Usage:
D250E (5TN),
D300E (7FN) Articulated Trucks
Reference: Service Magazine; July 2, 1990; Page 1; "Welding On Fuel And Hydraulic Tanks".
Tank mounted fuel gauges are available for the above listed machines. When installing the gauges refer to the charts, illustrations, and the following procedure.
1. Park the machine on a hard level surface in a stable position.
2. Drain the contents of the fuel tank into a suitable container.
3. Purge the tank with carbon dioxide gas (CO2).
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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. This can result in injury or death. DO NOT weld or flame cut on any tank that has held flammable liquid without taking the proper safety precautions. Read the article entitled "Welding On Fuel And Hydraulic Tanks" in the July 2, 1990 Service Magazine.
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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.
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Read and understand the manufacturer's instructions 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 general area. Wear correct eye, ear, and body protection. Do not touch live electrical parts.
See 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 CRF 1910, available from U.S. Dept. of Labor, Washington, D.C. 20408.
NOTE: Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OSHA limits.
All repair welding operators must be qualified for fillet welding as outlined in the current ANSI/AWS 14.3 or Caterpillar Manufacturing Practice MC1000-105. The welding operator must also have used the welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained for welding operator's qualification.
The SMAW process shall be used with E7018 (ANSI/AWS A5.5) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:
- 500 MPa (72 KSI) Tensile Strength
- 420 MPa (60 KSI) Yield Strength
- 22% Elongation in 50.0 mm (2.00 in)
- 27 J (20 ft lbs) Notch Toughness at -29° C (-20° F)
- 420 MPa (60 KSI) Yield Strength
These are low hydrogen electrodes and must be stored in an electrode oven at 120° C (250° F) when not in use. If the electrodes get damp, scrap or recondition them to manufacturer's specifications.
The following recommendations relate to electrode diameter and approximate current settings:
- Diameter - 3.2 mm (.12 in)
- Amperage - 70-140
4. Cut a square opening in the fuel tank as shown in Illustration 1.
Illustration 1. Square opening location.
5. De burr the edges of the square opening.
6. Clean the area around the square opening of oil, paint, and grease to prepare it for welding.
Illustration 2. 5U-2272 Flange
7. Fabricate a 5U-2272 Flange, from mild steel, as shown in Illustration 2.
8. Install the 5U-2272 Flange (Illustration 2) by inserting the flange on edge into the square opening in the tank from corner to corner. Now raise the flange into position with the flange centered in, and covering the square opening from the inside of the tank with the tapped holes facing outward.
9. Tack weld the flange in place. (As it appears in Illustration 4).
10. Weld 3.0 mm (.12 in) between flange and tank all around square opening.
Illustration 3. 6U-6568 Guard
11. Fabricate a 6U-6568 Guard, from mild steel, as shown in Illustration 3.
Illustration 4. Guard location.
12. Locate and weld the 6U-6568 Guard (illustration 3) as shown in Illustration 4.
13. Install the 137-8430 Float Sender Group using the 5P-3729 Seal and four 4B-1326 Screws.
NOTE: If a 137-8430 Float Sender Group is not available a 8W-0650 Float Sender Group can be used by sliding the float forward and securing it at the 266.7 mm (10.5 in) dimension (Illustration 5).
Illustration 5. Modification of 8W-0650 Float Sender Group (X) 266.7 mm (10.5 in).