GEAR & WEIGHT AS 1456100 - Caterpillar

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WELD REPAIR PROCEDURE - TRUCK BODY SUPPORT
PRELIMINARY
Welder Qualification/Safety
All welders must be qualified for fillet and groove welding as outlined in the current ANSI/AWS D1.1, or D14.3, or Caterpillar Manufacturing Practice MC1000-105. The welding operator must also have used the welding process during the last six months or be re-certified for this process before welding. Personal protection should be provided to assure that total weld fume in the operators breathing zone is within safe limits. Attach the welding ground cable directly to the body assembly as close to the area to be repaired as possible. Protect all machined surfaces from sparks or spatter produced by the welding, chipping, and/or grinding operations. The welder must be familiar with air Carbon Arc Gouging (CAC-A) and know how to safely use it.
Caution: This material is sensitive to hydrogen induced cracking. Cleanliness of material (weld joint) and consumables are of utmost importance.
Electrode /Characteristics
Two processes may be used for welding of this support assembly: SMAW or FCAW.
SMAW
The SMAW process may be used with E7018 (ANSI/AWS A5.1) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:
TENSILE STRENGTH 480 MPa (70 KSI)
YIELD STRENGTH 400 MPa (58 KSI)
ELONGATION 22%
IMPACT TOUGHNESS 20 FT LBF @-20F (27J @-18C)
Caution: These are low hydrogen electrodes and must be stored in an electrode oven at 120 degrees C (250 degrees F) when not in use. If the electrodes get damp, scrap or recondition to manufacturer's specifications.
The following chart relates to the electrode diameter and approximate current settings for welding:
DIAMETER AMPS
3.2MM (0.125?) 1/8? 70-140
4.0MM (0.156?) 5/32? 110-180
4.8MM (0.166?) 3/16? 190-270
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass weave width shall not exceed two times the electrode diameter.
FCAW
As an alternative process the FCAW process may be used with E71T-1 H8 (ANSI/AWS A5.20) welding electrode and the manufacturers specified shielding gas (es). The weld deposited by these electrodes will have the following mechanical properties:
Caution: Only use flux-cored electrodes that have been properly stored in moisture resistant packages that are undamaged or which have been placed in a drying oven maintained at 250 degrees F (120 degrees C).
TENSILE STRENGTH 480 MPa (70 KSI)
YIELD STRENGTH 400 MPa (58 KSI)
ELONGATION 22%
IMPACT TOUGHNESS 20 FT LBF @-20F (27J @-18C)
Welding parameters will vary due to weld position and manufacturer of the welding electrode. For 1.3mm (0.052 inch) diameter electrode typical welding parameters should be:
WIRE FEED SPEED VOLTAGE APPROX. AMPERAGE
MIN 200 IMP 24 210
OPT 275 IMP 28 250
MAX 325 IPM 29 300
Use the direct current electrode positive (DC reverse polarity) setting and remove the slag after every pass.
Caution: Post heat the weld repair (thermal soak) to 300 degrees F (150 degrees C) for at least 30 minutes (or 1 hour per 25