PUMP AS-FUEL INJECTION 1862636 - Caterpillar

This is a 8.0-hour job
A a maximum of $2600.00 U.S. will be allowed for labor and materials to fabricate the four weld strips shown in the illustrations. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the machine folder for audit purposes.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
793C Fuel Tank Rework 215-3500
The following procedure is written to update the 793C fuel tank with external plates to be used if cracks develop in the plug weld locations on the end walls of the tank that have the fast fill flanges.
General pictures with part descriptions are shown below in Images 1.1.1 and 1.1.2. Drawings each part are included at the back of this document.
Image1.1.1
Image1.1.2
PRELIMINARY
Welder Qualification/Safety
All welders must be qualified for the material, process and position. The welder must have used the welding process during the last six months or be re-certified for this process before welding. Personal protection equipment should be worn to assure that total weld fume in the operators breathing zone is within safe limits. The welder must also be familiar with both the air Carbon Arc Gouging (CAC-A) and grinding processes and know how to safely use them.
Welding
Follow guidelines for tank preparation as outlined in REHS 1841 ?Welding on Fuel Tanks?. Remove all necessary components. See instructions for welding below. Remove slag and repaint as necessary.
WELDING ELECTRODE
Electrode /Characteristics
FCAW
The FCAW process may be used with E71T-1 (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 @ 0F (27J @-18C)
Welding parameters will vary due to weld position and manufacturer of the welding electrode. For 1.1mm (0.045 inch) diameter electrode typical welding parameters should be:
WIRE FEED SPEED.....VOLTAGE......APPOX. AMPERAGE
MIN 175 IPM..........22-24..........130
MID 350 IPM..........26-28..........210
MAX 425 IPM..........29-31..........275
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......APPOX. AMPERAGE
MIN 200 IPM...........22-24..........185
MID 300 IPM...........25-27..........245
MAX 425 IPM...........28-30..........295
SMAW
The SMAW process may be used with E7018 (ANSI/AWS A5.1) welding electrode. The weld metal 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 approximates the current settings for welding:
DIAMETER...................AMPS
2.4MM (0.094?) 3/32?......70-100
3.2MM (0.125?) 1/8........90-160
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass volume shall not exceed two times the electrode diameter.
PREHEAT/POSTHEAT REQUIREMENTS
No pre-heat/post-heat