General Welding Procedures (0679, 7000) (REHS1841-23)

21/10/2022 16:00 SIS 2.
2021/06/09 General Welding Procedures {0679, 7000} (REHS1841-23)
SMCS - 0679, 7000 i08477220

Caterpillar Products
All
Introduction
Revision History
Revision Summary of Changes
23 Added bore welding information.
22 Updated preheat table.
21 A note for 794 AC Off-Highway Truck weld procedures was removed.
20 Updated Toe/Burr Grinding depths in the Post Weld Treatment Section.
Added General Knowledge section, Welding Electrode and Parameter section, Workmanship section, and Post Weld Treatments
19
section.
Table 1
This Special Instruction provides the necessary information on all welding procedures.
Note: For Electric Rope Shovels follow Machine Preparation Procedure in M0069230 , "Testing and Adjusting 7495 and 7495 HF
Electric Rope Shovel". The procedure can be found on Caterpillar Service Information System (SIS).
Reference
Reference: Operation and Maintenance Manual
Safety
The following information is an explanation of various labels that are found in this document.
Warnings
The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.
Notices
A notice informs the technician that component damage can occur as a result of a condition that exists.
Notes
A note contains general information for the technician about the operation that is being performed.
Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines basic recommended procedures.
Some of the procedures require special tools, devices, or work methods.
Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all safety information
before you perform any repairs or before you perform any maintenance.
Safety information is provided in this document and on the machine. If these hazard warnings are not heeded, bodily injury or death could occur to
you or other persons.
The “Safety Alert Symbol” that is followed by a “Signal Word” identifies a hazard. “DANGER”, “WARNING”, and “CAUTION” are “Signal Words”.
Illustration 1 g00008666
The signal word “WARNING” has the following meanings:
Pay Attention !
Become Alert !
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Your Safety Is Involved !
The message that appears under the safety alert symbol explains the hazard.
Operations or conditions that may cause product damage are identified by "NOTICE" labels on the machine and in the service information.
The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution when you perform service work.
Special knowledge of the systems and of the components is important. Before you remove or disassemble any component, obtain knowledge of
the system and knowledge of the component.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document
and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating
techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine.
Determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
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 instruction 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 the general area. Wear
correct eye, ear and body protection. Do not touch live electric
parts.
Refer to the 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 CFR 1910, available from U.S. Dept. of
Labor, Washington D.C. 20210.
Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from
entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.
NOTICE
To prevent damage to components. The power train high-
voltage system must be shorted to the cabinet ground before
welding anywhere on the truck.
NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components
are filled with fluid, or during any maintenance operation.
Basic Precautions
Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair

on this product, until you have read and understood the
operation, lubrication, maintenance and repair information.
Always observe the list of basic precautions that follows:
Safety Signs
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Safety signs include the items that follow: signs, information plates, and decals. Read all “Safety” signs on the machine before operating,
lubricating, or repairing the machine. Understand all “Safety” signs on the machine before operating, lubricating, or repairing the machine. Replace
any safety signs that are in the conditions that follow: damage, unreadable and missing.
Protective Equipment
When you work around the machine, always wear protective equipment that is required by the job conditions. Protective equipment includes the
items that follow: hard hat, protective glasses, and protective shoes. In particular, wear protective glasses when you use a hammer or when you
use a sledge hammer. When you weld, use the appropriate protective equipment that is required by the job conditions. Protective equipment for
welding includes the items that follow: gloves, welding hood, goggles, and apron. Do not wear loose clothing or jewelry that can catch on parts of
the machine.
Mounting and Dismounting

Use steps and handholds when you mount a machine. Also, use steps and handholds when you dismount a machine. Before you mount the
machine, clean any mud or debris from steps, walkways, or work platforms. Always face the machine when you use steps, handholds, and
walkways. When you cannot use the accesses on the machine, use ladders, scaffolds, or work platforms to perform safe repair operations.
Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturer weights to determine the application when you select
the following items: cable, chain, and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows to see
the effect of the lift angle on the working load limit.
Note: The lifting devices that are shown in this publication are not Caterpillar parts.
Note: Ensure that the hooks are equipped with a safety latch. Do not place a side load on the lifting eyes during a lifting operation.
Lift angles for lifting slings.
(A) The load capacity is 100%
of the working load limit for the sling.
(B) The load capacity is 86% of the working load limit for the sling.

(C) The load capacity is 70% of the working load limit for the sling.
(D) The load capacity is 50% of the working load limit for the sling.
Hot Fluids and Parts

To avoid burns, be alert for hot parts on machines which have been stopped and hot fluids in lines, tubes and compartments.
Be careful when you remove filler caps, breathers, and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed by
pressurized liquids. When the machine has been stopped, the danger of hot fluids is greater.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to contact the skin for extended periods of time.
Avoid repeated contact with the skin. Do not drink corrosion inhibitor. If there is contact, immediately wash skin with soap and water. For contact
with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.
Batteries
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Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from
the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is
released from the electrolyte through the battery outlets. Do not allow battery electrolyte to contact skin or eyes. Battery electrolyte is an acid. If
there is contact with battery electrolyte, immediately wash the skin with soap and water. For contact with the eyes, flush the eyes with large
amounts of water for at least 15 minutes. Seek medical attention.
Pressurized Items
1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body tissue. Fluid
penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must
get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
2. Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are disconnected or removed. Always make sure
that all raised components are blocked correctly. Be alert for possible pressure when you disconnect any device from a system that utilizes
pressure.
3. Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged and lubrication lines that are
loose can cause fires. Hydraulic lines, tubes, and hoses that are damaged can cause fires. Loose hydraulic lines, loose tubes, and loose
hoses can cause fires. Do not bend or strike high-pressure lines. Do not install lines which have been bent or damaged. Check lines, tubes,
and hoses carefully. Do not use your bare hand to check for leaks. If fluids are injected into your skin, you must get treatment immediately.
Seek treatment from a doctor that is familiar with this type of injury.
4. Pressure air or water can cause personal injury. When pressure air or water is used for cleaning, wear a protective face shield, protective
clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). When you use a pressure
washer, keep in mind that the nozzle pressures are high. The nozzle pressures are frequently above 13790 kPa (2000 psi). Follow all the
recommended practices that are provided by the manufacturer of the pressure washer.
Welding on Engines and Machines with Electronic Controls
The Power Train Electric Drive System will contain hazardous

voltage levels during machine operation and for a short period of
time after engine shutdown.
Do not remove any covers that will expose energized high

voltage electrical components while the engine is operating.
Any type of maintenance on the following components can only

be performed after the Power Train Electrical System Service
Shutdown procedure has been followed:
High voltage compartments in the inverter cabinet
The rear axle housing that contains the electric drive

traction motors
The generator
The retarding resistor grid, the grid blower motor and the
grid system cabling
The excitation field regulator
The high voltage cables and connection enclosures
Failure to follow these instructions could result in personal injury

or death.
NOTICE
Because the strength of the frame may decrease, some
manufacturers do not recommend welding onto a chassis frame
or rail. Consult the OEM of the equipment or your Cat dealer
regarding welding on a chassis frame or rail.
Proper welding procedures are necessary to avoid damage to the electronic controls. When welding on a machine with electronic controls, use the
Steps that follow.
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1. Turn off the engine. Place the engine start switch in the OFF position.
2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the
negative cable at the battery.
NOTICE
Do Not weld plates to the frame for grounding or clamping
purposes. Use existing blocks, brackets, bosses, and so on, to
attach the clamp.
NOTICE
Do Not use electrical components as a ground point for the
welder. Do Not use ground points for electronic components as
the ground point for the welder.
3. Attach the clamp for the ground cable as close as possible to the area that is being welded. This process will reduce the likelihood of damage
from the welding current to the following components:
Bearings
Hydraulic components
Electrical components.
4. Protect the wiring harnesses and machine surface from sparks and weld spatter.
Welding on Machines Equipped with LiDAR
NOTICE
The varying current flow in welding operations results in
electromagnetic radiation. The EMI radiation will be transmitted
to any conductors that are positioned as antenna in the
radiation field. This or any activity that can induce current, will
damage the sensor.
1. Remove the electrical connections to the LiDAR sensor.
2. Disconnect the M12 and Deutsch connector.
3. Remove the ground straps that connect sensor to the machine ground.
4. Keep sensor a minimum 3.05 m (10 ft) away from the welding area. Ground the sensor case to an earth ground that is not connected to the
welder return.
Note: Caterpillar recommends that the machine chassis is grounded, before the cables and ground straps are connected to the sensor.
Welding on Fuel Tanks and Hydraulic Tanks

The following information is not intended to replace any regulatory standards or practices of industries that have expert knowledge of handling
hazardous substances.
Reference: National Fire Protection Association (NFPA), NFPA 326 "Standard for the Safeguarding of Tanks and Containers for Entry, Cleaning, or
Repair"
Reference: American Welding Society (AWS), AWS F4.1:2007 "Safe Practices for the Preparation of Containers and Piping for Welding and
Cutting"
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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.
Personal injury or death can result from an explosion.
Do not weld or flame cut on any tank that has held flammable
liquid without taking the proper precautions such as filling the
tank with either inert gas or water.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
Dispose of all fluids according to local regulations and

mandates.
NOTICE
The fuel tank and/or hydraulic tank must be drained of all fuel
and/or oil so that there is no residual fuel and/or oil left in the
tank.
NOTICE
Do not put water in a hydraulic tank. Water can damage the
valves in the hydraulic system.
Required Tooling
Required Tooling
Item Part Number Description
A - Oxygen Indicator
B - Combustible Gas Indicator
C 1U-5490 Cleaner (de-greaser)
Table 2
The equipment is to be calibrated with a calibration gas that is appropriate to the potential hazard.
Calibrate the equipment prior to first use.
The adjustment of the equipment is to be checked daily before use.
The equipment is to be maintained in accordance to the manufacturer recommendations.
Definitions
Hot Work: any work that is a source of ignition including open flames, cutting, and welding, sparking of electrical equipment, grinding, buffing,
drilling, chipping, sawing, or other operation that creates hot metal sparks or surfaces from friction or impact.
Inert Gas: any of the chemically inert gaseous elements of the helium group in the periodic table.
For purpose of tank cleaning, or repair, a gas that is nonflammable, chemically inactive, non-contaminating for the use intended, and oxygen-
deficient to the extent required.
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Inerting: a technique by which the atmosphere in a tank or container is rendered non-ignitable or non-reactive by the addition of an inert gas.
Qualified Person: a person designated by the employer or contractor, in writing, as capable by education or specialized training, or both, of
anticipating, recognizing, and evaluating employee exposer to hazardous substances or other unsafe conditions. This person shall be capable of
specifying the necessary control and protective action for worker safety.
Basic Precautions
NOTICE
The fuel tank and/or hydraulic tank must be drained of all fuel
and/or oil so that there is no residual fuel and/or oil left in the
tank.
Extreme caution shall be used when work is performed on a tank or a container that holds or has held flammable, combustible, or other hazardous
substances.
Extreme caution shall be used when work is performed on a tank or a container that contains vapors related to the substances that are stored or
were previously stored therein.
Before any work is performed on a tank or container that has held flammable, combustible, or other hazardous substances, the tank, or container
shall be made safe.
The person conducting the work shall have a thorough understanding of the following:
The characteristics of the substance that is or was previously stored in the tank or container.
The potential health and safety risks associated with the work to be conducted.
The procedures for safeguarding the tank or container prior to conducting the work.
Preparing the Tank for Cleaning

Determination of hazardous characteristics of contents.
Before any tank or container is cleaned, the hazardous characteristics of the substance previously help by the tank or container shall be
determined by a qualified person.
Unknown substances.
If the source and identity of the material in the container cannot be determined, and if chemical analysis cannot be performed, the tank or container
shall be disposed in accordance to local, state, and federal regulations.
Designation of cleaning procedure.
A qualified person shall designate the cleaning procedure to assure that the cleaning can be performed safely in an environmentally responsible
manner and can render the container free of all hazardous concentration of materials.
Tank or container location.
The tank or container shall be moved outdoors, if practical. If the tank or container is cleaned indoors, the room shall be well vented so that
hazardous vapors will not accumulate and will be carried away from the breathing zone quickly and safely.
Tank or container contents.
The tank or container shall be emptied and drained thoroughly, including all internal piping, traps, and standpipes. Sludge and sediment shall be
removed. All residue and used cleaning agents shall be disposed of in an environmentally safe manner according to local, state, and federal
regulations.
Cleaning Methods
Water cleaning.
Note: Water method for use on fuel tanks only.
Where the substance is known to be safely and readily soluble in water, the residue can be removed by completely filling the container with water
and draining several times.
Hot chemical solution cleaning.
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This method generally uses trisodium phosphate or a commercial caustic cleaning compound dissolved in hot water. Care must be taken to guard
against injury from vapors, gases, or contact with the cleaning compounds. Suitable personal protective equipment (PPE) shall be used and
adequate ventilation shall be provided.
Steam cleaning.
This method generally uses low-pressure steam and a hot soda or soda ash solution. Solution agitation is used to flush the inside surfaces, and
steam is used to promote a good cleaning action. Care must be taken to avoid injury from vapors, steam, and cleaning solution. Suitable personal
protective equipment (PPE) shall be used and adequate ventilation shall be provided.
Note: The tank and nozzle shall be grounded during steam cleaning to minimize the possibility of static charge buildup and spark discharge.
Chemical cleaning.
Use tooling (C) cleaner (de-greaser) to clean the tank or container.
When the tank or container holds deposits insoluble in water. Care shall be used in selecting a chemical solvent, some solvents may be hazardous
as the deposits the solvents are intended to remove.
Note: If chlorinated solvents are used, all residue must be removed before welding or cutting begins.
Note: When selecting chemical solvents, consult the manufacturer of the material being removed. Chemical manufacturers may recommend a
solvent to use and a detailed cleaning procedure.
Combination of methods.
Occasionally, combinations of the cleaning methods must be used. Care must be exercised when combining some of the cleaning methods to
protect personnel and prevent hazardous reactions.
Preparing for Welding

The following guidelines ensure that the tank or container and the work area are safe for welding and cutting. The guidelines are intended to
protect personnel and equipment by ensuring that the hazards are understood and adequate precautions are taken. The qualified person
responsible for the work being performed on the tank or container shall ensure that the guidelines are followed.
Do Not Weld an Empty Fuel Tank.
Do Not Weld on a Closed Hydraulic Tank.
An empty fuel tank or hydraulic tank cannot be cleaned sufficiently to ensure that all the flammable vapors have been removed. Vapors remain
even after cleaning with steam or washing with a caustic solution. Also, when caustic solutions are heated, caustic solutions can also be explosive.
To prepare a fuel tank for welding, use one of the following procedures:
Safe Practices
The following steps must be taken to ensure that the work area and the tank or container are maintained safe for welding.
1. The immediate area outside and inside the tank or container shall be cleared of all obstacles and hazardous materials.
2. Personal protective equipment (PPE) and fire protection equipment shall be available, serviceable, and in position for immediate use.
3. Ventilation shall be adequate for providing a safe work atmosphere prior to and during welding. Testing may be necessary to test for toxic or
flammable vapors and to verify that the oxygen content of the atmosphere in the work area is maintained within acceptable limits.
Where adequate ventilation is not available, an independent source of breathing air shall be provided.
4. A qualified person shall inspect the tank or container to verify that the cleaning is adequate. All test equipment is to be suitable for the
intended measurement. Prior to welding ensure that the atmosphere inside the tank or container is safe for welding.
5. Use a calibrated and adjusted combustible gas indicator and test the tank or container for flammable vapors.
6. Prevent pressure buildup in the tank or container during welding. Exhaust gases and other gases produced during welding shall be
discharged in a safe and environmentally acceptable manner.
7. Test the container for hazardous gases, fumes, and vapors periodically to ensure that the tank or container and the work area are safe during
welding.
8. Inert the tank or container. Maintaining the tank or container in a welding condition, free from flammable or explosive hazards by filling the
tank or container with an inert medium such as water or inert gas.
9. Inert gas method.

Fill the tank or container with inert gas. When this method is used, the qualified person shall be informed of the percentage of inert gas that
must be present and how to produce and maintain this percentage safely during welding, as well as be alert for suffocation hazards.
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These inerting guidelines are suitable for use with metal lined jacketed containers that might be difficult to clean thoroughly.
10. Carbon dioxide method.

Note: Portable carbon dioxide fire extinguishers cannot be used as a source of inert gas.
When solid carbon dioxide is used, the solid carbon dioxide must be crushed and distributed evenly over the greatest area possible for rapid
sublimation.
Use a carbon dioxide indicator to measure the permitted oxygen percentage calculated from the percentage of carbon dioxide in the tank.
Note: Use proper safety equipment and safe handling procedures when working with solid carbon dioxide.
NOTICE
Do not put water in a hydraulic tank. Water can damage the
valves in the hydraulic system.
11. Water Method.

Note: Water method for use on fuel tanks only.
Place the tank or container so that the tank or container can be kept filled with water within a few inches ( 25 mm (1.00 inch) to 75 mm
(3.00 inch)) of the point where the welding is to be performed. Vent the space above the water level so the heated air can escape from the
tank or container.
Note: After welding on the fuel tank, the fuel tank must be drained and cleaned. Refer to the "Cleaning Methods" section for acceptable
cleaning methods.
Note: To remove the water from the tank, perform the following Steps:
1. Empty the water from the tank.
2. Install the tank onto the machine.
3. Fill the tank with fuel and let the machine stand without disruption for a minimum of 12 hours.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
Dispose of all fluids according to local regulations and

mandates.
4. After a minimum of 12 hours open the purge screw on the fuel tank, to drain any residual water and sediment that has settled in the bottom of
the fuel tank. Close the purge screw when clean fuel begins to exit from the fuel tank.
5. Drain the Fuel System Primary Filter (Water Separator) - Drain. Refer to Operation and Maintenance Manual.
6. Continue to monitor and drain the Fuel System Primary Filter (Water Separator) - Drain as needed.
General Knowledge
To repair Cat® structures by welding, the individual performing the welding must be certified/qualified. Certification/qualification can be
accomplished via a recognized national or international welding code or specification. Examples of recognized codes or specifications
are AWS D1.1, ISO 9606–1, AS NZS 1554.1. Certification/qualification is awarded based on welding process, welding position, material type, and
material thickness. The company performing the repair is responsible for ensuring the welders are certified/qualified for the work being performed.
All welder qualification tests will be evaluated by qualified personnel such as AWS CWI (Certified Welding Inspector) or the equivalent by any other
national or international SCO (Standards Developing Organization) as a minimum.
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Note: In general, the requirements for a welder are to be certified/qualified in all positions (fillet and groove welds) for unlimited
thickness structural steel using the flux cored arc welding process (FCAW).
Five Types of Weld Joint
Butt joint

Lap joint

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T joint

Corner joint

Edge joint

Note: Edge joint is not commonly used for structural applications.
Illustration 3 through Illustration 7 the five possible ways of bringing plate, castings, and forgings together for welding.
The two most common types of welds used to join these joints are fillet welds and groove welds.
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Fillet welds main parts

Fillet welds are commonly used to join lap, t, and corner joints. Fillet welds typically do not require any modification to the plate edges and are an
efficient means of joining two materials.
The main parts of a fillet weld are shown in Illustration 8. The size of a fillet weld is defined by the leg length and the throat. The throat dimension
pictured would be the actual throat, which is what is measured using a standard fillet weld gage.
Note: The leg length is the measurement used to identify size on a print or procedure, the throat also has to be a corresponding size (min. throat =
0.707 x leg length).
Groove welds main parts

Groove welds are most commonly used to join a butt joint. However, groove welds can also be used in t and lap joint. The type of groove weld is
associated with how the edges or ends of the material are modified.
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Single bevel

Single bevel both sides

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Single V

Single V both sides

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J groove

Illustration 10 through Illustration 14 shows common groove weld preparations.
Crack Detection Methods

Crack Detection Methods Advantages and Disadvantages
Detection
Advantages Disadvantages
Method
- Least Expensive

- Limited to surface-only defects.
- Detects most damaging defects.

knowledge of welding and fabrication in
Visual Testing (VT)
- Requires inspectors to have broad
- Immediate Results

addition to Non-Destructive Testing (NDT).
- Minimum part preparation
- Inexpensive

- Least Sensitive
Liquid Penetrant - Minimal Training

- Detects surface
cracks only.
Testing (PT) - Portable

- Rough or porous surfaces interfere with test
- Works on nonmagnetic material.
- Portable
Dry Magnetic
- Fast/Immediate Results
- Works on magnetic material only.
Particle (MT)
- Detects surface and subsurface - Less sensitive than Wet Magnetic

Particle Testing (MT).
discontinuities
- More sensitive than Liquid Penetrant
- Requires power for light.
Wet Magnetic Testing (PT).

only.

- Works on magnetic material
Particle (MT) - Detects subsurface as much as
- Liquid composition and agitation must be monitored.

0.13 mm (0.005 inch).
- Most Sensitive
- Detects deep material defects.

- Most Expensive
Ultrasonic Testing

training and certification.
- Immediate Results
- Requires operator
(UT)

- Wide range of materials and thickness - Surface must be accessible to probe

can be inspected
Table 3
Applicable Crack Detection Standards
Minimum
Acceptance
Required
Detection Method Standard

Criteria Personnel
Qualifications
EN-ISO 5817
EN-ISO 5817 - Level B
EN-ISO 9712
Visual Testing (VT)

AWS D1.1
AWS D1.1 - Table 6.1

ANSI-ASNT SNT-TC-1A
EN-ISO 3452
EN-ISO 23277
EN-ISO 9712
Liquid Penetrant Testing (PT)

ASTM E165
AWS - D1.1

ANSI-ASNT SNT-TC-1A
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EN-ISO 17638
EN-ISO 23278 - Level 1
EN-ISO 9712
Magnetic Particle Testing (MT)

ASTM E709
AWS D1.1 - Table 6.1

ANSI-ASNT SNT-TC-1A
EN-ISO 17640 - Level B
EN-ISO 11666 Technique 2 - Level 2
EN-ISO 9712
Ultrasonic Testing (UT)

AWS D1.1 AWS D1.1 - Class A - Table 6.3 ANSI-ASNT SNT-TC-1A
Table 4
NOTICE
Regardless of which crack detection method is used, close
adherence to instructions furnished with the detection
equipment is important when checking any component. Failure
to do so may cause inaccurate results or may cause injury to
the operator and/or surroundings.
There are five major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Testing (VT), Liquid Penetrant Testing
(PT), Dry / Wet Magnetic Particle Testing (MT), and Ultrasonic Testing (UT).
Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, Dry/ Wet MT, and UT are
methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most
versatile. For example, PT can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using Wet MT is
more accurate. Refer to Table 3 for advantages and disadvantages and Table4 for standards and requirements for these NDT methods.
Welding Positions
Note: The welding positions shown below are both United States and European.
Groove weld positions

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Fillet weld positions

Basic features of a welding symbol

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Basic weld symbols

Note: The post-weld finishing symbol in Illustration 18 shows the letter G under of over the flush symbol to indicate Grind flush. The following
designators may be used to specify other means of post-weld finishing. G = Grinding, M = Machining, and U = Unspecified.
A complete welding symbol, however, indicates the location, size, and finish of the weld and gives other specifications and information. A weld
symbol placed below the reference line goes on the arrow side of the joint. A weld symbol placed above the reference line goes on the other side of
the joint. The eight elements of the welding symbol are:
Reference line
Arrow
Basic weld symbols
Weld size
Supplementary symbols
Finish symbols
Tail
Specification
Preheat Information
The following preheat information is intended for mild steels, carbon-manganese steels, and low alloy steels with yield strengths up to 600 MPa
(87022 psi) for use in typical structural applications on Caterpillar products. For all other materials (for example: aluminum and stainless steels),
refer to the appropriate industry specifications and information provided by the material supplier.
Steels having a Carbon Equivalent (CE) value over 0.61 will normally require preheating
Steels in the CE range over 0.46 through 0.61 are frequently weldable without preheating, provided a low hydrogen welding process has
been specified
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Regardless of carbon equivalent values, steels with 0.30 percent carbon or greater will usually require preheating when the section thickness
is 25 mm (1.0 inch) or over at the weld joint
When determining preheat and inter-pass temperatures, consideration should also be given to the steel manufacturer guidelines and
recommendations
Preheat Table
European Material Interpass
American Standard Wall Thickness Preheating Temperature
Name Temperature
Room Temperature (minimum Maximum 250° C
ASTM A36 S235JR All
20° C (68° F) (482.° F)
less than 40 mm (1.60 inch) Minimum 20° C (68° F)
Maximum 250° C
A572–50 S35512+N greater than or equal to 40 mm
Minimum 100° C (212° F) (482.° F)
(1.60 inch)
Maximum 220° C
A709–100 S690QL greater than or equal to 80 mm
Minimum 150° C (302° F) (428° F)
(3.15 inch)
Maximum 250° C
SAE 1524/ASTM A27 G20Mn5+QT greater than or equal to 50 mm
Minimum 100° C (212° F) (482.° F)
(2.0 inch)
Maximum 250° C
UNS J02503 G21Mn5+QT greater than or equal to 50 mm
Minimum 150° C (302° F) (482.° F)
(2.0 inch)
UNS F20004/ASTM A709 Maximum 220° C
G24Mn6+QT greater than or equal to 50 mm
Grade QST 70 Minimum 150° C (302° F) (428° F)
(2.0 inch)
greater than or equal to 20 mm
Minimum 75° C (167° F)
(0.80 inch)
Maximum 225° C
Hardox 400 greater than or equal to 50 mm
Minimum 175° C (347° F) (437° F)
(2.0 inch)
Minimum 200° C (392° F)
(3.15 inch)
Minimum 125° C (257° F) Maximum 225° C
Hardox 450 (0.80 inch)
(437° F)
Minimum 150° C (302° F)
(1.60 inch)
Minimum 175° C (347° F) Maximum 225° C
Hardox 500 (0.60 inch)
(437° F)
Minimum 200° C (392° F)
(1.20 inch)
Table 5
Weld Inspection and Acceptance Criteria

Inspector Qualifications
Personnel who perform VT (visual testing) must be qualified and certified. Individuals must be certified for visual inspections at a minimum of
American Welding Society Certified Welding Inspector (AWS CWI) or international equivalent.
Visual Acceptance Criteria

Note: The following information is related to the minimum visual acceptance criteria for welded structures on Caterpillar machines. Some machines
may require more stringent criteria in local applications. The information is based on Caterpillar Engineering Specifications and is subject to
change.
ISO 6520 Defect

Defect Name Remarks Defect Limit
Reference Number
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Cracks -
1011, 1012, 1013,
Longitudinal,
1014, 1023, 1024,
Transverse, Not Permitted
1031, 1033, 1034,
Radiating, Transverse cracks (1021) are permitted for hard surfacing

1045, 1046, 1047,
Crater, welds
1051, 1053, 1054,
Disconnected,
1061, 1063, 1064
Branching
Expressed as Minimum Toe Angle
Overlap, Cold-
503, 506, 5061, 5062 (Applies to weld toes and adjacent pass Less than 90 ° Not Permitted
lap
intersections)
Lack of fusion 4011 Visual (Breaking the Surface) Not Permitted
Maximum Depth Measured from Plate
Surface - Any Length
Continuous
5011 Weld toes at the melted corner may have Maximum depth from plate surface = 0.5 mm (0.020 inch)
undercut
a scalloped appearance, which is not to be
labeled as undercut.
Any Length Weld Face Width 20 mm
4.0 mm (0.16 inch)
(0.80 inch) or less
Excess Weld Weld Face Width Over 20 mm (0.80 inch)
Metal - Groove 5.0 mm (0.20 inch)
but less than 30 mm (1.20 inch)
Weld 502
Reinforcement Weld Face Width 30 mm (1.20 inch) and
6.0 mm (0.24 inch)
(Convexity) Over
Conformance to Design - The toe angles must be greater than or equal to 90 ° and the excess must not
interfere with satisfactory end use of the component (for example: distortion and fit-up interference.)
Pores < 1 mm (0.040 inch) Permitted unless in clusters (see cluster porosity)
For pores between 1 mm (0.040 inch) and 2 mm (0.080 inch) see below.
Maximum Pores in Any 300 mm
6
2011, 2012, 2014, (11.80 inch) Length of Weld
Surface Pore
2017
Maximum Number of Pores in Any 50 mm
(2.0 inch) of Weld Length for Welds Less 1
Than 300 mm (11.80 inch) in Length
Pores > 2 mm (0.080 inch) Not Permitted
Maximum Length of Cluster in Any Weld
(pores of any diameter, where a cluster is
Clustered
2013 more than two pores with a distance Maximum length = 1/2 width of weld bead width (surface)
Porosity
separating the pores less than or equal to
3 times the diameter of the largest pore).
Measured in Terms of Excess Weld Metal
(Fillet Weld Convexity or Overlap on

Groove Welds, Lack of Fusion, or
Insufficient Throat
Excess Weld Metal on Fillet Welds, Defect
Limits Expressed as Minimum Toe Angles 90 °
Poor Start or Allowed
5171, 5172
Restart (Tie-In)
Overlap on Groove Welds, Defect Limits
Expressed as Minimum Toe Angles 90 °
Allowed
Lack of Fusion - Visual Maximum Length
Not Permitted
Pre Restart
Insufficient Weld Throat Not Permitted
Stray Arc
601 Not Permitted Without Repair
Strike
Under-filled
511 Smooth transition required
Groove Welds
Grinding or sanding of the weld or

adjacent base metal
Over-grinding
Depth of grinding/sanding (smooth Maximum depth lesser of 3 mm (0.12 inch) or 0.07 mm
transition) (0.0028 inch) material thickness
less than or equal to 0.1 mm (0.004 inch) thickness
Maximum 3 mm (0.12 inch)
Linear These criteria do not apply to local misalignment caused
Misalignment 5071 Measure of offset by heat deformation. Measurements should be taken as
(plates) close to the weld as possible while avoiding any deformed
areas. Any misalignment above the criteria should be
reworked to have a transition slope to of at least 4:1.
Backing Strip Separation between the groove-welded
Fit-up parts and permanent backing material
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Fusion to
backing
Fusion between cover fillets and backing

*Hydraulic
Not Permitted
material
Mining Shovels
only
TIG TOE Radius at the weld toe Minimum 3 mm (0.12 inch)
Dressing
(GTAW) Depth Maximum 0.5 mm (0.020 inch)
Radius at the weld toe Minimum 3 mm (0.12 inch)
Toe Grinding Minimum 0.5 mm (0.020 inch)
Depth of Grinding
Table 6
Note: All temporary attachments or supports and respective welds must be removed. Grinding criteria applies.
To verify the quality of the weld, refer to"American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D14.3".
Surface Appearance for Weld Assemblies

The information below contains acceptance criteria for the surface condition of welded components. Surface classifications are assigned to each
component by the structural designers to ensure fit and function. The following criteria apply to most surfaces on Mining equipment, however in
some instances more stringent criteria may be applied at the judgment of the product design control.
Discontinuities Acceptance Criteria

Acceptable if uniform pattern and depth less than or
Grinding Marks
equal to 0.5 mm (0.020 inch)

Deep Scratches
Not a defect
Scratch with depth of less than 0.25
mm (0.0010 inch)
Deep Scratches
Maximum quantity of 8 scratches permitted per any non-

Scratch with depth of greater than or equal to 0.25
mm (0.0010 inch) but less than or
overlapping 500 mm (20.0 inch) X 500 mm (20.0 inch)
equal to 0.8 mm (0.032 inch) and scratch length less than or equal to 30 mm
area
(1.20 inch)
Deep Scratches

None permitted
Scratch with depth greater than 0.8 mm (0.032 inch) of any length

Dent/Pit

mm (0.0010 inch) Not a defect
Dent/pit with depth less than 0.25
Dent/Pit
Maximum quantity of 8 Dents/Pits allowed any non-

Dent/pit diameter less than or equal to 7.0 mm (0.30 inch). Dent/pit depth greater than overlapping 500 mm (20.0 inch) X 500 mm (20.0 inch)
or equal to 0.25 mm (0.0010 inch) but less than or equal to 0.8 mm (0.032 inch) area
Dent/Pit

with depth greater than or equal to
Dent/pit diameter greater than 7.0 mm (0.30 inch) None permitted
0.25 mm (0.0010 inch)
Dent/Pit
None permitted
Dent/pit with depth greater than
0.8 mm (0.032 inch)

Weld Spatter

(0.060 inch) Not Acceptable
Diameter greater than 1.5 mm
Weld Spatter
10 Spatter allowed per any non-overlapping 100 mm

Diameter greater than 0.5 mm (0.020 inch) less than 1.5 mm (0.060 inch) (4.0 inch) X 100 mm (4.0 inch) area
Weld Spatter

mm (0.020 inch) No Clusters(1)
Diameter less than or equal to 0.5

Silicon Deposits from welding Less than 1.5 mm (0.060 inch) in diameter or length
Table 7
(1)
Clusters are defined as 5 or more spatter berries (Dia. 0.5 mm (0.020 inch) within a 20 mm (0.80 inch) X 20 mm (0.80 inch) square
Welding Electrodes and Parameters

Note: The hydrogen content of the welding consumable should be less than or equal to 5 ml of hydrogen per 100 g of weld metal. The
designator H(X) indicates the guaranteed or tested hydrogen level for that consumable.
For example: E71T-12MJH4 indicates an electrode that provides 4 ml/100 g of hydrogen when stored and used as specified by the manufacturer.
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Note: Impact properties (toughness) are also required for cold-weather applications. The J designator indicates 20 ft lbs (27J) at −40° C (−40° F).
The -1 designator indicates 20 ft lbs (27J) at −45° C (−50° F).
Electrode Requirements for the Flux Cored Arc Welding (FCAW) Process
Use the FCAW process with a welding electrode that meets ANSI/AWS A5.20 E71T-1MJH4, E71T-9MJH4, or E71T-12MJH4 and the manufacturer
shielding gases that are specified (typically 75% argon and 25% carbon dioxide). Electrodes that have a H5 designator are also acceptable.
The following Tables show the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode
diameters.
Welding Current for Flux Cored Welding Electrode that is 1.2 mm (0.047 inch)
Wire Feed Rate Voltage Amperage
7620 mm (300 inch) Per Minute to 10160 mm (400 inch) Per Minute 24 to 28 190 to 240
Table 8
Welding Current for Flux Cored Welding Electrode that is 1.4 mm (0.055 inch)
Wire Feed Rate Voltage Amperage
5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute 23 to 27 180 to 220
Table 9
Note: The settings listed above are recommendations based on experience from welding in the horizontal, vertical-up, and overhead positions.
Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode
manufacturers. The use of higher parameters than specified for welding in the flat position is acceptable.
Use polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored
welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld to reduce the possibility of
evolving gas that is trapped in the weld. The maximum size weld per pass should be equivalent to that of a 8.0 mm (0.32 inch) fillet weld.
Electrode Requirements for the Stick Electrode Shielded Metal (SMAW) Process
An alternate or when wind conditions are a factor, use SMAW, and low hydrogen electrodes that meet the following requirements.
ANSI/AWS A5.1 E7018-1 H4R meets the requirements for allowable hydrogen content.
Low hydrogen electrodes must be stored in an electrode oven at 120° C (248° F). If low hydrogen electrodes get damp, scrap the low hydrogen
electrodes or recondition the low hydrogen electrodes to the manufacturer specifications.
Welding Current for Low Hydrogen Electrodes

Diameter Amperage Rating
3.2 mm (1/8 inch) 105 -155
4.0 mm (5/32 inch) 130 - 200
4.8 mm (3/16 inch) 200 - 275
Table 10
Use polarity setting of DC reverse Polarity. Remove slag after each pass of the welding electrode. The width of the weld should not exceed two
times the electrode diameter.
Base Material Groupings

EN15608:2017 Base Material Groupings
EN15608:2017 Tensile Impact
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Group 1:
Steels with
a specified minimum yield strength ReH less than or equal to N/mm2 a and with analysis in percent (%):
C less than or equal to 0.25

Si less than or equal to 0.60
Mn less than or equal to 1.8

Mo less than or equal to 0.70b
S less than or equal to 0.045

Less than 460

N/A
P less than or equal to 0.045b
MPa
Cu less than or equal to 0.40b
Ni less than or equal to 0.5b

for castings)b
Cr less than or equal to 0.3 (0.4

Nb less than or equal to 0.06

V less than or equal to 0.1b

Ti less than or equal to 0.05
Group 2:

Less than 360
Thermomechanically treated fine-grain steels and cast steels with specified minimum yield strength ReH less than 360 N/A
MPa
N/mm2
Group 3:
Less than 360

Quenched
and tempered and precipitation hardened fine-grain steels except stainless steels with a specified minimum N/A
MPa
yield strength ReH less than 360 N/mm2
Group 4:

N/A N/A
Low vanadium alloyed Cr-Mo(Ni) steels with Mo less than or equal to 0.7% and V less than or equal to 0.1%
Group 5:

free of vanadium with C less than or equal to 0.35% N/A N/A
Cr-Mo steels
Group 6:

N/A N/A
High vanadium alloyed Cr-Mo-(Ni) steels
Table 11
Workmanship
General Information
All base material for welding shall be free from moisture, oils, grease, paint, rust, scale, or any other contaminant that may affect weld quality.
Note: All base material for welding shall be free from coatings such as rust/corrosion preventatives as well.
Welded joints shall not be painted until after inspection is completed and accepted. If a painted surface is desired for inspection purposes, the weld
shall be inspected before and after the application of paint.
Grinding and Sanding
Typical view of grinding disc

There is a difference between grinding and sanding when treating welds and base material surfaces. Grinding typically refers to the use of a hard
disk such as an alumina material type shown in Illustration 19. Grinding can be used to remove material that does not require a smooth surface
finish. For example, grinding and cleaning of inter-pass welds or back grinding the root pass to sound metal.
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Typical view of flexible sanding disc

Typical view of a flap sanding disc

Note: Ensure that proper personal protective equipment (PPE) is used when operating tooling with grinding or sanding attachments.
Sanding typically refers to the use of either a flexible sanding disc or flap sanding disc shown in Illustration 20 and Illustration 21. Sanding is ideal
for the final or finishing step for welds and base materials. For example, spatter removal, blending of weld tie-ins, profile, and flush sanding of the
top/cap of a weld and blending of base material surfaces.
Note: Grinding discs are not to be used for finishing work. Grinding discs result in deeper scratches and possibly divots that lead to detrimental
stress concentrations. Only use sanding disc (36 grit or finer) for finishing work.
Environment
In cases where preheat is not specified, ensure that base material temperature is greater than or equal to 20° C (68 ° F). Refer to "Base Material
Groupings" Section for guidance on how to measure preheat temperature.
Welding with gas shielded processes shall not be carried out when wind speeds exceed 8 km/h (5.0 mph) in the immediate area. Ensure that
welding area is not adversely affected by fans, overhead doors, or widows.
Preparation, Assembly/Fitment, and Tack

Tack welds shall be subject to the same quality and workmanship requirements as the final welds, including appropriate temperature controls like
preheat.
Tack weld length must be at least 50 mm (2.0 inch), and applies to all welding activities such as supports. (Exception: small parts).
Welding over cracked tack welds is not permitted.
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Temperature Scale vs Color

Distortion resulting from welding and fabrication may be corrected by mechanical means and flame heating methods provided the base material
(steel) does not exceed 700° C (1292 ° F). Refer to Illustration 22.
Cold forming is permitted for normalized, quenched, and tempered steels.
Hot forming is permitted for normalized steel up to 1050° C (1922° F) maximum. Refer to Illustration 22.
Hot forming is not permitted for quenched and tempered steel.
View of temporary bracing

Supports and bracing such as round/square tubing, shall be located in low stress areas as defined by engineering. Refer to Illustration 23.
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View of temporary bracing removed and sanded to profile
Bracing must be removed after the repair has been completed. The excess weld metal and base material shall be sanded flush to the profile of the
adjacent material. The area must then be subjected to VT and MT inspection to ensure a defect free surface with no sharp stress concentrations.
Refer to Illustration 24.
Surfaces and edges to be welded shall be uniform and free from fins, burrs, tears, cracks, and other defects that would adversely affect part fit up
and/or the quality or strength of the weld.
Surfaces cut by oxy-fuel, plasma, and so on must be free of scale via grinding/sanding and shall be VT and MT inspected for separations.
View of run-on/run-off tabs

Open ends of weld joints shall utilize run-on/run-off tabs. Tabs must be at least 50 mm (2.0 inch) in length as shown in Illustration 25. Arc starts and
end craters must be initiated for each pass on the tabs.
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View of tabs removed and excess sanded to profile

Tabs must be removed after completion of welding and inspection. The transitions finished by sanding to a notch free profile. Refer to Illustration
26.
Note: material should be a plain low carbon steel ASTM A36 equivalent. Recommended thickness of 6.0 mm (0.24 inch) minimum.
View of proper fitment of permanent backing

Permanent backing must be fit such that the gap is tight between the underside of the plate surface and the backing. Illustration 27 shows an
example of a good, tight fit.
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View of permanent backing maximum gaps

Note: Unless piece part tolerances prevent proper location of backing material, the separation between the groove-welded parts and the
permanent backing material shall not exceed 2.0 mm (0.08 inch) at the root of the weld. Refer to Illustration 28.
Parts to be welded must have a temperature of at least 20° C (68 ° F) prior to tacking, gouging, and welding unless otherwise directed to use a
higher temperature. Refer to "Base Material Groupings" Section for guidance on how to measure the temperatures.
Note: Observe the thermal parameters in the "Base Material Groupings" Section.
If two unequal thickness of parts with similar material will be welded together, the preheat/inter-pass temperature will be dictated by the thicker part.
Likewise, if two different materials are welded together then the preheat/inter-pass temperature with the higher requirements will be used. Refer to
"Base Material Groupings" Section for guidance on how to measure the temperatures.
View of axial or linear misalignment

Where two parts are butted together the surfaces of parts of equal thickness shall not be misaligned by more than the lesser of:
3.0 mm (0.12 inch) or 10% of the part thickness, for standard and stringent weld quality. Refer to Illustration 29.
2.0 mm (0.08 inch) of 50% of the part thickness for circumferential welds, for stringent quality levels, when identified in the welding symbol
note. Refer to Illustration 29.
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View of maximum root gap

Maximum Root Gaps

Material Thickness Maximum Root Gap (h)
Standard Quality Level Stringent Quality Level
Equal to or less than 3.0 mm
0.5 ± 0.1a mm (0.010 ± 0.004 inch)
(0.12 inch) 0.5 ± 0.1a mm
1.0 ± 0.3a mm (0.040 ± 0.012 inch) but maximum 4.0 mm (0.010 ± 0.004 inch)
Greater than 3.0 mm (0.12 inch)
(0.16 inch)
Table 12
View of temporary blocks and welds

When two parts are welded together perpendicularly, then the maximum gaps are defined in Table 12.
Use of temporary welds to hold temporary attachments shall be made to the same standard as permanent welds. All temporary welds and
attachments shall be removed after intended purpose has been fulfilled and respective surfaces reinstated to similar surface profile and texture as
the adjacent surfaces. Refer to Illustration 31. The image to left in Illustration 31 shows two blocks used to locate tooling for hardware placement.
The image to the right in 31 shows the two blocks and weld removed.
In Process
Before welding over previously deposited weld metal, all silicate and slag shall be removed and the weld and adjacent base material shall be
cleaned using a wire brush or other suitable means.
Peening may be used on intermediate weld layers for control of shrinkage stresses in thick welds to prevent cracking and/or distortion.
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No peening shall be completed on the root or surface layer of the weld or the base material at the edges of the weld, unless otherwise specified.
Care should be taken to prevent overlapping of the weld or base material.
Note: The preceding statements do not apply to post weld fatigue improvement techniques such as needle peening, hammer peening or high
frequency mechanical impact (HFMI).
Welding in the vertical down position (PG/3F/3G) is not permitted. The use of vertical down welding is only permitted if vertical down welding is
required in a specific welding procedure. For example, some open root welding processes and equipment are designed for vertical down welding
(Lincoln Electric STT, Miller RMD, and Fronius CMT).
Maximum Pass Width (GMAW/FCAW)

Wire Diameter Pass Width (maximum)
0.8 mm (0.03 inch) 8.0 mm (0.3 inch)
1.0 mm (0.04 inch) 10.0 mm (0.4 inch)
1.2 mm (0.05 inch) 12.0 mm (0.5 inch)
1.6 mm (0.06 inch) 16.0 mm (0.6 inch)
Table 13
Stringer beads (no weaving or oscillating) are to be used (Exception: Weaving is permitted in the vertical up position PF/3F/3G, provided the pass
width does not exceed 15.0 mm (0.5 inch)). Pass width (manual/semi-automatic welding) depends on wire diameter and welding parameters. Table
13 depicts the maximum pass width for welding positions PA/PB/PC/1G/2G/2F.
Maximum fillet weld size in the horizontal position (PB/2F) for GMAW/FCAW is 8.0 mm (0.3 inch) leg length.
View of weld starts/stops
Weld starts and stops must be avoided at weld crossings (intersections). A minimum distance of 50.0 mm (2.0 inch) is required. Refer to Illustration
32.
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View of edges and run-on/run-off tabs
Weld starts and stops at corners and edges is not permitted (should be minimized). A minimum distance of 50.0 mm (2.0 inch) is required where
possible. Exception: Wear plates.
Note: For cases where welding needs to be extended all the way to the edges, use run-on/run-off tabs. Refer to Illustration 33.
All arc initiations (weld starts) shall be conducted in the weld groove or in the run-on/run-off tabs.
Weld wire stubs are not permitted in the weld seam.
Inter-pass weld spatter is not permitted unless the weld splatter is randomly dispersed (not clustered) and has a maximum diameter of 2.0 mm
(0.08 inch). Exception: Wear plates.
View of terrace (block) sequence
View of cascade sequence
Weld starts and stops in multi-pass welds must be layered in a terrace (block) or cascade sequence. The distance between starts and stops must
be at least 20.0 mm (0.80 inch). Refer to Illustration 34 and Illustration 35.
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View of balanced weld sequence
Tack welds and weld ends require preparation before continuation of welding. Preparation implies the ends and face are ground so that subsequent
fill passes will obtain 100% fusion.
To minimize and/or avoid distortion, always utilize a balanced welding approach or sequence for symmetrical (size) welds. Refer to Illustration 36.
View of excavation opposite side to sound weld metal
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View of welding second side complete
For complete joint penetration (CJP) welding completed from two sides, the root of the weld will be gouged and/or ground to sound weld
metal prior to commencement of welding on the second side. Soundness will be verified via MT or PT. Refer to Illustration 37 and
Illustration 38.
Repair of Defects in Weld and Base Material

Removal of defective weld metal or portions of the base material shall be completed by machining, grinding, or gouging in such a manner that the
remaining weld metal or base material is not nicked or undercut. Defects shall be removed without substantial removal of the surrounding base
material.
The extent of the crack shall be ascertained by use of the appropriate NDT method, then the crack and sound metal 50.0 mm (2.0 inch) beyond
each end of the crack shall be removed and rewelded.
Oxygen gouged and air-arc gouged surfaces shall be, at a minimum, cleaned grinding/sanding/machining, to remove all carbon absorption and/or
contamination.
Gouged areas requiring rewelding shall have a root radius not less than 5.0 mm (0.20 inch) and sufficient width to allow the welder access to
reinstate the weld. In addition, the ends shall be tapered to allow adequate entrance and exit.
Repairs of welds and base materials can be broken down into tow major scenarios.
Partial Joint Penetration (PJP) or partial through thickness, which means that the crack is only partially through the weld throat or base
material thickness.
Complete Joint Penetration (CJP) or through thickness, which means that the crack is completely through the weld throat or base material
thickness.
Partial Joint Penetration (PJP) Repair Scenarios

The following Illustrations depict the steps necessary to remove a partial through thickness crack in base material. The steps consist of removing
the crack, preparing the weld joint by grinding/sanding, welding the joint, and then sanding the excess weld metal to profile.
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Partial penetration/partial through thickness crack

Crack excavation

Joint preparation by grinding

Desired weld joint dimensions (cross-sectional view)

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Longitudinal view of weld joint

Weld complete

Sand excess weld metal flush to profile

Note: Repair of a PJP crack in a groove weld or fillet weld toe would follow the same as previously mentioned except for the final step. If the weld
prior to repair did not require flush sanding, then neither will the repair.
Complete Joint Penetration (CJP) Repair Scenarios

The following depict the two most common types of groove welds that have permanent steel backing and are welded from one side.
Note: As long as the crack is contained within the weld joint, the repair is straightforward. If the crack branches off into the base material then the
repair will require a combination of a CJP weld repair and through thickness crack repair for the base material.
The most common type of CJP groove weld connection between two plates generally utilizes a steel strip. The steel strip is typically a plain, low
carbon steel that is approximately 25.0 mm (1.0 inch) to 50.0 mm (2.0 inch) wide and 6.0 mm (0.24 inch) to 10.0 mm (0.40 inch) thick.
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The following Illustrations depict the repair steps recommended for a through thickness crack in a CJP groove weld with a steel strip used for
backing.
Through thickness crack in groove weld
Excavate crack
Note: Verify that the crack is removed via MT and/or PT
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Grind and prepare edges (cross-sectional view)
Grind and prepare ends (longitudinal view)
Weld complete
The most common type of CJP groove weld connection between a plate/casting, casting/casting, or a plate/forging generally utilizes a cast or
forged integral backing. The integral backing or lip is usually 10.0 mm (0.40 inch) to 25.0 mm (1.0 inch) thick.
The following Illustrations depict the repair steps recommended for a through thickness crack in a CJP groove weld with integral backing. Follow
the steps below to remove the crack and prepare the area for welding.
Note: A gap (or offset) is shown at the root. This gap may or may not be present.
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Crack in the groove weld
Excavate the crack
Note: Verify that the crack is removed via MT and/or PT
Grind and prepare edges
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Weld complete
Another common type of CJP groove weld is one that is welded form two sides. Typically, the weld joint design is a double V and is most commonly
used in thick connections between steel plates, forgings, or castings. A typical double V weld joint is shown below in Illustration 55.
Double V CJP weld
Typical crack
Note: If a crack is to initiate in this type of weld, the crack will usually be at one of the weld toes and likely propagate through thickness before the
crack is detected.
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A proper repair for this type of crack will require access from both sides.
Note: This repair recommendation is the same as the repair recommendations for a through thickness crack in base material.
Through thickness crack
Excavate half thickness
Grind/sand excavation
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Weld 1/3 to 1/2
Note: The number of welding passes does not reflect actual conditions. Welding passes will be controlled by material thickness.
Excavate opposite side to sound weld metal
Weld the second side complete
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Complete welding and sand both sides flush or to profile of adjacent material
If a through thickness crack exists and the decision is made to conduct a temporary one sided repair, then the recommendation is to insert a steel
backing strip.
Note: Sometimes when a crack is detected, the decision is made to perform a temporary repair due to the knowledge that there is an upcoming
maintenance downtime activity planned. During the scheduled maintenance downtime a permanent two-sided weld repair can occur.
The following Illustrations demonstrate the steps for a temporary one sided weld repair for a through thickness crack in base material.
Gouge/grind dimensions
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Approximate finished ground dimensions prior to insertion of backing strip
Backing strip in position
Illustration 64 and Illustration 65 demonstrate the approximate dimensions for a weld joint requiring a permanent backing strip.
The dimensions of the permanent steel, backing strip will depend on the configuration of the excavation. Every attempt should be made to
accommodate a single, continuous strip that runs the full length of the weld joint. A 6.0 mm (0.24 inch) thick by 38.0 mm (1.50 inch) wide by the
required length are typical dimensions required for most applications. The steel backing strip material can be any common structural steel such as
ASTM A36. Attach a wire (or other means) to backing strip and insert through the root opening/gap and pull flush to the inside plate surface.
The thickness of the backing strip should be kept to a minimum to assist with the insertion process. The thicker the backing strip the more difficult it
will be to insert through the gap into and enclosed cavity. A 6.0 mm (0.24 inch) thick backing strip is the minimum that should be used and is
sufficient to prevent burn through using the welding parameters specified. Select a backing strip width that will ensure a minimum overlap of
6.0 mm (0.24 inch) of the backing strip to both sides of the weld joint along the entire length, refer to Illustration 66. Attempt to minimize the gap to (
0.0 mm (0.0 inch) if possible) between the backing strip and the inside plate surface.
Tack weld backing strip in position. Remove wire/rod and grind 1/2 the thickness of the tack welds prior to finish welding to ensure proper fusion
between tack welds and fill passes.
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Welding complete
Sand flush with plate profile
After completion of welding, blend sand the excess weld material flush with the surrounding plate profile.
Finishing
Maximum grinding/sanding depth

Base material surface defects shall be blended smoothly into surrounding surface by sanding. The maximum depth of sanding shall not be more
than 0.5 mm (0.02 inch) or 10 percent of the base material thickness, whichever is less.
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Direction of grinding/sanding marks

Grinding or sanding marks of weld seam surface or base material surface must be performed longitudinal (parallel) to the direction of loading. Refer
to Illustration 70.
View of casting surface high

Adjacent base materials shall be aligned as close as possible. Sometimes, where there is a cast material on one or both sides, some misalignment
of the surfaces due to profile tolerances of the cast surface will exist.
Illustration 71 shows the situation when the casting surface is on the high side of the profile tolerance.
View of casting surface low

Illustration 72 shows the situation when the casting surface is on the low side of the profile tolerance.
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Weld spatter is not permitted except for occasional weld spatter (maximum of 2.0 mm (0.08 inch) diameter).
Notches which occur during hammering, peening, chipping, grinding, gouging, and thermal cutting are not permitted. Repair must be completed
and approved.
Welds must be checked visually after completion of welding. The visual inspection must be completed prior to any additional non-destructive testing
(NDT). Exception: UT may be performed prior to VT.
Weld starts and stops should be blended smoothly by sanding.
For materials and/or crack sensitivity materials allow 24 to 48 hours between the final welding activities and final NDT testing (VT/MT/UT) to ensure
detection of indications due to delayed cracking.
Note: If required, allowing 24 to 48 hours between final welding activities will be specified in the field repair welding procedure.
Groove welds that intersect at the corners of box sections, shall be treated as shown in Illustration 73. Sanding marks must be parallel to the
loading direction.
Bore Welding
Note: Prior to performing any bore welds/repairs, contact Product Support for bore size and tolerances.
A dial bore gauge on a boring bar or inside micrometers are recommended for measuring bores, and perpendicular surfaces to the bores. The
vertical and horizontal bores should be in line within the dimensions and tolerances to part specifications. Bores out-of-round should be treated as
worn out and should be checked for cracks.
Required Tooling
Required Tooling
Item Part Number Part Name
Tool Gp (Line Boring)
T1 477-3166(1)
Portable Boring Bar (110
v)
Tool Gp (Line Boring)
T2 477-3167(1)
Portable Boring Bar (240
v)
T3 477-3189 Bore Welder Tool
Table 14
(1)
Various bar lengths and extra Tooling are available through Dealer Service Tools.
General Welding Tips
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Pattern for welding
(W1) Surface weld
(W2) Surface weld
(W3) Surface weld
1. Make sure that all pin bores are free from all oil, grease, paint, and other contaminants.
2. Preheat the bores to part specifications. Preheating will help to eliminate potential hydrogen gas. Preheating can also reduce weld stress.
3. Follow the recommendations for the use of the welder.
4. Allow the welds to cool slowly following build-up of the bores.
5. When you are using the SMAW process or the GMAW semi-automatic process, outline the area for repair. Outlining can be done by making
weld (W1) and weld (W2). Refer to the Illustration 74. Make a series of transverse welds (W3) to complete the buildup.
Note: If more weld deposits are required, repeat the welding procedures for the appropriate processes.
Build-up Methods
Bore welded with portable bore welding machine (T1) or (T2) method

The preferred method to build up bores is to use a portable bore welding machine which rotates around the bore axis. This method also produces a
quality weld with minimal defects and a build-up that is easier to machine. Refer to Illustration 75.
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Manual bore weld build-up method.
(A) Direction of the axis
Manual bore weld build-up method.
(A) Direction of the axis

(B) Edge of the bore
If a portable weld boring machine cannot be obtained, the bores can be welded manually by hand using the following technique.
1. Deposit several weld passes around the circumference of the bore in the direction of the axis (A).
2. Deposit weld passes at the edge of the bore (B) to ensure both the bore inside diameter and face clean-up during machining.
Equipment for Bore Build-up and Machining
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Portable equipment
(T1) 477-3166 Tool
Gp
(T2) 477-3167 Tool Gp
(T3) 477-3189 Bore Welder Tool
Welding Procedure
Parameters for Welding the Bores
Welding Wire (AWS) Wire Diameter Wire Speed Amperage (DCEP) Volts
ER-70S-3 Ø 0.9 mm (0.035 inch) 4.47 to 7.11 m/min (180 to 280 in/min) 75 to 140 A 18 to 22 V
ER-70S-6 Ø 0.9 mm (0.035 inch) 3.35 to 5.79 m/min (132 to 228 in/min) 3.35 to 5.79 m/min (132 to 228 in/min) 15 to 18 V
Table 15
Note: The bore welding/machining system offers improved performance over SMAW and GMAW welding systems. If the bore welding/machining
system is not available, you can use an E7018 SMAW electrode. The E7018 SMAW electrode has a diameter of 3.18 mm (0.13 inch). If an E7018
SMAW electrode cannot be found, you can also use a Welding Rod or GMAW welding.
1. Clean the bores and the surrounding area.
2. Inspect the bores. If a defect is found, remove the fault by cutting or machining.
3. Preheat the base metal of the bores to 95° ± 10°C (203° ± 18°F). Preheating the metal will prevent cracking of the base metal. Preheating will
also reduce the chances of hydrogen embrittlement.
4. If possible use an automated bore welding/maching system to build up the bores with welds correctly. Automated welding will result in clean,
even metal deposition.
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Outline the bores with welds (W1) and (W2). Apply transverse welds (W3) to the bores. The transverse welds should connect the welds which outline the bores.
(W1) Surface weld

(W2) Surface weld
(W3) Surface weld
5. Apply weld (W1) and (W2) to each opening of the bores. Refer to Illustration 79.
6. Apply multiple welds (W3) to the length of the bores. The welds must connect the welds which outline the bores. Refer to Illustration 79.
Note: Allow the welds to cool slowly. Repair any welds by removing the existing weld. Apply a weld to the area which is being repaired.
Before you begin welding again, preheat the pin bore.
Boring Procedures
Use a bore welding/machining system to machine the bores. To line bore the bores, the bore welding/machining system should be in line with the
center of the two inside bores.
Machining Elongated Bores

Note: Prior to performing any bore welds/repairs, contact Product Support for bore size and tolerances.
Metal-to-metal contact of the pin to any frame member can result in material deformation. Deformed material may contain cracks and should be
removed. Pre-machining results in a concentric bore with a stable base material for weld build-up.
Welding Electrodes and Parameters

Caterpillar recommends using:
Gas Metal Arc Welding (GMAW) with AWS A5.18 ER70S-6 solid wire
Shielded Metal Arc Welding (SMAW) with AWS A5.1 E7018 electrode
Weld Parameters for Machining Elongated Bores (1)

Wire Part Number Wire Diameter Wire Feed Speed Amps (DCEP) Volts
1U-5367 Ø 0.9 mm (0.035 inch) 4.56 to 6.36 m/min (180--250 in/min) 140-175 A 18-22 V
1U-6368 Ø 1.2 mm (0.045 inch) 3.30 to 5.08 m/min (130 to 200 in/min) 160-200 A 17-18 V
Table 16
(1)
Use a shielding gas of 75% Argon-25% CO2 at a rate of 35cfh.
Automated welding results in clean and even metal deposition. Weld quality is improved over SMAW and semi-automatic GMAW. The
recommended weld consumables are shown in the above chart.
The bores may be built up to size using E7018 SMAW 3.2 mm (0.125 inch) diameter electrode, (1U5232), or by the (GMAW) process. Use the
recommended consumables for the bore welder for semi-automatic welding.
Post Weld Treatments

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General Information
Fatigue crack at the weld toe

Post weld treatments are utilized in situations where the as-welded fatigue life is unable to achieve the design or desired life. Usually, it is confined
to a localized area such as one or more of the fillet weld toes or weld face, or it can also be the weld toes or weld face of a groove weld. Refer to
Illustration for an example of a typical fatigue crack at a fillet weld toe.
There are three main reasons why fatigue cracks appear in welds:
Tensile residual stresses
Stress Concentrations
Microscopic flaws
Note: Assuming that quality (both internal and external) is not a factor.
Tensile residual stresses

Residual stresses develop due to the rapid heating and cooling that occurs during and after the welding process. Rapid heating and cooling
typically results in a tensile residual stress at the weld toe, which is detrimental to the service life of the connection. Refer to Illustration 81.
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Stress concentrations
Stress concentrations are inherent to the shape and profile of the fillet weld. This is due to the sharp change in section locally at the weld toe that
interrupts the load path acting as a stress riser resulting in a high localized stress directly at the weld toe. Refer to Illustration 82.
Microscopic flaw

Arc welding inherently produces small, crack like flaws at the weld toe. Illustration 83 shows an example of a microscopic flaw. The combination of
tensile residual stress, stress concentrations, and microscopic flaws all at the weld toe results in that localized area being susceptible to cracking.
To extend the fatigue life of a weld, a post weld treatment can be used to modify or eliminate one or more of the three main reasons why fatigue
cracks appear in welds.
There are four types of post weld treatments that are typically used on Caterpillar structures:
TIG Toe Dress (TTD)
Toe/Burr Grinding
High Frequency Mechanical Impact (HFMI)
Profile/Flush Sanding - fillet weld or groove weld face and toes
Combination Treatments - using more than one post weld treatment on one weld
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TIG Toe Dress (TTD)

TTD is an acronym that Caterpillar created, TIG dressing is the common vernacular.
To provide clarification and details, a video has been created outlining the Post Weld - TIG Dressing. Reviewing the video prior to
performing any Post Weld - TIG Dressing. Watching the video on Caterpillar Channel 1 is required prior to conducting any TTD on
Caterpillar structures.
Note: A CWS login is required to access Caterpillar Channel 1.
https://channel1.mediaspace.kaltura.com/media/Off-Highway+Truck+Post+Weld+Treatment+-+TIG+Dressing/1_gmocv9ae

The link above contains the following video:
Post Weld - TIG Dressing
Before and after TTD

TTD utilizes a TIG (Tungsten Inert Gas) or GTAW (Gas Tungsten Arc Welding) torch to direct a heat source in the localized area requiring
treatment. The electric arc remelts the weld toe reducing or eliminating the microscopic defects and reshapes the transition into a generous radius.
Refer to the example in Illustration 85.
Equipment Requirements
GTAW (TIG) Power supply and torch capable of 200 amps (minimum 60 percent duty cycle)
Shielding gas - 100 percent Argon and flow meter
Electrode - Lanthanated, Ceriated, or Thoriated Tungsten [3/32" (2.4 mm) diameter] ER70S-2 filler metal [1/16" (1.6 mm) diameter] (if needed
for repairing undercut)
Hand or foot current control (amptrol)
Grinder - Pneumatic or electric with carbon steel wire wheel attachment
Tungsten electrode sharpening tool with a diamond blade

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Radius gages
Cleaning and Preparation
Wire wheel attachment

Note: Ensure that proper personal protective equipment (PPE) is used when operating a grinder with a wire wheel attachment.
The base material and weld toe to be treated require a high level of cleanliness. The immediate area will need to be cleaned using a carbon steel
wire wheel attachment. Refer to Illustration 86.
View of contaminants removed prior to treatment

The welding-related silicates/slag require removal. In addition, the adjacent base material needs to be free of any contaminants that will affect the
welding arc. Illustration 87 demonstrates the appearance requirements of the weld and base material. The top is a weld produced by GMAW and
the bottom is a weld produced by FCAW.
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Tungsten sharpening tool

Preparation of the tungsten electrode is also critical to obtaining a good TTD. Using a dedicated tungsten grinder with a diamond wheel or blade is
recommended. Illustration 88 demonstrates a tungsten electrode being sharpened using a cost effective, hand-held unit.
Note: There are many types of tungsten electrode sharpening tools available that range considerably in cost. Most are bench-mounted units, but
there are cheaper hand-held units like that shown in Illustration 88.
View of sharpened tungsten electrode

Orient the grinding lines parallel to the length of the electrode like that shown in Illustration 89. This is a simple task if performed on a dedicated
tungsten electrode grinder.
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Sharpening a tungsten electrode

Sharpening a tungsten electrode on a common aluminum oxide bench grinding wheel is also acceptable, however it is not as straightforward as
using a tool that is designed for that purpose. Refer to Illustration 90 if using an aluminum oxide bench grinding wheel.
Note: Tungsten preparation is not to be completed on a grinding wheel that has been used for sharpening other objects or materials as this can
become embedded in the tungsten electrode.
View of tungsten electrode extension

The recommended placement for the tungsten electrode is for the electrode to extend approximately three electrode diameters from the end of the
gas cup. Refer to Illustration 91.
Technique
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View of a relatively good initial profile

The shape of the fillet weld (weld toe angle and geometry) will determine what technique to use when performing the TTD. An example of a
relatively good profile or shape is shown in Illustration 92. This profile has a flat to slightly convex weld face and the weld toe angle is approximately
135 degrees.
Arc placement

The technique used would consist of the following:
Center the TIG arc on the weld toe
Utilize a stringer bead with standard work
Lead angles
Guidance for arc placement is provided in Illustration 93.
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Standard work angle

A standard work angle of 10 to 15 degrees would be used as shown in Illustration 94.
Standard lead angle

In addition, a standard lead angle of 10 to 15 degrees would be used as shown in Illustration 95.
Proper TTD

When treated properly by TTD the resulting profile will appear as shown in Illustration 96.
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For less than ideal weld toe angle

When there is less than ideal geometry at the weld toe, the person performing the TTD will need to vary the work angle and may also have to
initiate a slight weave. Refer to Illustration 97.
Stop and restart technique

For long distances, there will sometimes be a need to stop the arc and restart the arc. Two of common methods are shown in Illustration 98.
Stop and restart technique

The second method is shown in Illustration 99. The arc is stopped up in the fillet weld face not the weld toe. It is then restarted in the weld face
behind the stop location and guided downward onto the weld toe and continued forward.
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View of TTD around corners

Performing starts and stops at corners are not advised. Proper TTD of corner is shown in Illustration 100.

Correct TTD on fillet weld distinct start and stop


Incorrect TTD on fillet weld distinct start and stop

When TTD is completed on fillet weld that has a distinct start and stop, it is critical that TTD is done completely and correctly. Illustration 101 shows
the correct technique, which is to TTD completely around the fillet weld start or stop. Illustration 102 shows the incorrect technique.
Note: There may be occasions when multiple weld toes require treatment. Refer to the procedure for specific regarding which weld toe
and how many.
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Inspection

View of radius gage

In addition to the visual acceptance criteria such as undercut, porosity, and others there is at least one other requirement, which is the radius. Refer
to the welding procedure or print to determine the required radius. Typically, a 5.0 mm (0.20 inch) radius is specified for TTD. Illustration 103 shows
the use of a 5.0 mm (0.20 inch) radius gage to confirm that the minimum requirement has been achieved.
The surface of the TTD should be smooth. A smooth surface is indicative of a tightly spaced solidification pattern (ripples).
Note: An area that is unacceptable for any reason can easily be treated again.
Toe/Burr Grinding

Typical before and after cross-sectional view of a burr ground fillet weld toe

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Treating the weld toe by a mechanical means such as grinding is another option for extending the fatigue life of a weldment. Typically, a burr of
some shape is used to remove the remnant of the original toe leaving behind a smooth transition between the weld and base material. In the
process, any inherent defects present at the toe would be removed. As a result, there will be a loss of material section.
Illustration 104 shows a typical before and after cross-sectional view of a burr ground fillet weld toe. Illustration 105 shows a close up view of the
burr ground area from different perspectives.
Note: Burr grinding is not to be used on plate thickness less than 10.0 mm (0.40 inch). 10.0 mm (0.40 inch) is the minimum plate
thickness.
Equipment

View of burr shapes

Burr types: There are many different sizes and shapes of burr bits to choose from. Illustration 106 shows several different shapes to consider when
burr grinding.
Note: The main criteria for shape selection is spherical or hemispherical resulting in a radius at the tip.
Note: The size will be determined by the required radius.

View of burr cuts

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There are many different cuts or textures to choose from. Illustration 107 shows two contrasting cuts. The top image is a coarse cut designed to
remove material quickly at the expense of the surface finish. The bottom image is a fine cut designed to remove material at a slower rate but
results in a better surface finish.
Note: The fine cut is ideal for the whole burr grinding operation or as a final step to attain a suitable surface finish.
The diameter is the main size characteristic that should be considered when selecting a burr as a minimum radius will be specified.
Rotary tool: A high speed pneumatic or electric rotary tool capable of 15,000 to 40,000 rpms is required. A sufficient pressure and volume of air
shall be provided to prevent the tool from stalling.
Groove Dimensions

The main reasons for performing the burr grinding treatment are to remove any microscopic defects and stress concentrations at the weld toe. To
accomplish this task, a certain amount of material requires removal. The minimum depth (d) of grinding shall be equal to or greater than 0.5 mm
(0.020 inch) below the weld toe to parent material interface or until all traces of the original weld toe have disappeared, but no greater the
maximum 2.0 mm (0.08 inch) grinding depth or 3.0 mm (0.12 inch) maximum for base material thickness above 40 mm (1.60 inch).
The diameter of the burr should be in the 10.0 mm (0.40 inch) to 25.0 mm (1.0 inch) range for application to welded joints with plate thickness from
10.0 mm (0.40 inch) to 50.0 mm (2.0 inch). The resulting root radius (r) of the groove should be no less than 0.25 of plate thickness.
Method
The finished quality of burr grinding will depends on the skill level of the individual and the quality and selection of tools. Practicing on several test
pieces prior to determine to optimum technique is recommended.
The diameter of the burr should be in the 10.0 mm (0.40 inch) to 25.0 mm (1.0 inch) range for application to welded joints with plate thickness from
10.0 mm (0.40 inch) to 50.0 mm (2.0 inch). The resulting root radius (r) of the groove should be no less than 0.25 of plate thickness.
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Work and travel angles

The main factors for proper burr grinding are:
The burr should be centered on the weld toe
The work angle should be 45 to 60 degree
The travel angle should be 30 to 45 degree
Refer to Illustration 109 for proper work and travel angles.

General location and orientation

Illustration 110 demonstrates the proper location and orientation of the burr bit to the fillet weld toe.
In general, it is preferred to push the burr bit in the direction of travel as opposed to away from the direction of the travel. However, some prefer to
go back and forth in both directions for a short distance while gradually moving in the forward direction along the whole length.
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Burr grinding weld ends

When you encounter ends of welds or welds that extend around the ends of plates, there are certain requirements and recommendations. Weld
ends must be treated in the same way as the weld toe or toes. If the burr grinding treatment is not continued around the weld ends (starts and
stops), then cracking is still possible and the benefits are not realized. Illustration 111 shows the incorrect and correct method for treating weld ends
(starts and stops).
Note: Extend the burr as far around the weld end as possible without getting into the vertical plate (unless both weld toes require treatment).

Burr grinding recommendations and example

In some situations when most the weld is parallel to the stress direction, but the ends that wrap around are perpendicular, the recommendation
usually dictates to treat a certain length of weld. Illustration 112 provides guidelines for treatment and an example of a burr ground fillet weld that
wraps around the end of a stiffener plate. The length of burr grinding is required to extend four times the thickness (stiffener plate) from the end of
the stiffener plate.
Inspection
In addition to the visual acceptance criteria there are a few other requirements.
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Visible traces of the original weld toe

No traces of the original weld toe shall be visible. This will typically be seen or witnessed as a line as shown in Illustration 113. Further burr grinding
would be required to remove this feature.

Depth measurement

After the original weld toe has been removed, check the depth and radius for conformance. Refer to the welding procedure or print to determine the
required depth and radius. Illustration 114 shows the use of a bridge cam gage for measuring the depth. There are multiple gages that can be used
for this purpose.

Radius measurement

Illustration 115 shows the use of a Starrett gage to measure that the radius produced by burr grinding. For this example, the radius is acceptable
per the 4.5 mm (0.18 inch) gage, but not the 5.0 mm (0.20 inch) gage.
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High-Frequency Mechanical Impact (HFMI)

HFMI describes various processes that transfer pneumatic or ultrasonic frequency acoustic energy through metallic strikers into the base material.
The energy results in localized movement (compression) of material that causes the area of application to take on the shape of the semispherical
metallic striker. When applied to the weld toe, this process creates more desirable weld toe geometry and induces compressive residual stresses,
both improving the fatigue life of the weld.
Common processes are:
Ultrasonic Impact Treatment (UIT)
Ultrasonic Peening (UP)
High-Frequency Impact Treatment (HiFIT)
Equipment and Method

View of UIT equipment

Illustration 116 shows an example of the equipment requirements when performing UIT process.

UIT treatment

Illustration 117 shows a fillet weld toe being treated using UIT equipment.
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UIT treatment tool work angle

The typical treatment consists of applying a tool work angle between 30 and 60 degrees to the weld toe/base material interface shown in Illustration
118 and using a back and forth oscillating motion shown in Illustration 119.
Inspection/Groove Dimensions
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Weld toe/base material interface

Visual inspection is the best method for inspecting the application of HFMI. Visually, there should be a smooth, blended radius that will likely exhibit
a shiny appearance. Sometimes, visual inspection may reveal an incomplete application of the process. One condition is when there is a line at the
bottom of the weld toe or a double radius. Refer to Illustration 120. This condition may exist when the impact pins have not been properly applied at
the weld toe, leaving a line at the weld to base metal interface. This condition should be rectified by reapplying the process to the area until the line
and/or double radius is removed and the desired smooth radius is achieved.
Note: Illustration 120 shows evidence of the weld toe/base material requiring additional treatment.

View of depth gage

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View of radius gage

Depending on the material yield strength and the size of the indenters, typically the optimum HFMI groove will be 0.2 mm (0.008 inch) to 0.5 mm
(0.020 inch) in depth and the radius will be equal to or greater than 1/2 the diameter of the indenter used. Inspection for these features can be
completed using a depth gage and radius gage similar to that shown in Illustration 121 and Illustration 122.
Considerations:
The minimum plate thickness for HFMI treatment is 5.0 mm (0.20 inch). For base material thickness less than 5.0 mm (0.20 inch), TTD is the
preferred weld toe treatment.
Specific weld toe treatment procedures vary from application to application and depend on the equipment being used.
Consequently, the procedures prescribed by the HFMI tool manufacturer should be followed in a manner to meet the requirements
set forth.
The maximum applied stress from the external loading remains below 80 percent of the base material minimum yield strength and that the
applied loading is not fully tensile (R>0).
Profile/Flush Sanding
Aside from the more common and published post weld treatments outlined previously, there also exists a method for extending the fatigue life of
some welds. Profile sanding of large fillet welds , offset groove welds, casting repairs, and flush sanding of aligned groove welds.
Large Fillet Welds

Anticipated progression for an unequal legged fillet weld

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Anticipated progression for an equal legged fillet weld

Sanding the face and weld toes of an unequal legged large fillet welds, large (multi-pass), equal fillet weld or large unequaled fillet welds to improve
the fatigue life is advantageous. Illustration 123 shows the anticipated progression for an unequal legged fillet weld. Illustration 124 shows the
anticipated progression for a large (multi-pass) equal legged fillet weld.
Groove Welds - Sanding Excess Weld Metal Flush

Groove weld sanded flush on both sides

Frequently, it is necessary to sand the excess weld metal flush or to profile for a groove weld. Illustration 125 shows the before and after of sanding
a groove weld flush on both sides when the plates are aligned.

Casting repair sanded to profile

21/10/2022 16:00 SIS 2.0
In addition, it is a good practice to sand flush or to profile after performing repairs on base materials (plate/casting/forging). Illustration 126 shows a
repair completed on a steel casting and the excess weld metal sanded to conform the casting profile.
Combined Treatments

View of weld face


Weld to description

Occasionally more than one post weld treatment is specified. Usually, one type of post weld treatment will be specified for the outer weld toes and
a different type of post weld treatment will be specified for the inter-pass weld toes. Refer to Illustration 127 and Illustration 128 for descriptions.
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Combined post weld treatments

One of the more common combined treatments is TTD for the outer weld toes and profile or flush sanding for the inter-pass weld toes and weld
face. Illustration 129 shows this combined treatment.
Note: The treatment of the outer weld toes is always completed before sanding of the inter-pass weld toes.
Note: Flush sanding of the inter-pass toes and face will be completed with flexible sanding disc with a minimum of 36 grit.

Cross section of the combined treatment

Illustration 130 is an etched cross section of the combined treatment shown in Illustration 129. TTD at the outer weld toes with flush sanding of the
inter-pass toes and face.
PIP-10853253

2022/10/21

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General Welding Procedures (0679, 7000) (REHS1841-23)

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General Welding Procedures (0679, 7000) (REHS1841-23)

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21/10/2022 16:00 SIS 2.

2021/06/09 General Welding Procedures {0679, 7000} (REHS1841-23)

SMCS - 0679, 7000 i08477220

The signal word “WARNING” has the following meanings:

Your Safety Is Involved !

Protect yourself and others; read and understand this warning.

Read and understand the manufacturer's instruction and your

Refer to the American National Standard Z49.1, "Safety in

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

Always observe the list of basic precautions that follows:

Mounting and Dismounting

Specifications for Cables, Chains, and Lifting Devices

Hot Fluids and Parts

Welding on Engines and Machines with Electronic Controls

The Power Train Electric Drive System will contain hazardous

Do not remove any covers that will expose energized high

Any type of maintenance on the following components can only

High voltage compartments in the inverter cabinet

The rear axle housing that contains the electric drive

The excitation field regulator

The high voltage cables and connection enclosures

Failure to follow these instructions could result in personal injury

Welding on Machines Equipped with LiDAR

1. Remove the electrical connections to the LiDAR sensor.

2. Disconnect the M12 and Deutsch connector.

Welding on Fuel Tanks and Hydraulic Tanks

Applying heat to a tank which has held flammable liquids, even

Personal injury or death can result from an explosion.

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Dispose of all fluids according to local regulations and

Calibrate the equipment prior to first use.

The adjustment of the equipment is to be checked daily before use.

The equipment is to be maintained in accordance to the manufacturer recommendations.

Preparing the Tank for Cleaning

Designation of cleaning procedure.

Tank or container location.

Tank or container contents.

Note: Water method for use on fuel tanks only.

Hot chemical solution cleaning.

Use tooling (C) cleaner (de-greaser) to clean the tank or container.

Preparing for Welding

Do Not Weld an Empty Fuel Tank.

Do Not Weld on a Closed Hydraulic Tank.

9. Inert gas method.

10. Carbon dioxide method.

11. Water Method.

1. Empty the water from the tank.

2. Install the tank onto the machine.

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Dispose of all fluids according to local regulations and

Five Types of Weld Joint

Note: Edge joint is not commonly used for structural applications.

Illustration 10 through Illustration 14 shows common groove weld preparations.

Crack Detection Methods

- Detects most damaging defects.

Liquid Penetrant - Minimal Training

Testing (PT) - Portable

- Detects surface and subsurface - Less sensitive than Wet Magnetic

Wet Magnetic Testing (PT).

- Liquid composition and agitation must be monitored.

- Detects deep material defects.

- Wide range of materials and thickness - Surface must be accessible to probe