Welding

Maintenance

Welding

Welding

About Welding

WARNING

Risk of Poisoning

When heated, the paint forms substances that can cause eczema, eye irritation, respiratory system difficulties, and in severe cases, asthma, or other health problems.

  1. Always use personal protection such as appropriate breathing apparatus, eye protection, and gloves.

  2. Always make sure that there is good ventilation when welding, grinding and other hot work that involves heating the paint.

WARNING

Thermal Cracks

Can cause severe personal injury.

  1. Follow the instructions.

  2. Do not weld on the booms.

  3. Do not weld on the framework of the cab or mountings.

  4. Pay attention to special certification for FOPS and ROPS.

NOTE

Unauthorized modification of the machine is not allowed.

NOTE

Always keep a fire extinguisher for oil fires near during all types of welding, cutting, and grinding. Screen off the work area from flammable materials.

Contact Epiroc before repair welding on components or frames, approval of welding method and choice of electrodes.

  • Qualified personnel must perform all welding.

  • Turn off the current supply to the machine.

  • Disconnect the cables from the alternator, the battery, the electronic modules, and the firefighting equipment.

  • Grind off rust and paint from the area to be welded and carefully prepare the joint.

  • Welding equipment must be grounded correctly.

  • Weld in a dry area.

  • If repair welding is necessary, damaged units must preferably be removed and repaired separately.

  • Framework, brackets, and load-carrying structures are made of special materials. Any repair welding performed with incorrect materials or additives can weaken the structure.

  • Avoid welding close to bearings and bushings.

  • Do not weld on the boom, hydraulic tanks, hydraulic cylinders, valve blocks, compressed air tanks, or pressure lines.

  • Do not weld on a FOPS and ROPS approved cab. The certification would then be invalid.

  • Protect hoses, cables, and electrical components.

  • If possible, grind the surface of the weld smooth and treat it with anti-corrosion paint.

CAN Bus System Disconnection before Welding

NOTE

The CAN bus and RCS can be severely damaged when welding.

Consult Epiroc for approval of welding and choice of electrodes.

  • Locate all modules present on the machine. Disconnect supply voltage to all modules, both + (positive) and - (ground).

    • Example of modules which can be present: application module, I/O module, resolver module, and CS-module.

  • Locate all sensors on the machine and disconnect them.

  • Locate the safety controller and disconnect supply voltage, both + (positive) and - (ground).

  • Locate all panels included in RCS and disconnect supply voltage, both + (positive) and - (ground).

  • Remove the battery ground cable.

Electrode Recommendations

Use only intact and clean electrodes that have been stored in a dry place. The generally recommended type of electrode is ESAB OK 48.00, ESAB OK 48.30 or the equivalent in accordance with the specified standard:

Electrode Recommendations

ISO

2560 E51 5B 120 20 H

SS

14 3211 H10

DIN 1913

E51 55 B10

AWS

A/SFA 5.1 E 7018

The use of MIG welding equipment is perfectly acceptable. The generally recommended type of electrode is ESAB-OK Autorod 12.51 or equivalent in accordance with the following standard:

MIG Electrodes

SS

14 3403 3423

DIN 8559

SG 2

AWS

A/SFA 5.18 ER 70 S-6

If in any doubt, contact Epiroc for advice.