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Special Instruction
General Welding Procedures{7000}
Media Number -REHS1841-02 Publication Date -22/02/2007 Date Updated -22/02/2007
i02707198
General Welding Procedures{7000}
SMCS - 7000
Caterpillar Products: All
Introduction
This Special Instruction provides the necessary information on all welding procedures.
Proper Cleaning for Inspection
When it is necessary to work under the machine with the body (bed)
raised, attach the body (bed) retaining cables to the rear tow points.
Install the rear tow point pins through the ends of the retaining cables.
Failure to properly secure the body (bed) may result in personal injury
or death.
Personal injury can result from working with cleaning solvent.
Because of the volatile nature of many cleaning solvents, extreme
caution must be exercised when using them. If unsure about a
particular cleaning fluid, refer to the manufacturer's instructions and
directions.
Always wear protective clothing and eye protection when working with
cleaning solvents.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Before you inspect the area, clean the area with an appropriate high pressure washer. Be careful not to damage wires or other components. Use
an appropriate degreaser to remove any oil or grease from the frame assembly. It may also be necessary to use a wire brush or a scraper to
remove excessive dirt and grease. Make sure that the substances that follow are removed from the area that will be inspected.
z Oil
z Grease
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z Dirt
Preparing the Area for Welding
Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.
z Oil
z Grease
z Paint
z Dirt
If 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.
Weld Specifications and Qualifications
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 kill.
Read and understand the manufacturer's instruction and your
employer's safety practices. Keep your head out of the fumes. Use
ventilation, exhaust at the arc, or both, to keep fumes and gases from
your breathing zone and the general area. Wear correct eye, ear and
body protection. Do not touch live electric parts.
Refer to the American National Standard Z49.1, "Safety in Welding
and Cutting" published by the American Welding Society, 2501 N.W.
7th Street, Miami, Florida 33125: OSHA Safety and Health Standards,
29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C.
20210.
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 1U-8088 Type H Respirator for breathing protection.
Qualifications
Welders must be qualified for fillet welding and groove welding. The welders should be qualified in the use of the welding processes that
follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to "American
National Standards Institute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards
the qualifications for the processes that follow: SMAW process, FCAW process and GMAW process. The welders must have used the process
at some time within the last six months. The welders must complete the process of certification if the welders have not used the welding
processes for six months.
Proper Welding Procedure on Machines and Engines with Electronic Controls
Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps
that follow:
1. Turn off the engine. Put the key start switch in the OFF position.
2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the
negative battery cable at the battery.
3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground
cable as close as possible to the area that is being welded. This will reduce the chance of damage from welding current to the components
that follow: bearings, hydraulic components and electrical components.
Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a
ground point for the welder.
4. Protect the wiring harnesses from the weld splatter.
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Specifications
Low Hydrogen Electrodes for the SMAW Process
The tables that follow list the mechanical properties of welds that are deposited by low hydrogen electrodes.
Table 1
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.5 E10018-D2"
Tensile Strength
690 MPa (100076 psi)
Yield Strength
400 MPa (58015 psi)
Elongation 22%
Impact Toughness 27 J @ -18 °C (20 ft lb @ -20 °F)
Table 2
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018"
Tensile Strength
480 MPa (69618 psi)
Yield Strength
400 MPa (58015 psi)
Elongation 22%
Impact Toughness 27 J @ -18 °C (20 ft lb @ -20 °F)
Low hydrogen electrodes must be stored in an electrode oven at 120 °C (248 °F). If low hydrogen electrodes get damp, scrap the low hydrogen
electrodes or recondition the low hydrogen electrodes to the manufacturer's specifications.
The table that follows shows setting for the welding current for the electrode diameter.
Table 3
Welding Current for Low Hydrogen Electrodes
Diameter Amperage Rating
70-140
3.2 mm (0.125 inch)
110-180
4.0 mm (0.157 inch)
190-270
4.8 mm (0.189 inch)
Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed
two times the electrode diameter.
Flux Cored Welding Electrode for the FCAW Process
As an alternative process, use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer's
shielding gases that are specified for inside welding. The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible
hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical
properties:
The table that follows lists the mechanical properties of welds that are deposited by the flux cored welding electrode.
Table 4
Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1" (1)
Tensile Strength
480 MPa (69618 psi)
Yield Strength
400 MPa (58015 psi)
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Elongation 22%
Impact Toughness 27 J @ -18 °C (20 ft lb @ -20 °F)
(1) The properties that are listed are for three passes of the welding electrode.
The table that follows shows setting for the welding current for the flux cored welding electrode that has a diameter of 1.3 mm (.051 inch).
Table 5
Welding Current for Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1"
Wire Feed Rate Voltage Amperage
Minimum
24 210
5080 mm (200 inch) Per Minute
Optimum
28 250
6985 mm (275 inch) Per Minute
Maximum
29 300
8255 mm (325 inch) Per Minute
Note: The settings for the welding current can vary due to the position of the weld. Also, the settings for the welding current can vary with the
manufacturer of the welding electrode.
Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux
cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the
possibility of evolving gas that is trapped in the weld. The volume of the fillet weld should not exceed 8.0 mm (.315 inch).
Arc Welding Electrodes for the GMAW Process
The table that follows lists the mechanical properties of welds that are deposited by the GMAW Process.
Table 6
Mechanical Properties of Welds from Arc Welding Electrodes That Are Classified as "ANSI/AWS A5.28 ER100S-2"
Tensile Strength
690 MPa (100076 psi)
Yield Strength
610 MPa (88473 psi)
Elongation 16%
Impact Toughness 68 J @ -51 °C (50 ft lb @ -60 °F)
The welding parameters will vary with the position of the weld and with different electrode manufacturers.
Weld Inspection
The weld should not have any of the conditions that follow:
z Cracks
z Porosity
z Undercut
z Incomplete Fusion
In order to verify the quality of the weld, refer to"American National Standards Institute (ANSI)/American Welding Society (AWS)
Specification D14.3".
General Repair for Cracked Welds
1. Remove any components that prevent access to the cracked weld.
2. Clean the weld of the substances that follow: oil, grease and dirt.
3. Use the dye penetrant to inspect the entire area for possible cracks.
4. Protect machined surfaces from sparks and weld deposits.
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5. Use an air carbon arc torch or use a grinder in order to remove cracks. Use a grinder to remove cracks that extend through the castings.
Remove at least 50.8 mm (2.0 inch) of material past each end of the crack. When the crack is removed, the bottom of the groove should
have an angle of 90 degrees in order to ensure sufficient penetration. The side walls of the groove should extend upward at an angle of 45
degrees.
6. Use the dye penetrant to inspect the gouged area in order to ensure that the crack has been removed. Be sure to clean the prepared groove
before welding.
7. Use Welding in order to repair the prepared groove by using passes that do not exceed two times the electrode diameter. If the alternate
welding process is selected, the size of the weld pass should not exceed 7.88 mm (0.31 inch) by volume. Do not allow any slag inclusion
when multiple pass welding is used.
8. Clean the weld and inspect the weld. The weld must be free from the following: cracks, porosity, undercut and incomplete fusion. All
quality of the weld must conform to ANSI/AWS standard 14.3.
Welding Instructions for Certain Truck Bodies
The following materials are used in order to fabricate the MSD II truck body:
z 400 Brinell Hardness Material
z 450 Brinell Hardness Material
Before welding on the MSD II truck body, verify the materials that are used in order to fabricate your MSD II truck body. There are specific
welding procedures for each material. Refer to the following procedures in order to successfully weld the materials during the assembly of the
truck body.
Note: When two or more different materials need to be welded together, use the procedure for the material that has the more stringent
requirements.
400 Brinell and 450 Brinell Hardness Material
The following procedure covers the requirements for welding the assembly of the MSD II truck bodies that are fabricated with 400 Brinell or
450 Brinell Hardness Material. Refer to ""Weld Specifications and Qualifications" " for qualifications, safety, and welding electrode parameters.
Attach the welding ground cable directly to the body assembly. Protect all of the machined areas from sparks and spatter that are produced by
welding, chipping, and grinding operations.
Proper preparation of the welding area must be conducted prior to welding. All weld joints and welding areas must be exceptionally clean.
Clean the welding area with a grinder. Completely remove all paint, rust, scale, slag, dirt, moisture, grease, etc before welding.
NOTICE
400 Brinell and 450 Brinell Hardness Material are both sensitive to
hydrogen induced cracking. Cleanliness of the weld joints and of the
consumables is of utmost importance.
Tight fitup of the body assemblies is very important. Ensure that every effort is made in order to minimize the gap spacing. Minimizing the gap
spacing reduces the residual stresses.
In order to minimize the possibility of cracking, use large tack welds. The tack welds should have a maximum width of 8 mm (0.32 inch) and a
length of 75 mm (3 inch).
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Illustration 1 g01286162
View of a TigerTorch
A TigerTorch can be used in order to preheat the material that is welded. Preheating is most critical during the tack welding procedure and
during the welding of the root pass. Refer to Table 7 for the required preheat temperature of the weld area:
Table 7
Preheat Temperatures
Combined Thickness of Material Welding Preheat
0 mm (0 inch) to
100 °C (212 °F)
65 mm (2.6 inch)
66 mm (2.6 inch) to
125 °C (250 °F)
100 mm (3.9 inch)
greater than
100 mm (3.9 inch) 175 °C (350 °F)
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Illustration 2 g01125276
Calculations for Combined Thickness
(A) Combined thickness = t1 + t2
(B) Combined thickness = 2 * t1 + t2
(C) Combined thickness = 2 * t1 + t2
(D) Combined thickness = t1 + t2
(E) Combined thickness = t1 + t2
(F) Combined thickness = 2 * t1 + t2
Ensure that the weld groove and 76 mm (3 inch) in each direction from the weld groove is preheated to the specified temperature. Verify the
preheat temperature with a 164-3310 Infrared Thermometer or with a temperature stick.
The minimum interpass temperature should equal the preheat temperature. The maximum interpass temperature should not exceed 250 °C (480
°F).
Note: When the ambient temperature is below 0 °C (32 °F) the initial preheat temperature should be taken to 121 °C (250 °F) 76 mm (3.0 inch)
in each direction from the weld joint in order to avoid the heat sink effect of the floorplates.
Note: The above preheat and interpass temperatures are for mild restaint to moderate restraint. If clamping devices are utilized in order to
reduce the gap spacing to less than 3 mm (0.12 inch), use the next higher preheat temperature, when possible. Additional stresses are offset by
using the next higher preheat temperature.
All welded areas need to be inspected. Hydrogen induced cracking normally occurs within 72 hours of welding. Allow the welded areas to cool
for 48 hours to 72 hours prior to performing a visual inspection. If any welding areas are suspected of being cracked during the visual
inspection, then use the dye penetrant process or the magnetic particle inspection process in order to inspect the welding areas. The welds shall
be free from the following defects: cracks, porosity, undercut and incomplete fusion. All weld quality shall conform to American National
Standards Institute (ANSI)/American Welding Society (AWS) D14.3.
Welding on Engines and Machines with Electronic Controls
NOTICE
Because the strength of the frame may decrease, some manufacturers
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do not recommend welding onto a chassis frame or rail. Consult the
OEM of the equipment or your Caterpillar dealer regarding welding
on a chassis frame or rail.
Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. The following steps should be
followed in order to weld on a machine or an engine with electronic controls.
NOTICE
Do not ground the welder to electrical components such as the ECM or
sensors. Improper grounding can cause damage to the drive train
bearings, hydraulic components, electrical components, and other
components.
Clamp the ground cable from the welder to the component that will be
welded. Place the clamp as close as possible to the weld. This will help
reduce the possibility of damage.
1. Turn off the engine. Place the engine start switch in the OFF position.
2. If equipped, turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery
cable at the battery.
3. Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the harness to a position that will not allow the harness to accidentally
move back and make contact with any of the ECM pins.
Illustration 3 g01075639
Use the example above. The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components.
(1) Engine
(2) Welding rod
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
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(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Maximum distance between the component that is being welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
4. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make
sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to
reduce the possibility of damage to the following components:
{ Bearings of the drive train
{ Hydraulic components
{ Electrical components
{ Other components of the machine
Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the
welder ground and the weld, current flow from the welder could severely damage the component.
5. Protect any wiring harnesses from the debris which is created from welding. Protect any wiring harnesses from the splatter which is
created from welding.
6. Use standard welding procedures in order to weld the materials together.
Welding on Fuel Tanks
Personal injury or death can result from an explosion.
Applying heat to a tank which has held flammable liquids, even when
empty, can result in residual flammable liquid or vapor igniting with
explosive force.
Do not weld or flame cut on any tank that has held flammable liquid
without taking the proper precautions such as filling the tank with
either carbon dioxide or water.
Do Not Weld an Empty Fuel Tank.
An empty fuel tank can not be cleaned sufficiently in order to ensure that all the flammable vapors have been removed. Vapors remain even
after cleaning with steam or washing with a caustic solution. Also, when caustic solutions are heated, caustic solutions can also be explosive. In
order to prepare a fuel tank for welding, use one of the following procedures:
z Fill the tank with carbon dioxide.
z Fill the tank with water.
Filling the Fuel Tank with Carbon Dioxide
Use the following procedure in order to prepare the tank for welding:
1. Cover all openings or plug all openings, except for the filler hole.
2. Fill the tank with carbon dioxide from a CO2 fire extinguisher.
3. Put a board, or some other object with a flat surface, over the filler hole in order to keep the carbon dioxide in the tank.
4. Weld the tank by using the welding practices that are detailed in this document.
Filling the Fuel Tank with Water
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Use the following procedure in order to prepare the tank for welding:
1. Cover all openings or plug all openings, except for the filler hole.
2. Fill the tank with water.
Note: The water must be kept at the very top of the filler hole at all times. This will ensure that there are no vapors that have collected in
empty cavities.
3. Weld the tank by using the welding practices that are detailed in this document.
Note: After welding on the tank, the fuel tank must be drained. Fill the fuel tank with a mixture of fuel and methyl alcohol (methanol). A ratio
of 0.5 L (0.13 US gal) methanol to 38 L (10.04 US gal) of fuel is satisfactory. The methanol will mix with the water. The methanol and water
will burn with the fuel.
Welding on Hydraulic Tanks
Do not weld on a closed hydraulic tank.
Use the following procedure in order to prepare the tank for welding:
1. Remove the cover.
2. Position the tank so that the welding area is at the highest point. This position makes sure that any oil that is left in the tank flows away
from the welding area. With no cover on the hydraulic tank, there is little danger of a buildup of explosive vapors.
Note: Do not put water in a hydraulic tank. Water can damage the valves in the hydraulic system. If necessary, carbon dioxide can also be used
in hydraulic tanks. Refer to ""Fill the Fuel Tank with Carbon Dioxide" " for the correct procedure.
Copyright 1993 - 2008 Caterpillar Inc. Mon Apr 7 10:49:22 EST 2008
All Rights Reserved.
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