CONTROL GP-ENGINE ELECTRONIC 2099587 - Caterpillar

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. This can result in injury or death. DO NOT weld or flame cut on any tank that has held flammable liquid without taking the proper safety precautions. Read the article entitled "Welding On Fuel And Hydraulic Tanks" in the July 2, 1990 Service Magazine.
Top View of Hydraulic Tank Assembly (A) 81.5 mm (3.20 in). (B) 52.5 mm (2.06 in). (C) 3.0 mm (.12 in) fillet weld all around.1. Drain hydraulic tank.2. Purge tank and drill 9.5 mm (.38 in) diameter hole at location given in illustration.3. Locate 090-9624 Boss over previously drilled hole.4. Weld boss with a 3.0 mm (.12 in) fillet weld all around. Read the warnings and references in regards to welding.5. Install 2G-8227 Valve Gp. and 3J-1907 Seal.6. Flush tank and fill with hydraulic oil.Weld Information
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 instructions 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 general area. Wear correct eye, ear, and body protection. Do not touch live electrical parts.
See 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 CRF 1910, available from U.S. Dept. of Labor, Washington, D.C. 20408.
Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OSHA limits.All repair welding operators must be qualified for groove and fillet welding, as outlined the current ANSI/AWS D14.3, or Caterpillar Manufacturing Practices MC1000-105. The qualification will be for the SMAW (Shielded Metal Arc Welding) process in the vertical welding positions. The welding operator must also have used this welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications. The alternate process for this repair could be FCAW (Flux Cored Arc Welding).
The area to be welded and the surrounding area must be at a minimum temperature of 16° C (60° F) before and during welding.
Since weld distortion is a possibility, minimizing the heat into the casting is important.The SMAW process shall be used with E7018 (ANSI/AWS A5.5) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:
500 MPa (72 KSI) Tensile Strength420 MPa (60 KSI) Yield Strength22% elongation in 50 mm (2 in)27 J (20 ft lb) Notch Toughness at -29° C (-20° F)These are low hydrogen electrodes and must be stored in an electrode oven at 121° C (250° F) when not in use. If the electrodes get damp, scrap or recondition