LINES GP-FUEL INJECTION 9Y0299 - Caterpillar

Diameter Amps
3 mm (0.125 in) 130
4 mm (0.156 in) 180
4.8 mm (0.166 in) 260Use the direct current electrode positive (DCreverse polarity) setting and remove the slag after every pass.As an alternate process the GMAW process maybe used with ER70S-3 (A5.18) welding electrode and the manufacturers' specifiedshielding gas(es). The weld deposited by these electrodes will have thefollowing minimum mechanical properties:500 MPa ( 72 KSI ) Tensile Strength420 MPa ( 60 KSI ) Yield Strength22% elongation in 50 mm ( 2 inches )27 J ( 20 ft lb. ) Notch Toughness at -18 degreesC (0 F)Welding parameters will vary due to weld positionand manufacturer of the welding electrode. For 1.3 mm (0.052 inch) diameterelectrode typical welding parameters should be:
Wire Feed Speed Voltage Approximate Amperage:
Minimum 200 IPM 24 210
Optimum 275 IPM 28 250
Maximum 325 IPM 29 300Use the direct current electrode positive (DCreverse polarity) setting and remove the slag after every pass.Attach the welding ground cable directly tothe tank. Do not allow welding current to travel through the machine'sbearings or hydraulic cylinders. Protect all hydraulic cylinders, struts,hoses, and machined surfaces from sparks or spatter produced by the welding,chipping, and/or grinding operations.Weld the joint using stringer beads or a weavepattern as desired. The welding pass size should be manageable, and generally,not exceed two times the electrode diameter. With a single pass of 1/8inch E7018, the weld metal should be two times the electrode diameter.If the GMAW process is used the welding pass size should not exceed 8mm(0.312-inch) fillet volume.Note: When welding on hydraulic tanks, followthe safety procedures detailed in 2nd July 1990 Service Magazine (MediaNumber SEPD0025) Article - "Welding On Fuel And Hydraulic TanksRepair ProcedureNote: Some illustrations in this procedureare shown with various components removed from the machine for photographicclarityParts List
Part Number Description Quantity
188-7298 Gasket 1
150-5939 Adapter 1
132-8876 Filter Element 3
Item 3 Plate 1Note: Item 3 Plate is to be fabricated bythe dealer using the dimensions and additional information provided inthis procedure. Material to be used for plate manufacture is: - ASTM A572Grades 42, 50 or BS 4360 Grade 50B.Machine PreparationReferring to the Operation and MaintenanceManual, and the procedures detailed in RENR5140 - Disassembly and Assembly,735, 740 and 740 Ejector Articulated Truck Machine Systems - remove thehoist and brake systems hydraulic tank. Thoroughly clean the outside ofthe tank in preparation for repairs. Remove the top cover assembly fromthe tank.
Plate Repair Procedure1. Remove all dirt, oil, grease and paint fromthe areas to be welded.2. Inspect the area for cracks. Where cracksare present, use dye penetrant to identify the extent of the crack thencarry out weld repairs as required. Dress the welded area flush to thetank face.3. Manufacture Item 3 Plate using the dimensionsand specifications provided below - all dimensions are in millimeters.
4. Position the Item 3 Plate on the right-handside of the hydraulic tank, using the cut-out for the brake pump supplyhose adapter to correctly position the plate on the side of the tank -see the illustrations below. Note that the side face of the tank may havebowed and it may be necessary to push the plate flush to the tank face.
5. Secure the plate to the right-hand faceof the tank using a 4mm fillet