Welding Wire and Flux {0679, 4150, 7950} Caterpillar

Welding Wire and Flux {0679, 4150, 7950}

Usage:

D6D 01Y

Caterpillar Products: Machines with Grease Lubricated Track with Swage; Machines with Greased Lubricated Track (GLT); Machines with Positive Pin Retention (PPR) Track; Machines with Positive Pin Retention 2 (PPR2) Track; Machines with Rotating Bushing Track; Machines with Sealed Positive Pin Retention (PPR) Track; Machines with Sealed Track; Machines with Sleeve Bearing Track; Machines with SystemOne Undercarriage; Machines with non-PPR Sealed and Lubricated Track
Track Drills: MD5150C (S/N: SEY1-UP)

Introduction

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Table 1
Revision	Summary of Changes in SEBF8509
23	Added serial number prefixes for New Product Introduction.
21–22	Added serial number prefixes for New Product Introduction.
20	Added serial number prefixes for New Product Introduction. Updated introduction information.
19	Added serial number prefixes for New Product Introduction.

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Undercarriage Reconditioning Bulletin contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Undercarriage Reconditioning Bulletin must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Summary

Undercarriage components are heat treated to achieve desired hardness and wear resistance. The heat treat process requires complex, expensive equipment, and close controls. This process is not practical for dealer use. The hardness and resistance to wear on a welded rebuilt undercarriage component is obtained by the high alloy concentration in the hardsurfacing weld deposit. The consumable alloy content and recommended welding parameters control the weld deposit hardness. Rockwell “C” hardness is the usual standard for measuring hardness and resulting wear resistance. A hardsurfacing deposit may not measure as high on the Rockwell “C” hardness scale. This hardsurfacing deposit will provide a lower resistance to abrasive wear than a heat treated part.

Hardsurfacing will be present on most of the undercarriage components after the submerged arc welding process. In submerged arc welding, the arc is blanketed by a fusible, granular material called flux. This flux is used to shield the arc and the molten metal from impurities and contamination. When submerged arc welding is used, both wire and flux are melted by the arc. Either the wire or flux can supply the necessary alloys to the weld deposit during submerged arc welding .

While material cost is less when using an alloy flux (rather than alloy wire), the use of alloy flux and neutral wire is not supported by Caterpillar. Use of alloy flux causes a variation of deposit hardness because the alloy concentration is difficult to control. The amount of alloy deposited depends on how much flux is melted. The amount of flux melted is determined by the heat generation of the welding arc.

Adding the alloys by using an alloy wire and a neutral flux will produce better results and is the supported method by Caterpillar. Use of an alloy wire and neutral flux provides consistent hardness and deposit chemistry. Hardness depends the welding parameters.

Welding Consumables

Proper wire and flux combinations should be used for rebuilding undercarriage components. An evaluation of weld consumables has been performed in the recommendation of proper welding wire and flux combinations. These recommended wire and flux combinations will provide weld deposits of the correct hardness and uniform chemistry. The following tables list the recommended welding consumables by component. The tables outline the welding parameters and weld deposit hardness. The deposition rates shown in these tables are stated per single head.

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Table 2
Recommended Track Roller Weld Consumables and Parameters
Wire	Stoody 205HD	Stoody 105 or Stoody 105B	Lincore 40	Welding Alloys P-S
Flux	Stoody Rollrite HD	Stoody Rollrite	Lincoln 880, Lincoln 801	Stoody Rollrite
Wire Feed Speed	103/95 I.P.M.⁽¹⁾	52 I.P.M.	107/70 I.P.M.⁽¹⁾	100/73 I.P.M.⁽¹⁾
Amperage	450/400⁽¹⁾	375	475/375⁽¹⁾	450/375⁽¹⁾
Voltage	30	28	28	28
Polarity	Reverse	Reverse	Reverse	Reverse
Deposition Rate⁽²⁾	16.1 lb/hr 15.3 lb/hr⁽¹⁾	9.5 lb/hr	14.0 lb/hr 10.4 lb/hr⁽¹⁾	14.9 lb/hr 10.9 lb/hr
Deposition Efficiency	94%	90%	87%	92%
Stickout	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)
Flux/Wire Ratio	0.3 kg (0.60 lb)	0.5 kg (1.12 lb)	0.4 kg (0.80 lb)	0.3 kg (0.65 lb)
Deposit Hardness	42 to 44 Rc	43 to 45 Rc	40 to 42 Rc	41 to 44 Rc

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⁽¹⁾	Smaller rollers (D7H and smaller) must be rebuilt at reduced welding parameters to avoid problems with weld pool, control, and slag removal.
⁽²⁾	The deposition rates shown are per single head.

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Table 3
Recommended Idler Weld Consumables and Parameters
Wire	Stoody 205HD	Stoody 105 or Stoody 105B	Lincore 40	Welding Alloys P-S
Flux	Stoody Rollrite HD	Stoody Rollrite	Lincoln 880, Lincoln 801	Stoody Rollrite
Wire Feed Speed	103/95 I.P.M.⁽¹⁾	52 I.P.M.	107/70 I.P.M.⁽¹⁾	100/73 I.P.M.⁽¹⁾
Amperage	450/400⁽¹⁾	375	475/375⁽¹⁾	450/375⁽¹⁾
Voltage	30	28	28	28
Polarity	Reverse	Reverse	Reverse	Reverse
Deposition Rate⁽²⁾ per hour	7.3 kg (16.1 lb) 7 kg (15.3 lb)⁽¹⁾	4.3 kg (9.5 lb)	6.4 kg (14.0 lb) 4. 7 kg (10.4 lb)⁽¹⁾	6.8 kg (14.9 lb) 4.9 kg (10.9 lb)
Deposition Efficiency	94%	90%	87%	92%
Stickout	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)
Flux/Wire Ratio	0.3 kg (0.60 lb)	0.5 kg (1.12 lb)	0.4 kg (0.80 lb)	0.3 kg (0.65 lb)
Deposit Hardness	42 Rc	42 Rc	40 Rc	41 Rc
Alternate Flux for Stringer Beads only	-------	Linde 50	Lincoln 801	Linde 50

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⁽¹⁾	Smaller idlers (D7H and smaller) must be rebuilt at reduced welding parameters to avoid problems with weld pool control and slag removal.
⁽²⁾	The deposition rates shown are per single head.

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Table 4
Recommended Track Link Weld Consumables and Parameters
	Link Buildup Material
Wire	Stoody 104	Lincore 30	Welding Alloys P-S
Flux	Stoody Rollrite	Lincoln 880, Lincoln 801	Stoody Rollrite
Wire Feed Speed	69 I.P.M.	100 I.P.M.	100 I.P.M.
Amperage	450	475	450
Voltage	28	28	28
Polarity	Reverse	Reverse	Reverse
Deposition Rate⁽¹⁾ per hour	5.4 kg (12.0 lb)	6.2 kg (13.7 lb)	6.9 kg (15.3 lb)
Deposition Efficiency	90%	87%	92%
Stickout	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)
Flux/Wire Ratio	0.5 kg (1.12 lb)	0.36 kg (0.80 lb)	0.29 kg (0.65 lb)
Deposit Hardness	29 to 31 Rc	30 to 32 Rc	28 to 31 Rc
Alternate Flux for Stringer Beads only	Linde 50	------	Linde 50
	Link Hardsurface Material
Wire	Stoody 105 or Stoody 105B	Lincore 40	Welding Alloys P-S
Flux	Stoody Rollrite	Lincoln 880, Lincoln 801	Stoody Rollrite
Wire Feed Speed	69 I.P.M.	107 I.P.M.	100 I.P.M.
Amperage	450	475	450
Voltage	28	28	28
Polarity	Reverse	Reverse	Reverse
Deposition Rate⁽¹⁾ per hour	5.5 kg (12.1 lb)	6.4 kg (14.0 lb)	6.8 kg (14.9 lb)
Deposition Efficiency	90%	87%	92%
Stickout	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)	31.8 mm (1.25 inch)
Flux/Wire Ratio	0.5 kg (1.1 lb)	0.4 kg (0.80 lb)	0.3 kg (0.7 lb)
Deposit Hardness	42 Rc	39 to 40 Rc	41 to 43 Rc
Alternate Flux for Stringer Beads only	Linde 50	------	Linde 50