GENERAL INFORMATION - Welding Procedure Section 000-0010 Welding WARNING Welding and flame cutting cadmium plated metals produce odourless fumes which are toxic. Recommended industrial hygiene practice for protection of the welding operator from the cadmium fumes and metallic oxides requires enclosure ventilation specifically designed for the welding process. A respiratory protective device such as the M.S.A. 'Gasfoe' respirator with G.M.A. cartridge will provide protection against cadmium, fumes and metallic oxides. The 'Gasfoe' respirator has been approved by the U.S. Bureau of Mines: Approval number 23B-10, and is designed to protect against gases, vapours, and/or metal fumes.
WARNINGS Before any welding is done on a machine equipped with any electronic systems, disconnect the following (if applicable) in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables and electrical connections at the engine ECM, transmission ECU, body control lever, hydraulics ECU and cab bulkhead to avoid damage to electrical components. Turn off battery master switch to isolate the batteries before disconnecting any components. After welding connect all of the above in the reverse order. Note: The current from the welding rod always follows the path of least resistance.
If, for example, the ground clamp is attached to the rear frame when welding is performed on the front frame, the current must pass a frame connection to return to the welding machine. Since the pivot coupling offers the least resistance but not a sound electrical connection, small electric arcs may be set up across the moving parts which may cause welding blotches on their wearing surfaces and increase the wear rate of these components. Before any welding is done ensure all paint has been removed from the area to be welded. Failure to do so may result in hazardous fumes being given off from the paint. Note:
Always fasten the welding machines ground cable to the piece/frame being welded if possible. Electric arc welding is recommended for all welded frame repairs. Since the nature and extent of damage to the frame cannot be predetermined, no definite repair procedure can be established. As a general rule however, if parts are twisted, bent or pulled apart, or a frame is bent or out of alignment, no welding should be done until the parts are straightened or realigned. General Welding Procedure The following general procedure should be used for the repair of defects outwith the vicinity of alloy steel castings. 1. Completely ARC-AIR gouge or grind out the crack until sound metal is reached.
If ARC-AIR method is employed, pre-heat area to 100° C (212° F), measure 3 - 4" either side of repair prior to gouging. On completion of gouging grind to remove thin carbon layer. Successfully welded repairs will depend to a great extent upon the use of the proper equipment, materials and the ability of the welder. The Customer Support Department can be consulted regarding the feasibility of welding repairs. 2. Apply dye-penetrant check to ensure crack has been completely removed. SM 2172 10-02 1