D11 Main Frame Inspection and Weld Repair Procedure {0679, 7051} Caterpillar

Track-Type Tractor

D11R (S/N: AAF1-UP; 7PZ1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; MDG1-UP; JEL1-UP; JNS1-UP)

Introduction

In some severe applications, cracks may begin to form in the main frame. The cracks are the result of normal fatigue, and if caught in a timely manner are fully repairable. Use the following procedure to inspect the frame and repair main frame cracks as required.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction provides the information that is necessary to repair cracks in the main frame.

Safety Section

Show/hide table

Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

Show/hide table

Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Show/hide table

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.

Show/hide table

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

Show/hide table

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.

Show/hide table

NOTICE
Do not allow dirt or foreign material to get into the hydraulic system during assembly, connection of lines, while components are being filled with fluid, or during any maintenance operation.

Note: Do not coat any of the fasteners with oil or grease prior to tightening. Instructions are given when lubrication is required.

Show/hide table

Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Required Parts

Table 1

Necessary Parts
Part Number	Description	Qty	Weight
190-2872	Plate	2	87.8 kg (193.5 lb)

The parts that are listed in Table 2 may be required if the frame rail is cracked.

Table 2

Necessary Parts
Part Number	Description	Qty	Weight
191-1669	Section	1	43.45 kg (95.8 lb)

Material Requirements

The preferred material for the window is the 190-2872 Plate. This plate is 20 mm (0.79 inch) thick low carbon structural steel with a minimum yield strength of 290 ± 450 MPa (42060 ± 65265 psi). An alternate material for the window is 19.05 mm (0.75 inch) thick low carbon structural steel with a minimum yield strength of 290 ± 450 MPa (42060 ± 65265 psi).

Welding Specifications and Qualifications

Show/hide table

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 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn 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 Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to American Welding Society (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 precaution 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.

4. Protect the wiring harnesses from the welding spatter.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C (60° F).

Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6° C (60° F) requirement.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the welding spatter.

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW Process

Use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer's 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 3

Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1 H8"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -18 °C (20 ft lb @ -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 4

Welding Current for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch)
Wire Feed Rate	Voltage	Amperage
7620 mm (300 inch) Per Minute to 10,160 mm (400 inch) Per Minute	24 to 28	190 to 240

Table 5

Welding Current for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch)
Wire Feed Rate	Voltage	Amperage
5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute	23 to 27	180 to 220

Note: The settings listed above are recommendations which are based on experience for 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. Using higher parameters than specified is acceptable 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 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

As an alternate process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

Table 6

Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -29 °C (20 ft lb @ -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 manufacturer's specifications.

The Table that follows shows the settings for the welding current based on electrode diameter.

Table 7

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.

Arc Welding Electrodes for the GMAW Process

The Table that follows lists the mechanical properties of welds that are deposited by the GMAW Process.

Table 8

Mechanical Properties of Welds from Gas Metal Arc Welding Electrodes That Are Classified as "ANSI/AWS A5.18 ER70S-6"
Tensile Strength	480MPa (70,000 psi)
Yield Strength	400 MPa (58,000 psi)
Elongation	22%
Impact Toughness	27J @ -30 °C (20 ft lb @ -20 °F)

The use of the GMAW process for field repairs is only recommended for certain conditions. Whenever the GMAW process is appropriate, specific parameters and equipment will be defined.

Weld Inspection and Acceptance Criteria

Table 9

Defect Name	ISO 6520 Defect Reference Number	Remarks	Defect Limit
Cracks - Longitudinal, Transverse, Radiating, Crater, Disconnected, Branching	1011, 1012, 1013, 1014, 1023, 1024, 1031, 1033, 1034, 1045, 1046, 1047, 1051, 1053, 1054, 1061, 1063, 1064	--	Not Permitted
Crack - Transverse	1021	Hard Surfacing Welds Only	Permitted
Crack - Transverse	1021	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	6
		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	1
Clustered Porosity	2013	Maximum Length of Cluster in Any Weld	3 mm (0.120 inch)
Elongated Cavities	2015	Maximum Height or Width	3 mm (0.120 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Elongated Cavities	2016	Maximum Dimension of Any Single Cavity	3 mm (0.120 inch)
		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	1mm (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	1mm (0.040 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Puckering (Oxide Inclusion - Aluminum)	3034	--	Not Permitted
Metallic Inclusion	3041, 3042, 3043	--	Not Permitted
Lack of Fusion	4011, 4012, 4013	Visual (Breaking the Surface)	Not Permitted
		Subsurface Maximum Height or Width	1mm (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 1mm (0.040 inch)
		Maximum Allowed Total Length of Reduced Penetration	10% of Weld Length
Undercut	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 5 mm (0.20 inch) or Less	1 mm (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)	2 mm (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	--
Excess Penetration	5041, 5042, 5043	Without Drawing Limitation	2 mm (0.080 inch) (Any Length)
		With "Melt - Through" and "Flush" Weld Symbols	1 mm (0.040 inch) (Any Length)
		With "Melt - Through" and "Grind Flush" Symbols	Not Permitted (After Grinding)
Incorrect Weld Toe	505	When 1E2995 Applies (Expressed as a Toe Radius Rather Than a Toe Angle)	3 mm (0.120 inch) Minimum Radius
Overlap	5061, 5062	Expressed as Minimum Toe Angle	90 Degrees
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 1 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 (for example, Distortion, Fit-Up Interference)	--
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 Size - Undersize	5213	Nominal Size (0.7 x Leg Size) Not Inclusive of Penetration Beyond the Weld Root	Not Permitted
		Weld Crater Only - Maximum Undersize	2 mm (0.080 inch) MAX - and Not to Exceed 20% of Specified Throat, Not Inclusive of Penetration Beyond the Weld Root (0.7 x Leg Size)
Incompletely Filled Groove Weld	511	Careful Consideration Needs to be Given When Plate Mismatch is Apparent	Not Permitted
		Weld Depth Must be Maintained as a Minimum	--
Root Concavity on Open Root Groove Welds	515, 5013	Maximum Depth measured From Plate Surface or Tube Inner Surface - Any Length	0.5 mm (0.020 inch)
Poor Restart (Tie - In)	5171, 5172	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 Minimum Toe Angles Allowed	90 Degrees
		Overlap on Groove Welds, Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
		Lack of Fusion - Visual Maximum Length Per Restart	3 mm (0.120 inch)
		Insufficient Weld Throat	Not Permitted
Stray Arc Strike	601	--	Not Permitted
Slag Residue	615	SMAW, SAW, FCAW, GMAW	Not Permitted
		GTAW	Silicon Residue 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%
		(No Single Type of Imperfection Can Exceed the Limits for That Single Type of Imperfection)	--

To verify the quality of the weld, refer to Specification 1E99 which is shown above in Table 9.

Inspection Qualifications and Procedure

Note: The Ultrasonic Inspection can be applied to machines with factory geometry only. If previous repairs have been made, call the Dealer Solution Network (DSN) for specific inspection procedure development.

Inspection Scope

During inspection of in-service units, only visual and ultra-sonic testings are recommended for top left and right butt welds, location (1A) in Illustration 1 . Magnetic particle testing can be used to supplement the visual testing if needed.

During inspection of a unit at machine rebuild, Visual, Magnetic Particle, and Ultrasonic Testing is recommended for all butt welds, locations (1A), (1B), and (2) in Illustration 1. Visual inspection is recommended for areas (1A) through (5) as shown in Illustration1. The crack at location (3) may not be visible until partial disassembly of the pivot shaft or the lube oil leaks externally.

Note: For machines working in high impact applications and/or machines equipped with blades larger than the standard Caterpillar blades, it is also recommended to inspect the inner inboard side plate ("pork chop plate") when the second engine is replaced with the third engine (roughly 25,000 to 30,000 machine hours). The procedure for cutting a window in the frame outer side sheet is in section "Outboard Side Plate Window 1A - Small Window Instructions" - Steps 7-9.

Approved Inspection Methods

Visual inspection (VT), magnetic particle inspection (MT) and ultrasonic inspection (UT) are recommended for this inspection procedure. These inspection methods shall be conducted and reported by qualified personnel. Examples of qualified personnel are as follows: VT - AWS CWI (American Welding Society Certified Welding Inspector) or equivalent. MT/UT - ASNT (American Society of Nondestructive Testing) Level II (minimum) for each method used.

Note: Do not use the magnetic particle inspection process around components that will be affected by magnetism.

Accept/Reject Criteria for Visual Testing (VT)

Cracks – Not Permitted

D11 VT Inspection Areas

During In-Service Field Inspection: VT inspect all surfaces of weld location (1A) per Illustration 1 that are visible and open to the outside surface or accessible with a bore scope.

During Machine Rebuild: Inspect welds in location (1A) through (5) per Illustration 1. VT Inspect all surfaces of weld locations that are visible and open to the outside surface. All paint shall be removed in the area of interest.

Note: For machines working in high impact applications and/or machines equipped with blades larger than the standard Caterpillar blades, it is also recommended to inspect the inner inboard side plate ("pork chop plate") when the second engine is replaced with the third engine (roughly 25,000 to 30,000 machine hours). The procedure for cutting a window in the frame outer side sheet is in section "Outboard Side Plate Window 1A - Small Window Instructions" - Steps 7-9.

Requirements for Magnetic Particle (MT) Testing

Accept/Reject Criteria

Cracks – Not Permitted

Lack of Fusion – Not Permitted

D11 MT Inspection Areas

During In-Service Field Inspection: MT inspection should be used where possible but is not required. Inspect Welds in Location (1A) per Illustration 1.

During Machine Rebuild: Inspect Welds in Location (1A) through (5) per Illustration 1. MT Inspect all surfaces of weld locations that are visible and open to the outside surface.

Note: For machines working in high impact applications and/or machines equipped with blades larger than the standard Caterpillar blades, it is also recommended to inspect the inner inboard side plate ("pork chop plate") when the second engine is replaced with the third engine (roughly 25,000 to 30,000 machine hours). The procedure for cutting a window in the frame outer side sheet is in section "Outboard Side Plate Window 1A - Small Window Instructions" - Steps 7-9.

Illustration 1	g06113932
(1A) Front top butt weld joints (1B) Bottom front butt weld joints (2) Top rear butt weld joints (3) Pivot shaft mounting face. (4) Equalizer bar saddle at the radius where the saddle blends into the frame rails (5) Front support and Trunnion bell

Requirements for Ultrasonic (UT) Testing (Personnel)

Personnel performing the inspections shall be at least Level II Certified Technicians in the Ultrasonic Testing method, as defined by ASNT SNT-TC-1A, ASNT CP-189, or equivalent international standard.

Personnel performing the inspections shall be trained by a Level II or Level III, until the personnel show proficiency and understanding of procedures and rejection criteria.

Apparatus (Ultrasonic (UT) Instrument)

The UT flaw detection instrument shall be capable of generating, receiving, and amplifying high-frequency electrical pulses at such frequencies and energy levels required to perform a meaningful examination and provide suitable readouts.

Preferred functions/features include but not limited to: inspection program recording, dual transducer capability, signal gating system, measurement data display, DAC/TCG recording, and 0 Db Reference.

UT instrument certification/qualification should be performed annually according to ASTM E317 or equivalent. This includes the verification of key performance characteristics, such as horizontal limit and linearity, vertical limit and linearity, resolution - entry surface and far surface, sensitivity and noise, accuracy of calibrated gain controls.

Angle Beam/Shear Wave Search Unit

The ultrasonic transducer (probe, or search unit) shall be capable of transmitting and receiving ultrasound at the required frequencies and energy levels necessary for discontinuity detection in the material being examined. Frequencies of 2 MHz to 5 MHz shall be employed for angle-beam shear wave inspection.

Transducer crystal can be round, square, or rectangular. Crystal size recommended for weld examination shall be in the range of 9 mm (0.35 inch) to 25 mm (1.0 inch).

Selection of a transducer is determined by testing variables. Testing variables include weld thickness, testing surface, acceptable flaw size, flaw orientation, and the acoustic properties of the metal.

In angle-beam inspection, the wedge/shoe is attached to the transducer to generate the desired incident beam angle and wave mode in the parts. The common beam angles used in weld inspection are 45°, 60°, and 70°. The refracted angle shall be no greater than ± 2° from normal. The edge distance shall not exceed 25 mm (1.0 inch). The wedge angles shall be selected according to information found in the ""Probe Selection" " Section.

Couplant

Couplant is required between the face of the search unit and the examination surface. Couplant permits the transmission of ultrasonic waves from the search unit into the material under examination.

Typical couplants include cellulose gel, glycerin, and light machine oil. Corrosion inhibitors or wetting agents may be added. Couplants shall be selected that are not detrimental to the product or the process. Special couplant and search unit may be required at elevated temperatures above 52° C (125° F).

Distance Calibration Blocks

Refer to ASTM E164 for two options of distance calibration blocks. Other suitable blocks may be used.

Illustration 2	g06101558
Option 1: IIW Type 1 or Type 2 Block

Illustration 3	g06101561
Option 2 : DSC Block

Sensitivity Calibration Blocks

Three options for 1.5 mm (0.06 inch) sensitivity calibration blocks are given but other blocks may be used. Option 1 Cat® DAC Block is preferred. Minimum requirements shall meet the requirements determined in the "Sensitivity Calibration Section".

Illustration 4	g06101689
Option 1: Cat® DAC Block (A) 340 mm (13.40 inch) (B) 90 mm (3.55 inch) (C) 40 mm (1.60 inch) (D) 1.5 ± 0.05 mm (0.05 ± 0.001 inch) diameter SDH's (E) 10 ± 0.1 mm (0.40 ± 0.004 inch) (F) 20 ± 0.1 mm (0.80 ± 0.004 inch) (G) 30 ± 0.1 mm (1.20 ± 0.004 inch) (H) 40 ± 0.1 mm (1.60 ± 0.004 inch) (J) 63 ± 0.1 mm (2.5 ± 0.004 inch) (K) 126 ± 0.1 mm (5.0 ± 0.004 inch) (L) 189 ± 0.1 mm (7.40 ± 0.004 inch) (M) 252 ± 0.1 mm (9.90 ± 0.004 inch)

Option 1: Cat® DAC Block 1.5 mm (0.06 inch) SDH's at 10 mm (0.40 inch) steps from the surface to include all depths over all thickness ranges to be used.

Use the dimensions in Illustration 4 to fabricate Cat® DAC Block using ASTM A572 Grade 42/50 steel.

Illustration 5	g06101695
(X) 250 mm (10.0 inch) (Y) 75 mm (3.0 inch) (Z) 40 mm (1.60 inch) (AA) 1.5 ± 0.05 mm (0.06 ± 0.001 inch) diameter SDH's (BB) 18.75 ± 0.1 mm (0.7 ± 0.004 inch) (CC) 37.5 ± 0.1 mm (1.5 ± 0.004 inch) (DD) 20 ± 0.1 mm (0.80 ± 0.004 inch) (EE) 230 ± 0.1 mm (9.0 ± 0.004 inch)

Option 2: Cat® t Blocks: Blocks the same material and thickness as the parts to be tested. Machined 1.5 mm (0.06 inch) SDH's at 1/4t and 1/2t depths. Blocks must be enough for full skip path and wide enough for the entire search unit to sit on the scanning surface.

Use the dimensions in Illustration 5 to fabricate Cat® t Blocks using ASTM A572 Grade 42/50 steel.

Illustration 6	g06101712
Option 3: IIW Type 1 or 2 Blocks

Option 3: Use 1.5 mm (0.06 inch) SDH position (A). An attenuation factor for indication interpretation will have to be used to compensate for attenuation of the sound beam as the sound beam propagates through the material. Reference AWS D1.1 or equivalent code or standard for further instruction.

Use the dimensions to fabricate IIW blocks. Use ASTM A572 Grade 42/50 steel.

Sample Preparation

Surface Preparation

The surface shall have contour allowing the close coupling between the search unit and scanning surface.

The inspection surface shall be free of loose scale, loose paint, weld spatter, dirt, excessive roughness, or other foreign objects that would interfere with the transmission of sound energy from the search unit into the part. Cleaning and/or grinding may be needed.

Test Procedure

Equipment Calibration

In addition to the annual UT equipment certification/qualification, periodical calibration or standardization is required to verify that UT equipment is performing as intended for day-to-day usage.

Angle Beam Calibration

Calibration:The distance and sensitivity calibration shall be verified by the UT operator.

Re-calibration shall be made a minimum of every 4 hours or process change, such as changing operator, search unit or cable, battery, and re-couple search unit.

Verify the Beam Index Point: (The following example is conducted on an IIW Type Block.) Position the UT probe toward the 100 mm (4.0 inch) radius on the IIW-type reference block.

Set proper range in the instrument to ensure that the signal from the 100 mm (4.0 inch) radius is displayed. Scan the search unit back and forth to peak the 100 mm (4.0 inch) signal. The point on the search unit wedge aligning with the 0 reference line on the calibration block is the beam index/entry point (position (D) in Illustration 1).

Verify the Beam Angle: Position the search unit toward the Lucite/open window on the IIW-type reference block.

Set proper range in the instrument to ensure that the signal from the Lucite/open window is displayed. Scan the search unit back and forth to peak the signal.

The angle marked on the reference block in line with the search unit index point is the actual beam angle. The beam angle tolerance shall be within ± 2°. Depending on the beam angle and the type of reference block, other techniques recognized by related industrial standards may be used (position B or C in Illustration 1).

Distance Calibration: To ensure the accuracy of locating weld discontinuities, the distance shall be calibrated through the entire sound path used during the specific examination.

100 mm (4.0 inch) radius on the IIW-type reference block is commonly used for distance calibration in angle beam applications (position D in Illustration 1.

Position the UT probe toward the 100 mm (4.0 inch) radius. Set the proper range in the instrument to ensure the second reflection from the 100 mm (4.0 inch) radius can be displayed.

To obtain meaningful readings, other instrument settings, such as probe angle, gate and gain level shall be properly selected.

Sensitivity Calibration

1.5 mm (0.06 inch) side-drilled-holes (SDH) parallel to the inspection surface and perpendicular to the sound path shall be used as the calibration target for send/receive probes. For pitch/catch dual probes a 1 mm (0.04 inch) flat bottom notch shall be utilized.

DAC/TCG - DAC (distance-amplitude-correction) or TCG (time corrected gain):: The signal from the 1.5 mm (0.06 inch) SDH should be calibrated to be 80% FSH (full-screen height) for the first point of a DAC curve and all points for the TCG. DAC and TCG shall be used to ensure the same inspection sensitivity at different sound paths across the entire range.

Minimum of three points shall be used to establish the DAC/TCG, over the entire range and a full skip distance for the material thickness being tested.

Use Sensitivity Calibration Blocks Option 1 or Option 2 described in the ""Sensitivity Calibration Blocks" " section.

Example for DAC/TCG set-up for a 75 mm (3.0 inch) thick weld joint using 45° wedge using the Cat® DAC Block use the 30 mm (1.20 inch), 60 mm (2.40 inch), and 120 mm (4.8 inch) holes.

Example for DAC/TCG set-up for a 16 mm (0.60 inch) weld joint using 70° wedge using the Cat® t block. Use the 1/4t hole, 3/4t hole, and the 7/4t hole.

Reference Reflector: When a single 1.5 mm (0.06 inch) Reference Reflector (refer to AWS D1.1) is used to attain a horizontal reference-line height indication. The maximum dB level used to obtain an 80% FSH peak signal shall be recorded as the Reference Gain Level.

An attenuation factor for indication interpretation will have to be used to compensate for attenuation of the sound beam as the sound beam propagates though the material. An Indication Rating should be calculated for the basis of Acceptance or Rejection. Use Sensitivity Calibration Block Option 3 position A in Illustration 6.

Scan Pattern, Scan Distance, and Scan Speed

Illustration 7	g06101766
(FF) Scan distance less than 150 mm (6.0 inch) per second (GG) First leg (HH) Second leg (KK) Scan pattern (LL) Scanning advance (not to exceed 75% of search unit width) (MM) Oscillating angle ± 15° (NN) Search unit

Send/Receive search unit inspections The entire volume of weld and HAZ (heat affected zone) shall be examined from each side of the weld wherever practical. Examination shall be made in the first and second leg wherever possible. Scan speed shall be less than 150 mm (6.0 inch) per second unless the inspection procedure specifies differently. Refer to Illustration 7.

To detect longitudinal discontinuities, the search unit shall be oscillated to the left and right with an angle of approximately ± 15° while continuously scanning perpendicularly to the weld axis. The lateral movement advancing the search unit shall not exceed 75% of the search unit width.

To ensure full volume coverage with angle beam inspections. The scan distance shall cover at least 1 full skip path (first and second leg) back from the weld center line. To detect transverse discontinuities, the sound beam shall be directed at approximately 15° parallel to the weld axis. The search unit shall be moved along the weld edge from both sides and from opposite directions.

Initial Surveillance Scanning

For initial scanning, extra gain (6dB or 12dB) may be required to facilitate detection of potential discontinuities. The evaluation of the indication shall be performed at the appropriate reference sensitivity.

Table 10

Weld Thickness	Wedge Angle(1)	Range(2)
6 mm (0.25 inch) through 20 mm (0.80 inch)	70°	100–125
20 mm (0.80 inch) through 80 mm (3.15 inch)	70°	150–500
38 mm (1.5 inch) through 80 mm (3.15 inch)	45°	150–200

(1)	Multiple wedge angles can be used for thickness outside guideline.
(2)	Range setting should be adjusted accordingly to have a full skip path on the screen.

Refer to the D11 UT Inspection Areas section below for thickness and probe selection instructions for each weld joint. Table 10 shall be used for reference if needed. Alternate angles can be used for multiple thicknesses if warranted by joint design or joint preparation.

Accept/Reject Criteria and Sizing

Illustration 8	g06101828
(AB) Search unit (AC) Search unit (AD) Search unit (AE) Distance between (L1) and (L2) ( AF) Signal amplitude (AG) Amplitude profile (AH) Threshold (AJ) 50% threshold (AK) Search unit position (L) Length of indication over the threshold (LR) Length of indication over the 50% threshold (L1) Longer discontinuity (L2) Shorter discontinuity

Note: Adjacent discontinuities: when (AE) is smaller than the designated minimum length (AE)< (L1) or a specified length, the two discontinuities shall be regarded as continuous and the overall length is (L1) + (AE) + (L2).

Subsurface internal weld quality will meet the requirements set forth by this document. To determine the rejectable lengths of indications that meet or exceed the following thresholds:

1.) A 0dB offset shall be applied to any DAC or TCG. Indications that meet or exceed this threshold for the prescribed length are rejectable.

2.) A 0dB Indication Rating for 0dB reference level shall apply. Indications that meet or exceed this indication for the prescribed length are rejectable.

The above thresholds are created from 1.5 mm (0.06 inch) SDH sensitivity reference point/s. These point/s are considered the reference level.

An indication that meets or exceeds the 0dB offset threshold level for DAC or TCG OR a + 0dB indications rating for 0dB reference level continuously for 12 mm (0.5 inch) or 17 mm (0.67 inch) aggregate length is rejectable.

Intermittent indications that do not meet the criteria but the aggregate lengths of the indications exceed 17 mm (0.67 inch) of total length is considered rejectable. Indications below 5 mm (0.20 inch) in length are not typically included in the aggregate indication length.

In determining the ends of rejectable indications, the 6dB drop method shall be used, with the flaw detector sensitivity set to the reference level (0dB). Move the search unit parallel to the weld until the tip of the signal drops to 50% of the DAC height. Mark the weld even with the center of the search unit. Move the search unit parallel to the weld in the opposite direction until the signal drops to 50% of the DAC height. Mark the weld even with the center of the search unit. Acceptability of welds with multiple defective areas. If the space between two defective areas is less than the largest defect length, the area between the two defective areas shall be considered rejectable and should be marked for repair. Refer to Illustration 8.

D11 UT Inspection Areas

During In-Service Field Inspection: UT inspection is recommended on welds in location (1A). In each location, both a 45° and a 70° send/receive conventional angle beam inspection should be used. These methods are described below.

During Machine Rebuild: UT Inspect welds in locations (1A), (1B), and (2). In each location both a 45° and a 70° send/receive conventional angle beam inspection should be used. These methods are described detail below.

Illustration 9	g06102125
Joints (A), (B), (C), and (D) joint cross section with send/receive 45º and 70° (A1) 45° (B1) 70° (C1) Rail section (D1) Casting (AA) 76.00 mm (3.0 inch) (BB) 226.36 mm (8.9 inch)

The Send/Receive transducer search units in both 45° and 70° shall be utilized for inspection. The transducers shall be scanned in both directions from the centerline of the weld where possible. Follow the Scan Pattern, Scan Distance, and Scan Speed and Accept/Reject Criteria and Sizing sections for determining if the welds are acceptable. The thickness of the instrument should be set to 75 mm (3 inch) nominal rail thickness. The 70° should be used strictly as a first leg inspection. As the scan distance from the edge of the weld will be approaching 250 mm (10 inch). The 45° search unit should be scanned at minimum 150 mm (6 inch) back from the edge of the weld for full weld volume coverage. Refer to Illustration 9.

Mark for Weld Repair

To repair the rejected weld, additional excavation length at each end of the rejectable discontinuity is normally required. A general guideline is to mark an additional 25 mm (1.0 inch) to 50 mm (2.0 inch) on both ends of the discontinuity to ensure proper removal of defective areas. This guideline shall be followed wherever practical.

Final Inspection Reporting

After the NDE inspections are completed the inspection result should be recorded. For VT and MT indications an overview picture of the area of interest and a close-up picture with a scale is required with a short description matching the weld locations. For UT inspections that are completed, fill out the form provided in Illustration 10 or equivalent form.

Illustration 10	g06161958

Crack Locations

Illustration 11	g06113932
(1A) Front top butt weld joints (1B) Bottom front butt weld joints (2) Top rear butt weld joints (3) Pivot shaft mounting face. (4) Equalizer bar saddle at the radius where the saddle blends into the frame rails (5) Front support and Trunnion bell

1. To repair cracks at location (1A), (1B), or (2) use the Sections associated with crack repair at location (1A).

   Note: It is possible to repair cracks at location (2) without removing the fenders.

2. To repair cracks at location (3) through location (5), refer to the General Crack Repair section.

3. Keep record of any repair locations and geometry for use in future inspection intervals.

General Crack Repair

For a successful repair, remove any crack well beyond the point of origin. Use a dye penetrant to check for cracks. No compromise should be allowed for removal of cracks. Determine if the working room is sufficient to repair the crack properly.

Examples of locations that this general crack repair can be applied to include the saddle and the ripper ears.

A proper repair of the crack includes the following Steps.

1. Gouge out the crack.

2. Grind the gouged surface to remove carbon that remains from the air arc gouging.

3. Prepare a proper weld joint

4. Reweld the joint. After the initial weld pass, inspect the weld for cracks. Grind the surface smooth. If the crack runs completely through the parent material of the frame, the crack must be gouged from the opposite side into the new parent weld. If the crack runs nearly through the parent material of the frame, the crack must be gouged from the opposite side. Grind the area around the gouge to remove any carbon. Reweld the crack and grind the surface smooth.

5. Needle peen all welded surfaces.

Crack Repair at Location 1A

Illustration 12	g06114327
Close up view of RH frame rail

Illustration 13	g06108873
Close up view of the RH frame rail (outboard side plate (10) not shown (C) 495 mm (19.50 inch) (11) Top or bottom rail (12) Inboard side plate (13) Inner board side plate (Pork Chop Plate) (14) Center of rear radiator guard pin

Illustration 14	g06108946
Section A-A RH frame rail (Distance from the center of the rear radiator guard pin to the crack is less than 495 mm (19.50 inch) (10) Outboard side plate (11) Top or bottom rail (12) Inboard side plate (15) Tractor center line

Illustration 15	g06109283
Section BB RH frame rail (Distance from the center of the rear radiator guard pin to the crack is greater than 495 mm (19.50 inch) (10) Outboard side plate (11) Top or bottom rail (12) Inboard side plate (13) Inner inboard plate (15) Tractor center line

1. Determine if there are cracks in top or bottom rail (11), outboard side plate (10), and / or inboard side plate (12). Using the visual, magnetic, and ultrasonic inspection procedure.

2. Determine the combination of cracks at location (1A) and then use the recommended repair sections.
   Show/hide table

   Illustration 16	g06109315
   Cracked top rail (11)

3. If top or bottom rail (11) is cracked and there are NO cracks in outboard side plate (10) AND NO cracks in inboard side plate (12), perform the applicable Steps in the “Top or Bottom Rail Weld Repair” Section or “Rails with Multiple Cracks” Section.
   Show/hide table

   Illustration 17	g06109371
   Cracked top rail (11) and cracked outboard side plate (10)

4. If top or bottom rail (11), outboard side plate (10) are both cracked, AND inboard side plate (12) is NOT cracked, perform the  applicable Steps in the following Sections: “Top or Bottom Rail Weld Repair” or “Rails with Multiple Cracks” section, and “Outboard Side Plate Repair”.
   Show/hide table

   Illustration 18	g06109406
   Cracked top rail (11) and cracked inboard side plate (12)

   Show/hide table

   Illustration 19	g06109418
   Cracked outboard side plate (10)

5. If top or bottom rail (11), outboard side plate (10), and inboard side plate (12) are all cracked, perform the applicable Steps in the following Sections: “Top or Bottom Rail Weld Repair” or “Rails with Multiple Cracks” Section, “Outboard Side Plate Repair”, and “Inboard Side Plate Repair”.

Weld Repair At Location 1A

Note: Repairs to inboard side plate (12) should be made AFTER top frame rail (11) is repaired and BEFORE outboard side plate (10) is repaired.

Determine if top rail (11) has a partial or full depth crack.

Illustration 20	g06109446
(11) Top rail (A) Crack depth less than 70 mm (2.75 inch) (B) 75 mm (2.95 inch)

A partial depth V crack is defined as a V crack that in less than or equal to 70 mm (2.75 inch) deep as measured from the outer surface of the frame rail.

Illustration 21	g06109498
(11) Top rail (A) Crack depth more than 70 mm (2.75 inch) (B) 75 mm (2.95 inch)

A full depth crack is defined as a crack that is greater than 70 mm (2.75 inch) deep as measured from the outer surface of the frame rail.

Note: For a full depth repair, a window in outside side plate (10) will need to be removed. See the Outboard Side Plate Window At Location 1A Section.

Partial Depth Top or Bottom Rail Weld Repair At Location 1A

A proper repair of the crack includes the following steps:

Show/hide table

Illustration 22	g06109796
(A) Gouged profile

1. Gouge out the crack.
   Show/hide table

   Illustration 23	g06109823
   (B) Ground profile (C) Bottom of V

2. Prepare bottom of V for proper root pass.
   Show/hide table

   Illustration 24	g06109862
   (D) Temporary plates for runoff tab

3. Add temporary plates (D) to each side of the rail in a “V pattern” to create a “Run-off” tab. Extend these run-off tabs past the edges of the rail lengthwise.
   Show/hide table

   Illustration 25	g06109914
   (E) Initial weld passes (F) Additional weld passes

4. Reweld the joint. After initial weld passes (E), inspect the weld for cracks. Grind the surface smooth to remove carbon. Add additional weld passes (F) until the V groove is filled. Finish with a cap pass that is high enough to grind off to make flush with the top surface. Remove the “Run-off” tabs and grind the top and side surfaces smooth to the original rail profile.

5. Needle peen all welded surfaces.

Full Depth Top or Bottom Rail Weld Repair At Location 1A

Note: Repairs to top or bottom rail (11) should be made BEFORE outboard side plate (10) and Inboard Side Plate (11) is repaired.

1. Create a Window in the outboard side plate per Steps in the Outboard Side Plate Window At Location 1A Section. Use the small 203 mm (8 inch) by 203 mm (8 inch) window size.

2. Remove the material until you penetrate through the section of the rail. This removal of material will allow full access for the welding gun.
   Show/hide table

   Illustration 26	g06109969
   (A) Gouged profile

   Show/hide table

   Illustration 27	g06109990
   (B) Ground profile

3. Grind the gouged surface to remove any carbon from the air arc process.

Note: Using ceramics during the weld repair will dramatically lessen the amount of grinding required. If ceramics are available, use the Repair Using Ceramics Steps below. Otherwise, use the Run-Off Tab Repair Steps below.

Repair Using Ceramics

1. Grind the backside of the root using a 10 mm (0.40 inch) ball grinder.
   Show/hide table

   Illustration 28	g06110027
   (G) Ceramic

   Show/hide table

   Illustration 29	g06161977
   (11) Top Rail (13) Fender (G) Ceramic

2. Use ceramic (G) as a weld dam (on the inboard side) and at the weld root as a backup strip (do not use steel). Illustration 28 is shown using ceramics as a weld dam. If repairing the rear butt welds with the fenders installed, use weld ceramics as a weld dam on the outboard side and at the weld root as a backup strip. Refer to Illustration 29.

3. Once the weld root is filled in, continue to use ceramics on the inboard side until the weld is completed.

4. Grind the top, bottom, and both side surfaces smooth to create the original geometry. Needle peen all the welded surfaces.

5. For instructions on replacing the window, see the Section, Outboard Side Plate Replacement at Location 1A

Repair Using Run-Off Tabs

Show/hide table

Illustration 30	g06110079
(C) Temporary plates for runoff tabs

1. Add temporary plates (C) to each side of the rail in a “V pattern” to create a “Run-off” tab.
   Show/hide table

   Illustration 31	g06110107
   (D) Temporary plates for runoff tabs (E) Additional weld passes

2. Create an opening in the bottom of the V-groove to allow adequate space for the root pass. Weld the V-groove to the full depth, extending past the edges of the rail section into temporary “Run-off” tabs.
   Show/hide table

   Illustration 32	g06110478
   (F) Remove root of V-groove weld

3. On the opposite side of the section of the rail, gouge out enough of the root of the V-groove weld to ensure good weld penetration / fusion. Weld the gouged out area to the full depth. Remove the temporary “Run-off” tabs and grind the top, bottom, and both side surfaces smooth to create the original geometry. Needle peen all the welded surfaces.

4. For instructions on replacing the window, see the Section, Outboard Window Plate Repair at Location 1.

Rails With Multiple Cracks

If multiple cracks exist through the rail, be sure that the piece of the rail between the cracks remains in the original intended position.

1. Lift the front frame rail of the section that has separated to close the gap in the rail.

2. To secure the frame rail in the proper position, weld a strap across any window openings on the inner plate and outer plate. Weld the straps across the upper one third of the window openings.

3. The frame rail may crack in multiple locations. Generally, the rail will only crack in two places. The cracks will usually be located approximately 80 mm (3.15 inch) to 100 mm (3.94 inch) from each other. Replace the failed portion of the frame rail. Use one 191-1669 Section. This section is approximately 430 mm (16.93 inch)in length.

4. One end of the new rail should start at one of the multiple cracks (usually near one side of the window opening). The rail should end near the opposite end of the window opening. Be sure that adequate space is available for welding to provide a satisfactory repair. The replacement rail will usually be 300 mm (11.81 inch) to 360 mm (14.17 inch) in length. Each situation will dictate the actual length that is needed. The windows may be resized to accommodate the required welding.

   Note: When cutting a window DO NOT cut into the front cast support or the Inner Inboard Side Plate .

1. Provide a “V” weld joint from the top to the bottom of each section. The weld joint should be large enough to obtain a full weld at the bottom of the joint. Provide a minimum of 5.0 mm (0.20 inch) for the root opening. Install backup strips under the 5.0 mm (0.20 inch) root opening.

2. Weld the joint. Grind the weld flush with the top of the rail.

3. Remove the backup strips. Gouge part of the way into the new weld to remove any defect.

4. Grind the weld to remove any carbon that remains from the air arc gouging. Weld the joint. Grind the weld flush with the bottom surface.

5. Grind all the welds on the rails and the area around the welds. Needle peen all welded surfaces

Inboard Side plate Repair

Note: Repairs to Inboard Side Plate (12) should be  made AFTER the top or bottom frame rail (11) is repaired and BEFORE the outboard side plate (10) is repaired.

Note: Use a dye penetrant to locate the cracks. Determine if the working area is sufficient for you to properly repair any crack. For a successful repair, remove any crack well beyond the point of origin. No compromise should be allowed for the removal of cracks.

To repair a crack on the inner sheet, first determine the distance from the rear radiator guard pin bore to the crack. If this dimension is less than 495 mm (19.50 inch), there are two possible repairs:

• Permanent repair using weld ceramics

• Temporary repair using steel backup strips

If the dimension is greater than 495 mm (19.50 inch), there are two possible repairs:

• Permanent repair using weld ceramics

• Permanent repair using window cut out. This likely requires the engine to be removed from chassis. This method is only advantageous where weld ceramics are not available, or when there are multiple and complex cracks in the inner sheet.

Inboard Side Plate Repair When the Crack is Less Than 495 mm (19.50 inch) from the Rear Radiator Guard Pin Bore

Note: When the inner side plate is not cracked more than 495 mm (19.50 inch) from the rear radiator guard pin bore. This means that the crack is NOT behind Inner Inboard Side Sheet (12) “Pork Chop Plate”.

Illustration 33	g06110523

1. Gouge out the crack from inside the box section

2. Grind the crack to remove the carbon that remains from the air arc gouging / welding.

3. Prepare a proper weld joint.

4. Place the weld ceramics on the engine side of the inner side sheet to lay in the root pass from inside the box section. The ceramics may be left in or knocked off after welding. No grinding is required.

5. From inside the box section, grind the root pass weld added in Step 4and check for cracks.

6. If no cracks are found, weld the remainder of the joint from inside the box section.

7. Grind all welds flush.

8. Needle peen all welded surfaces.

Note: This backup strip will need to be removed the next time the engine is removed from the machine.

A proper repair includes the following steps.

1. Gouge out the crack inside the box section. For cracks that run nearly through the parent material or all the way through the parent material, do the following repair. Add a backup strip to the engine side of the inside plate until the engine can be removed and the crack can be repaired. See the section “Final Repair Instructions” for information on repairing the crack. The thickness of the backup strip should be 3.0 mm (0.12 inch) to 5.0 mm (0.20 inch). The width of the strip should be 20 mm (0.79 inch) to 25 mm (0.98 inch).

2. Grind the crack to remove the carbon that remains from the air arc gouging.

3. Prepare a proper weld joint.

4. Reweld the joint. After the initial weld pass, inspect the weld for cracks. Grind the surface smooth.

5. Needle peen all welded surfaces.

6. Install the backup strips behind the sides of the window opening. The thickness of the backup strip should be 3.0 mm (0.12 inch) to 5.0 mm (0.20 inch). The width of the strip should be 20 mm (0.79 inch) to 25 mm (0.98 inch).

7. Fabricate a new plate for the window opening. Use a portion of one of the 190-2872 Plate. The plate thickness is 20 mm (0.79 inch). The material has a yield strength of 42000 psi to 60000 psi.

8. Put a 30 degree bevel on the rear edge of the new window. The bevel will provide a full depth bevel groove. Provide a 5.0 mm (0.20 inch) root opening for all the welds for full weld depth and penetration.

9. Position the new plate into the window opening. Adjust the plate to obtain a 5.0 mm (0.20 inch) root opening. Tack weld the plate in place. Weld a full depth bevel groove down the forward and rear edges of the plate. Weld a full depth J-groove across the top of the plate and across the bottom of the plate. Grind the welds flush. Needle peen all welded surfaces.

   Note: This repair is only a temporary repair. Continue to inspect the frame for cracks until the engine can be removed.

   For instructions on the final repair to the inside plate with the engine out of chassis, refer to the general crack repair section of this document.

Note: When the inner side plate is cracked more than 495 mm from the rear radiator guard pin bore.his means that the crack is behind Inner Inboard Side Sheet (12) “Pork Chop Plate.

Illustration 34	g06110558

Note: Repairs to Inboard Side Plate (12) should be  made AFTER the top or bottom frame rail (11) is repaired and BEFORE the outboard side plate (10) is repaired.

1. Gouge out the as much of the crack from inside the box section as possible.

2. Grind the remainder of the crack from the engine side.

3. From the engine side, prepare a proper weld joint. For the portion of the crack that runs over the pork chop plate, prepare the joint for a full penetration weld, using the pork chop plate as a backing strip. For the other parts of the crack, use weld ceramics as backing strips. This will minimize the amount of grinding required.

4. Weld in the root pass

5. Grind the root pass weld added in Step 4 and check for cracks.

6. If no cracks are found, weld the remainder of the joint.

7. Grind all welds flush.

8. Needle peen all welded surfaces.

Note: If a crack has propagated to a point that does not allow you to successfully gouge out the crack, cut a window in the frame to successfully repair the crack. An example would be a plate that has multiple cracks. Follow the instructions below.

Illustration 35	g06110621
Inside Window (1) Cut through the center line of the boss (2) 90 mm (3.54 inch) (3) 250 mm (9.84 inch) (4) 90 mm (3.54 inch) (A) Weld (B) Weld

1. Create a window by cutting the inside plate of the case and frame. The vertical edges of the window should be perpendicular to the bottom of the main frame.

2. Locate the forward edge of the window in line with the center line of the loop for the belly guard. The loop for the belly guard is located just behind the front engine support. The rear edge of the opening should be located 250 mm (9.84 inch) to the rear of the forward edge of the window. Cut through the forward edge and the rear edge of the side plate. Salvage the boss and the loop for the belly guard. These parts will be reinstalled.

   Note: Do not cut into the front cast support or the Inner inboard side plate.

3. Measure down perpendicular from the top surface to the upper frame rail approximately 90 mm (3.54 inch) at two locations that are spaced by approximately 600 mm (23.6 inch). Draw a line between these two points. This line will mark the top edge of the window. Cut through the side plate at the marks. DO NOT cut the portion of the top rail that is in the frame.

   Note: Use air arc gouging for the horizontal cuts.

4. Measure up perpendicular from the bottom surface of the bottom frame rail approximately 90 mm (3.54 inch)at two locations that are spaced by approximately 600 mm (23.6 inch). Draw a line between these two points. This line will mark the bottom edge of the window. Cut through the side plate at the marks. DO NOT cut the portion of the top rail that is in the frame.

   Note: Use air arc gouging for the horizontal cuts.

5. From the window opening on the outside of the frame, locate the weld that joins the inside plate to the backup plate. Remove the weld between points (A) and (B). See Illustration 35

6. After you remove the Initial window, remove the remaining inside plate material between the forward edge of the opening and the cast support. Then, remove the remaining material of the inside plate between the top of the window and the J-groove on the top rail. Also , remove the remaining material at the bottom of the window between the window and the J-groove.

Inboard Side Plate Replacement

1. Fabricate a new plate or the window opening. Use a portion of one of the 190-2872 Plates. The plate thickness is 20 mm (0.79 inch). The material has a yield strength of 42000 to 60000 psi.

2. Put a 30 degree bevel on the rear edge of the new window .The bevel will provide a full depth bevel groove. Provide a 5.0 mm (0.20 inch) root opening for all the welds for full weld depth and penetration.

3. Position the new plate into the window opening. Adjust the plate to obtain a 5.0 mm (0.20 inch) root opening. Tack weld the plate in place. Weld a full depth bevel groove down the forward and rear edges of the plate. Weld a full depth J-groove across the top of the plate and across the bottom of the plate. Grind the welds flush .Needle peen all welds.

4. From the window opening on the outside of the frame, weld the window replacement plate to the inner inboard side plate. Weld only between points (A) and (B) as shown in Illustration 35.

Outboard Side Plate Window At Location 1A

If creating an outer window to repair a full depth crack in the rail, or if repairing a crack in the outer sheet that is contained within an 203.20 mm (8 inch) by 203.20 mm (8 inch) window, use the Small Window instruction. If creating an outer window for access to a large crack on the inner sheet, or if the cracking on the outer sheet is not contained in an 203.20 mm (8 inch) by 203.20 mm (8 inch) window, continue using the Large Window instruction.

Small Window Instructions

Illustration 36	g06114386
(A) 510 mm (20.08 inch) (B) 310 mm (12.20 inch) (C) 90 mm (3.54 inch) (D) 178 mm (7 inch) (E) 203 mm (8 inch)

1. Use the dimensions in Illustration 36 to create a window by cutting through the outside plate of the case and frame. The forward edge and the rearward edge of the window should be perpendicular with the bottom of the main frame.

2. Use the following measurement to locate the forward edge of the window. Measure 310 mm (12.20 inch) from the center of the rear radiator guard pin bore. Use the following measurement to locate the rear edge of the window. Measure 510 mm (20.08 inch) from the center of the rear radiator guard pin bore.

3. .Measure down perpendicular from the top surface of the upper frame rail approximately 90 mm (3.54 inch) at two locations that are spaced by approximately 203 mm (8 inch). Draw a line between these two points This line will mark the top edge of the window. Cut through the side plate at the marks. DO NOT cut the portion of the top rail that is in the frame.

   Note: Use air arc gouging for the horizontal cuts.

4. Measure down perpendicular from the rear edge of the window approximately 178mm (7 inch). Draw a line between this point and a perpendicular line down from the front window edge. This line will mark the bottom edge of the window. Cut through the side plate at the mark. DO NOT cut the portion of the top rail that is in the frame.

   Note: Use air arc gouging for the horizontal cuts.

   Show/hide table

   Illustration 37	g06111134
   (A1) Remaining side plate material (B1) Top of the window that was cut into the side plate

5. After you remove the initial window, remove remaining side plate material (A1) between the top of the window and the J-groove on the top rail. Remove the remaining side plate material between the bottom of the window and the J-groove on the bottom rail. See Illustration 37.
   Show/hide table

   Illustration 38	g06111161
   Top and Bottom Rail Details (F) 176 ± 1.5 mm (6.93 ± 0.060 inch) (G) 76 ± 0.8 mm (2.99 ± 0.03 inch) (H) R 5 Max (J) R 5 Max (K) R 3 Max (L) 18 ± 0.8 mm (0.708 ± 0.03 inch) (M) 18 ± 0.8 mm (0.708 ± 0.03 inch) (P) 5º Max (Q) 54 ± 1.0 mm (2.13 ± 0.03937 inch) (R) 20º

6. Grind the J-groove weld at the top of the window and at the bottom of the window. Illustration 38 shows the details of the Top and Bottom rail.

7. Inspect the top frame rail , the bottom frame rail, and the inside plate of the box section for visible cracks. Use magnetic particle inspection to look for cracking near location (X) as shown in Illustration 39.
   Show/hide table

   Illustration 39	g06111412

8. Toe grind the ends of the welds at locations (X) and (Y) shown in Illustration39 with a 10 mm (0.39 inch) ball grinder bit.
   Show/hide table

   Illustration 40	g06183006

9. Illustration 40 is an example of the weld geometry after toe grinding has been completed at location (X).

10. If cracks are found in either of the frame rails, follow the appropriate Sections for Location 1.

Large Window Instructions

Illustration 41	g06111500
Inspection Window (A) Window placement (B) 90 mm (3.54 inch) (Top of opening to the top of the rail) (C) 400 mm (15.75 inch) (D) 60 mm (2.36 inch) (E) Weld joints (F) 90 mm (3.54 inch)

1. Use the dimensions in Illustration 41 to create a window by cutting through the outside plate of the case and frame. Cut a window in the plate on both sides of the machine. The forward edge and the rearward edge of the window should be perpendicular with the bottom of the main frame.

2. Use the following measurement to locate the forward edge of the window. Measure 60 mm (2.36 inch) to the rear of the center line for the forward most mounting hole for the engine side guard. Use the following measurement to locate the rear edge of the window. Measure 400 mm (15.75 inch) rearward from the forward edge of the window.

3. Measure down perpendicular from the top surface of the upper frame rail approximately 90 mm (3.54 inch) at two locations that are spaced by approximately 600 mm (23.6 inch). Draw a line between these two points. This line will mark the top edge of the window. Cut through the side plate at the marks. DO NOT cut the portion of the top rail that is in the frame.

   Note: Use air arc gouging for the horizontal cuts.

4. Measure up perpendicular from the bottom surface of the bottom frame rail approximately 90 mm (3.54 inch) at two locations that are spaced by approximately 600 mm (23.6 inch). Draw a line between these two points. This line will mark the bottom edge of the window. Cut through the side plate at the mark. DO NOT cut the portion of the top rail that is in the frame.

   Note: Use air arc gouging for the horizontal cuts.

   Show/hide table

   Illustration 42	g06111134
   (A1) Remaining side plate material (B1) Top of the window that was cut into the side plate

5. After you remove the initial window, remove remaining side plate material (A1) between the top of the window and the J-groove on the top rail. Remove the remaining side plate material between the bottom of the window and the J-groove on the bottom rail. See Illustration 42.
   Show/hide table

   Illustration 43	g06111161
   Top and Bottom Rail Details (F) 176 ± 1.5 mm (6.93 ± 0.060 inch) (G) 76 ± 0.8 mm (2.99 ± 0.03 inch) (H) R 5 Max (J) R 5 Max (K) R 3 Max (L) 18 ± 0.8 mm (0.708 ± 0.03 inch) (M) 18 ± 0.8 mm (0.708 ± 0.03 inch) (P) 5º Max (Q) 54 ± 1.0 mm (2.13 ± 0.03937 inch) (R) 20º

6. Grind the J-groove weld at the top of the window and at the bottom of the window. Illustration 43 shows the details of the Top and Bottom rail.

7. Inspect the top frame rail , the bottom frame rail, and the inside plate of the box section for visible cracks. Use magnetic particle inspection to look for cracking near location (X) as shown in Illustration 44.
   Show/hide table

   Illustration 44	g06111412

8. Toe grind the ends of the welds at locations (X) and (Y) shown in Illustration 44 with a 10 mm (0.39 inch) ball grinder bit.

9. If cracks are found in either of the frame rails, follow the appropriate Sections for Location 1.
   Show/hide table

   Illustration 45	g06183001

10. Illustration 45 is an example of the weld geometry after toe grinding has been completed at location (X).

Outboard Side Plate Replacement at Location 1A

1. Fabricate a new plate for the window opening on the outside of the frame. Use a portion of one of the 190-2872 Plates. The plate thickness is 20 mm (0.79 inch). The material has a yield strength of 42000 to 60000 psi.

2. Put a 30 degree bevel on the front edge of the new window and on the rear edge of the new window. The bevel will provide a full depth bevel groove. Provide a 5.0 mm (0.20 inch) root opening for all the welds for full weld depth and penetration.

3. Position the new plate into the window opening. Adjust the plate to obtain a 5.0 mm (0.20 inch) root opening. Tack weld the plate in place. Weld a full depth bevel groove down the forward and rear edges of the plate. Weld a full depth J-groove across the top of the plate and across the bottom of the plate. Grind the welds flush. Needle peen all welds