At Least 10% of Total Weld Length is at Least mm (0.040 inch) Over Nominal Size, Otherwise, No Undersize Length is Permitted Fillet Weld Leg Size - Oversize Applies to Either Weld Leg Measured Independent of the Other Maximum Oversize +25% (max 3 mm (0.120 inch)) Conformance to Design - Fillet Weld Leg Sizes May be Oversized (Within Defect Limitations or Beyond) Without Correction Provided the Excess Does not Interfere with Satisfactory End Use of the Component (i., Distortion, Fit-Up Interference, etc.) Fillet Weld - Linear Length when specified at less than the length of the joint Weld Size < + 6.5 mm (0.256 inch) 6.5 mm (0.256 inch) Weld Size > * 6.5 mm (0.256 inch) ‘12.5 mm (0.492 inch)Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 36 of 37 Fillet Weld Throat Nominal Size (0.7 x Leg Size) Not Inclusive of Penetration Beyond the ‘Weld Root Not Permitted 2 mm (0.080 inch) suet weld tao | sors MAX - and Not to - Exceed 20% of Weld Crater Only - Maximum Srecided Thsoat, Not Undersize Inclusive of Penetration Beyond the Weld Root (0.7 x Leg Size) Careful Consideration Needs to be Given When Plate Mismatch is |] Not Permitted Incompletely Filled | 514 Apparent Groove Weld s Weld Depth Must be Maintained as || _ a Minimum Root Concavity on Maximum Depth measured From Open Root Groove | 515, 5013 Plate Surface or Tube Inner Surface 5 vote Paty Lenath 0.5 mm (0.020 inch) Measured in Terms of Excess Weld Metal (Fillet Weld Convexity) or || _ Overlap on Groove Welds, Lack of Fusion, or Insufficient Throat Excess Weld Metal on Fillet Welds, Defect Limits Expressed as 90 Degrees Minimum Toe Angles Allowed PoorResaat (ie | sin), ura 2 Overlap on Groove Welds, Defect Limits Expressed as Minimum Toe |] 90 Degrees Angles Allowed Lack of Fusion - Visual Maximum Length Per Restart 3mm (0.120 inch) Insufficient Weld Throat Not Permitted Stray Are Stike | 601 ~ Not Permitted SMAW, SAW, FCAW, GMAW _|[ Not Permitted Silicon Resid Slag Residue 61s venmitted Unles GTAW Permitted Unless Removal Specified by Drawing Note Combined Discontinuities ‘Total Maximum Combined Length of All Imperfections in a Weld, Expressed as a Percent of Total Weld Length 15%Media Search - REHS8792 - Repair Procedure For The 16M Motor Grader Front Frame and Ce... Page 37 of 37 (No Single Type of Imperfection Can Exceed the Limits for That ~ Single Type of Imperfection) jant 1903 - arin Wed Nov 4 10:06:51 UTC-+0700 2015 All Rights Reserves j2iambe 7 vic For SIS Licenses