PSP FOR REWORKING BOOM TOWER PLATE BOSS WELDS ON CERTAIN 245B EXCAVATORS - PS4565 - MAILED CFEL, COSA, LIMITED COFA Caterpillar

AU-6.2
E-9
O-10
7051   PS4565
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the Program
is made by the dealer. When reporting the repair, use "PS4565"
as Part Number, "7755" as Group Number, and "96" as Description
Code.

January 31, 1992

The boom tower plate boss weld on certain 245B Excavators may crack, and in
some cases the crack may propagate into an adjacent plate.

Model Identification Number
245B 1SJ217-519, 713-718, 720-723, 725, 731, 735

Not Applicable.

This rework consists of removing the existing weld that may be suspect to
cracking, from around the boom tower plate boss, and replacing the weld with
a new one.

Product Caterpillar Dealer Suggested Customer Suggested
smu Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Cost)  (C/L) (Sell)
0-6000 - 65 0 0 0 0
6001-8000 - 0 0 32.5 0 32.5
NOTE: This is a 65-hour job.
NOTE: A maximum of $100.00 US will be allowed for weld electrodes and
special gages described in the attached procedure.

Any parts removed (with the exception of cores used for Caterpillar
Remanufactured parts) can be rendered useless and scrapped immediately upon
completion of the repair.

 FOR 245B UPPER FRAME
BOOM TOWER BOSS WELD CRACK
1. The purpose of this rework consists in the removal of
the suspect welds around the bosses which receive the
boom and to reweld them.
2. Material and environment.
A. A one meter slide gage (vernier) and a gage for a
diameter of 127.10 mm.
B. An arc air weld gauge unit of minimum 450 amperes,
the optimum would be 600 amperes.
C. A semi-automatic welding unit for solid wire with
a capacity of 300 amperes, or a stick electrode
weld unit of 200 amperes.
D. A hand burner unit with a flame power of 1000
liters/hour.
E. Complete protection for the welder (leder or
equivalent) specially fit for the arc air gauging
operation.
F. Complete machine protections (non inflammable)
G. Prepare plates protection set in order to receive
the arc air gouging burning slags.
H. Fire-extinguishers.
I. Prepare some platform arrangement for the welder
convenience.
J. Remove the grease in the involved bores and the
adjacent areas.
K. Burning of the paint around the bosses and clean
it by using metallic brushes.
L. The templates giving the area to be repaired and
the depth of the scarf-out.
M. Tie bars having a cross-section of around 400 mm2.
N. Disconnect the batteries, the start motor and the
alternator.
O. Polishing tools for bore re-adjustment or bore
honing head with a suitable power source.
3. Scarf-out and welding operation.
Take the actual measurements between the bosses and
record them: 166.4 - 939.55 and 166.4 mm.
Take the actual measurements of the bores, diameter of
127.10 mm (4 places at 0 and 90 deg.).
A. The parameters
- Solid weld wire of 1.2 mm diameter quality SG3
(Thyssen K56), under mixed shielding gas (argon C02)
Vertical uphill - 180 to 200 amps and 23 volts
Front vertical - 200 to 220 amps and 24 volts
(horizontal overhead position)
- Stick electrode
1 st pass - diameter 3.25 mm basic type AWS E 7018
Vertical uphill - 105 to 110 amps
Front vertical - 125 - 130 amps
(horizontal overhead position)
2nd pass and +, diameter 4.0 mm basic type AWS E 7018
Vertical uphill - 135 - 145 amps
Front vertical - 145 - 160 amps
B. Make a fillet weld of 8 mm all around the machined
bosses (inside the 166.4 mm) see sketch page 36.
C. Mark the area to be repaired by using the template.
Scarf out by arc air process the suspect welds in the
vertical uphill position (100 deg.) use the templates.
Clean carefully the scarfed out grooves by grinding
and let it cool down.
D. Put in place and tack weld (heavy) for tie bars (+ 90
deg. from each other). Adjust one tie bar between the
machined boss surfaces and make small tack welds on
this one, (two places).
E. Make the vertical uphill welds and control them
visually, let cool down the welds between each pass.
F. In order to improve the accessibility, remove the pin
holder blocks.
G. Scarf out by arc air process the horizontal overhead
welds (100 deg.) and remove progressively at least 25
mm of the foot of the previous vertical welds. Clean
carefully the scarfed out grooves by grinding and let
it cool down.
H. Make the horizontal overhead welds, let cool down the
welds between each pass, clean the welds by grinding
and perform the controls, take care do not grind
undercuts in the tower plates.
I. Let cool down all the areas.
J. Take the measurements of the bores (127.10 + 0.12 -
0.05 mm).
Three possibilities:
1. Within the requested tolerances
2. Too small - to be adjusted by polishing or honing
head.
3. Some of the internal surfaces are too big, record
the values, the surfaces proportion and contact
Caterpillar.
K. Remove the tie bars.
L. Take the measurement of 939.55 mm +/- 0.5 mm
M. If the actual dimension is too small and out of
tolerance, make a fillet weld of a length of +/- 125
mm. (see sketch), let it cool down, afterwards come
back on point K.
N. Take the measurements of 166.4 mm +/- 1.5 mm
O. If the actual dimension is oversized and out of the
tolerance, perform a fillet weld of a length of +/-
125 mm (see sketch), let it cool down, afterwards come
back on point M. Present the one piece boom assembly
pin and adjust if needed. Put the pin holder blocks
back in position and weld them.
P. Repair completed, perform complete cleaning of the
involved areas by grinding and sand paper, make sure
that all the weld spatters are removed from the bores.
Q. Paint all affected areas.
R. Assemble the machine.
Detailed rework procedure
****** IMAGE: SEBE4494.00001.001
CAPTION: 2 a A one meter slide gage and a gage for a diameter of
127.1 mm
****** IMAGE: SEBE4494.00001.002
CAPTION: 2 b An arc air weld gouge unit
****** IMAGE: SEBE4494.00001.003
CAPTION: 2 c A semi-automatic welding unit
****** IMAGE: SEBE4494.00001.004
CAPTION: 2 d A hand burner
****** IMAGE: SEBE4494.00001.005
CAPTION: 2 f Complete machine protections
****** IMAGE: SEBE4494.00001.006
CAPTION: 2 g Prepare a plate protection set
****** IMAGE: SEBE4494.00001.007
CAPTION: 2 g Close view on the protection set placed behind the
cabin
****** IMAGE: SEBE4494.00001.008
CAPTION: 2 j Remove the grease
****** IMAGE: SEBE4494.00001.009
CAPTION: 2 k Burning the paint around the bosses
****** IMAGE: SEBE4494.00001.010
CAPTION: 2 k Remove the burned paint by using a metallic brush
****** IMAGE: SEBE4494.00001.011
CAPTION: 2 l The templates giving the area to be repainted
****** IMAGE: SEBE4494.00001.012
CAPTION: 2 l The templates giving the depth of the scarf-out scale
1/1
****** IMAGE: SEBE4494.00001.013
CAPTION: 2 n Disconnect the batteries
****** IMAGE: SEBE4494.00001.014
CAPTION: 2 o Polishing tools or bore honing head
****** IMAGE: SEBE4494.00001.015
CAPTION: 3. Take the actual measurements between the bosses -
166.4 - 939.55 and 166.4 mm
3. Record of the results from fact to face
R.H.
----
166.4 mm - 16......... mm
R.H.  L.H.
----  -----
939.55 mm  93......... mm
L.H.
-----
166.4 mm - 16......... mm
****** IMAGE: SEBE4494.00001.016
CAPTION: 3. Take the actual bores diameters at 0 and 90 deg.
****** IMAGE: SEBE4494.00001.017
CAPTION: 3. Record the actual bores diameters Diameters of
127.10 mm
****** IMAGE: SEBE4494.00001.018
CAPTION: 3 b Fillet weld of 8 mm around the machined boss faces
****** IMAGE: SEBE4494.00001.019
CAPTION: 3 c Mark the area to be repaired
****** IMAGE: SEBE4494.00001.020
CAPTION: 3 c Fix the welding negative power cable on the pin
holding block
****** IMAGE: SEBE4494.00001.021
CAPTION: 3 c Scarf out my arc air process the suspect welds in the
vertical portion (100 deg.)
****** IMAGE: SEBE4494.00001.022
CAPTION: 3 c Clean carefully the scarfed out cuts and let them
cool down
****** IMAGE: SEBE4494.00001.023
CAPTION: 3 d Adjust, place and tack weld one tie bar between the
boss faces - 2 places
****** IMAGE: SEBE4494.00001.024
CAPTION: 3 d Put in place and tack weld (heavy) the three external
tie bars
****** IMAGE: SEBE4494.00001.025
CAPTION: 3 e Make the vertical uphill welds, let cool down the
welds between the passes. Hand touch temperature.
****** IMAGE: SEBE4494.00001.026
CAPTION: 3 g Scarf out the horizontal welds (100 deg.) do not
forget to remove the foot of the vertical previous
welds (25 mm). Grind carefully.
****** IMAGE: SEBE4494.00001.027
CAPTION: 3 h Make the horizontal over head welds, let cool down
between the passes. Hand touch temperature
****** IMAGE: SEBE4494.00001.028
CAPTION: 3 h Grind the welds - Take care not to undercut in the
plates.
****** IMAGE: SEBE4494.00001.029
CAPTION: 3 j Take the measurements of the bores and correct them
if needed
3 1 and N
Take the measurements from face to face,
compare them with page 20, and adjust
them following sketch page 37 and use
a hydraulic jack if necessary.
****** IMAGE: SEBE4494.00001.030
CAPTION: 3 o Present the boom assembly pin and adjust if needed
****** IMAGE: SEBE4494.00001.031
CAPTION: