5032864 JOHNSON DECAL, HP - Front/Rear

Introduction
Table 1
Revision History
Revision Summary of Changes
02 Effectivity has been updated to include 992K Wheel Loaders:
S/N:RM21-UP
S/N:RM51-UP
S/N:KK21-UP
S/N:KK41-UP This Special Instruction contains an improved procedure to repair a crack in the lift cylinder casting weld on the Non-Engine-End Frame of certain 992KWheel Loaders .References
Reference: Special Instruction, REHS1841, "General Welding Procedures"Reference: Special Instruction, REHS0252, "Y-Pin Support Casting Repair Procedure"Important Safety Information
Personal injury or death can result from sudden machine movement.Sudden movement of the machine can cause injury to persons on or near the machine.Prevent possible injury by performing the procedure that follows before working on the machine.Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the buckets or implements (loader and backhoe) and stabilizers to the ground.Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator.Engage the parking brake. Stop the engine.Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.
Welding Specifications
Table 2
Welding Process American Welding Society (AWS) Spec Electrode Designation
Shielded metal arc welding (SMAW) (stick welding) A5.1 E7018
Gas metal arc welding (GMAW) (metal inert gas (MIG) welding) A5.18 ER70S-3
Flux-cored arc welding (FCAW) (Gas Shielding) A5.20 E70T-1(1)
E71T-1(2)
(1) For welding horizontal and flat positions.
(2) For welding all positions.Use the following contact for any questions regarding the weld crack procedures.Caterpillar, Inc.
LWL Product Support
Aurora, IL
Preparing the Area for Welding
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.
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
Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.
Oil
Grease
Paint
DirtIf the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding process.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 weld splatter.Repair Procedure
Prepare the Area and Remove the Flaws
Refer to Special Instruction, REHS1841, "General Weld Procedures" for general welding procedures.
Remove any components or hoses to access all sides of the non-engine-end frame lift cylinder casting weld cracks.
Before welding or arc airing, the area to be repaired must be at least 21 ° C (70° F) and the surface must be dry and free of moisture, paint, and grease by preheating.
Refer to Special Instruction, REHS0252, "Y-Pin Support Casting Repair Procedure" to cut the frame to access the inside of the frame and repair any casting flaws and backside of the support casting welds.
Use dye penetrate to confirm removal of the flaws.
Grind the area that was air arced to remove any slag and carbon pickup.Y-Pin Support Casting Welding Procedure
Illustration 1 g03693781
Support casting cross section
(A) 230 mm (9.0 inch)
(B) 232 to 234 mm (9.1 to 9.2 inch)
(C) 97 to 101 mm (3.8 to 4.0 inch)
(E) 100 mm (3.9 inch)
(F) 230.5 mm (9.07 inch)
(G) 230.9 mm (9.09 inch)
Illustr