Replacing Tubes In Housings That Are Installed With Mechanical Joints (Expanded and Welded) {3016, 3154, 4104, 4133, 5057} Caterpillar

Introduction

© 2020 AVSpare All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered AVSpare: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables AVSpare dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to AVSpare. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from AVSpare.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair options or modifications to reuse and salvage techniques and/or methods.

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System website (SIS web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by AVSpare is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

AVSpare cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. AVSpare dealers can supply the most current information.

Summary

Many machines and components are built using tubes that are installed by a mechanical process of “rolling” (expanding) the end of the tube into the bore in which tube is installed. Special tools are required to roll (expand) these tubes in place. Sometimes these tubes are damaged or fail and require replacement. Since these tubes are installed in one piece, tubes frequently must be installed in sequence. Often there are several tubes installed in the same component. Also, the only way to remove a tube is to cut out tube, thus destroying the tube. Each end of the same tube may also require different tooling (expanders) to install tube in the housing.

The tube rolling process requires access from both sides of the housing. Access from the inside is required to install the tube in the housing. Outside access is required to toll the tubes in place. Often, major components such as fuel tanks and final drives, must be removed to access the outside of the housing.

References

Service Advisories, Service Letters, and Technical Service Bulletins

Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

Advantages Of New Repair Procedure

1. No special tools are required.

2. The tubes are either installed in one piece, or, if necessary, spliced to eliminate interference with adjacent tubes during installation.

3. The repair (installation) can be performed from one side of the frame (inside) possibly eliminating removal of some components such as final drives and fuel tanks.

Note: This repair procedure is intended as an extra option for repair. Procedure is not intended to replace the method of mechanically rolling tubes in place.

Welding

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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

Welder Qualifications

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 respirator for breathing protection.

Welders must be qualified for the appropriate type of weld that is being performed:

• Shielded Metal Arc Welding (SMAW)

• Flux Cored Arc Welding (FCAW)

• Gas Metal Arc Welding (GMAW)

• Gas Tungsten Arc Welding (GTAW)/ Tungsten Inert Gas (TIG)

Welders must be qualified for the appropriate position of weld that is being performed. Refer to AWS Specifications D1.1 and D14.3 or comparable standards for information that regards qualification 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. The welding operator must hold a current certification for this process. The operator must wear the appropriate equipment. The operator must also install all appropriate equipment. All equipment must maintain the amount of fumes, heat, and ultraviolet radiation at a safe limit.

References:

• SEBD0512Reuse and Salvage Guidelines, "AVSpare Service Welding Guide"

• ANSI/ AWS D1.1, D14.3

• AVSpare Manufacturing Practice MC1000-105

Welding Preparation

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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.

Procedure For Tube Replacement

The new procedure uses a smaller collar, like a bushing, that is arc welded to the housing where the tube joins the housing. The collar must be thick enough to be arc welded to the housing but thin enough to provide a stand-off that is long enough to accept silver solder in a relatively short time. These two methods enable you to use arc welding to attach a tube to a large housing (which acts as a heat sink) and silver solder thin tubing to achieve the required fatigue resistance . (See Illustration 3)

Illustration 3	g06406758
Typical Rolled-in joint

1. Remove the tube or section of the tube that is being replaced. May be necessary to remove the sleeve from the bore. (Note sleeve in Illustration 1.) Since the sleeve is installed into a counterbore, the sleeve must either be collapsed or pushed out of the front side of the bore. The replacement of the sleeve is optional as removal of the component on the front side of the bore may be necessary. See Illustration 4 .
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   Illustration 4	g06406778
   Tube repair showing front side of the housing.

2. Fabricate a collar to be welded to the housing. The Inside of the collar should slip over the tube outside diameter, and have a 4.6 mm (0.18 inch) wall thickness and have a length equal to the tube diameter.
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   Illustration 5	g06406793
   Fabricated collar repair.

3. Shape the end of the collar to fit flush with the housing surface to permit a good weld joint. Be sure the bore in the housing and the collar are in alignment. Use a short section of tube and sleeve as a guide to determine the shape of the collar. This procedure may eliminate repeated installation and removal of the entire length of tube.

4. Clean the bore and face of the housing where the tube will be installed. If practical, grind the face of the housing to clean up the area to be welded.

5. Install the collar on the end of the new tube. Coat the inside surface of each collar with silver solder flux before assembly.

6. Install the tube in position in the housing.

7. Assemble replacement sleeves into the housing counter-bores if needed.

8. Position the collars flush against the face of the housing.

9. Tack weld collars to the housing.

10. Make sure that the tube is not binding to the collars.

11. Weld the collars and the housing all around to provide an oil tight weld.

12. Silver solder the tube to the collars.

Notes and Precautions

1. If only one end of the tube is loose or damaged, cut the original tube. Then cut and fit a new tube for length and fabricate a coupling to splice the sections together. Fabricate the coupling for the splice with a length equal to four times the tube diameter and a wall thickness approximately the same as the tubing wall.

2. For silver soldering, the ideal clearance of the slip fit joint between the collar and the tube is 0.05 mm (0.002 inch) to 0.08 mm (0.003 inch) per side.

3. Remove any O-rings or seals closes to the repaired tube joint to prevent damage from heat.

4. If clearances prevent the installation of a collar on the tube, before the tube is installed in the housing, cut the collar in two pieces lengthwise. Then, install collar around the tube and weld in place. Make sure to weld the sides of the collar and silver solder the seams shut in the end of the collar to provide an oil-tight welded joint. (See Illustration 6 )
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   Illustration 6	g06406875
   Repair with fabricated split collar.

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   Illustration 7	g06406885
   Split collar welded in place on a rear case and frame for D8Ntractors

5. To prevent fatigue from vibration due to length or thickness of tubing, use a fabricated brace to strengthen the tube. Brace the tube to an adjacent tube or to the wall of the housing in at least one or two places.

Recommendations For Welding Rod/Wire

Steel Castings

Use Alloy Rod Corp., Spoolarc No. 85 or 88 in 0.89 mm (0.035 inch) or 1.14 mm (0.045 inch) diameter wire or equivalent. This wire is a solid MIG wire with an AWS specification of ER70. If stick electrode is to be used, and AWS 7018 electrode with 3.18 mm (0.125 inch) diameter is suggested.

Iron Castings

Use Inco Alloy International Inc., No. 44 wire with either 0.89 mm (0.035 inch) or 1.14 mm (0.045 inch) diameters or an equivalent. If stick electrode is used, AVSpare recommends either Inco Alloys International Inc., No. 44 or No. 55, 3.18 mm (0.125 inch) in diameter or, UTP 86FN AVSpare, 1U-5385 Weld Rod 3.18 mm (0.125 inch) in diameter.

Illustration 8	g06406947
Fabricated tube repair on a rear case and frame for D8N Tractors

Illustration 9	g06406971
Fabricated tube repair on a rear case frame for D8N tractors.