398-6786 Recommended J Series Flush Mount/Abrasion Adapter Welding Sequence {0679, 6800, 6801, 6802, 6803, 6805} Caterpillar

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The following weld application sequence is a general guideline. Always refer to the weld instruction sheet for the most current, specific instructions and procedures.

Note: All weld start and stop points and all weld illustrations are general. These generalizations should be considered identical for all top straps with minor variances. These minor variances are dependent upon component strap geometry unless otherwise specified on base edge assembly drawings.

Note: Weld zones must not exceed the maximum interpass temperature of 260° C (500° F).

Note: Ensure that there is a 25 degree bevel (L) under each adapter strap location as shown in Illustration 3.

Illustration 1	g03200340
Top view of adapter and base edge (A) through (J) are weld start points or weld stop points (1) Adapter (2) Base edge (5) Starter plate

Illustration 2	g03204784
(1) Adapter (2) Base edge (3) Adapter to base edge strap weld

1. Preheat adapters and edge to 150° C (300° F) minimum temperature with a maximum interpass temperature of 260° C (500° F). Assemble adapter bevel with hard contact against the base edge bevel with top strap flush to base edge top surface. Tack welding at mid length in root of weld groove on each side of adapter strap.

2. Tack weld a 10 mm (0.40 inch) thick mild steel starter plate (5) to the leading edge of the base edge at the junction of the upper and lower weld groves. Refer to Illustration 1(Two starter plates per adapter).

3. Begin first weld bead at front of top strap J-weld grove root shown as point (B) or (G) in Illustration 1. Apply weld passes in sequence to the groove to point (C) or (H).

4. Move to the other side of the adapter and repeat. Fill both J-grooves with alternating weld passes.

5. Start the first fillet weld pass at point (A) or (F). Continue welds 25 - 50 mm (1.0 - 2.0 inch) past the rear of the adapter shown by point (D) or (J) in Illustration 1, while tapering the weld to 3 mm (0.12 inch) at the end. Fillet weld bead passes should also be applied alternately on each side of the strap from front to back as described in Step 3. The final weld pass should be on the previously deposited weld near, but not on, the base edge weld toe.

6. Finish the tail welds. Begin the next weld at the rear of the adapter shown by point (E) or (K) in Illustration 1. Make the weld in one continuous pass 25 - 50 mm (1.0 - 2.0 inch) beyond the rear of the adapter shown by point (D) or (J), while tapering the weld to 3 mm (0.12 inch) at the end.

   Note: The same number of fillet weld passes should be applied to each side as per Step 5.

7. Continue welding alternate sides of the top strap until both welds are complete. Refer to Illustration 2.

8. Weld all adapter straps as per Steps 1 through 7.
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   Illustration 3	g03204796
   Bottom view of the adapter and cutaway view (1) Adapter (2) Base edge (3) Adapter to base edge strap weld (4) Lower weld (L) 25 degree angle in edge blunt height under adapter

9. Turn edge over (bottom side up) and arc-air gouge through the starter plates until the upper welds are exposed.

10. Fill the lower weld groove (4) by starting welds from alternate ends of the groove as shown in Illustration 3. At completion, the lower weld should be flush with the bottom of the base edge, and blended with the ends of the upper welds as shown in Illustration 3.

11. Weld all bottom grooves as per Steps 8 through 10.

12. If necessary, use grinding to blend all start, stops, and weld toe undercuts. All weld stops (after initial pass) must tie into previously applied weld ends.

13. Allow finished welds to slow cool.

14. If using adapter covers, check for oversize welds by test fitting the appropriate adapter cover. Ensure that the pin holes in the rear are lined up.