General Note General recommendations to ensure maximum longevity to the repair All repair jobs tobe done in controled environment such se dealer veld chop to prevent quick ‘0 down lowing repair +All welds tobe donein 2 horizontal position to make wsldfnsh smooth + ttis important to ind «root cause of crack and eliminate itbefore proceedir repair + tis critical to develo plan of action carefully to avold the loss of bore alignment + While a piteis removed, inspect all back-up strips for proper instalation (.e gap]. Ifthey are not Instaee propery they shouldbe remaved. The la seam must bear ares snd reveled ‘Without the use of backup tips + Orginal tack welds put on by factory during assembly an be removed if they appear tobe causing serach + pozsiba, itiimportant to provide stres rei on weldad joints using tole such ae naecle scaling + "Grinder frishshould be applied wherever possible to maintain smooth surface of structure vith the est of Welding requirement MATERIAL: For material fabrication, use the ASTM spec specified in each drawings of grade 42 or 42 ‘9r50 woldebe ste! or other ndustry spec equivalent + Allareas must be ust ree and clean prior to any welding operation. + Use LB-25 Electrodes (AWS £7016 or AWS £7018) or equivalert electrodes to weld the baffle plate ‘and enforcement plates. Baste veldng wre ESAB OK tubrodi8.O0 with @ 1.2 rom (0.08 Inch) “ameter can also be Use. The basi welding wire must be the equivalent to AWS AB.20 E7275 “with negative polarity. The welding wire must protected with €O2 or Argon/CO2 60/20 gas.Repair procedure Fabricate boom top plate, and perform the weld per the drawi Cut offa circle in the neutral axis, as dotted line on the boom. (As shown in picture ©, make sure that there is at least 3° distance from the nearest weld joint) After the we weld is performed inside at the baffle plate, then re-weld the cut of plate back to stick. Before adding the cut off plate back to the boom, grind off the inner wall of the boom flush to make sure that the backup plate Is flush to the inner wall. The alignment of the backup plate is critical for durability of the repair. ‘The backup plate should be fabricated from 8-10 mm thick ASTM AS72 grade 50 steel (or the same material as the top plate) as the half ring pattern shown on the next slide. {picture 1}. Backup plates should be tag welded into the inner wall as shown in picture 2. Before placing the backup plates back into the structure, bevel the mating surfaces into 30 degrees. (picture 3) Make sure there is an even gap of 3mm all around the circular pattern for best penetration. Fill gap with weld, then grind flat smooth to the surface Weld the stick cylinder ears referencing the dimensions on the finished boomPicture 0 A DIA 300 mm Picture 1 Picture 1 320 mm J Reference REHSOS4S & REHSO271