Welding General Notes - Ah60.00-D-0005-01KOP

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Model all (4xWD, CAR, Heavy transporter, Light transporter) Steel

Personnel

Welding work requires special knowledge and should be performed only by well-trained welders observing the "Instructions for repair welding on motor vehicles" and according to the specifications of the vehicle manufacturer.

Welders should be tested at least according to testing group B II, DIN 8560.

The relevant national regulations apply abroad.

Welding and related work

During all welding work, observe accident prevention regulations (UVV) VGB 15 for "welding, cutting and related types of work".

Evaluation group for weld seams according to DIN 8563, Part 3

For fillet welds BK
For butt seams BS

Further information is given in DIN 8563 Part 1-3.

Welding procedures

The following welding procedures are approved:

Arc welding with DC rectifier.
MIG welding.

Arc welding

Welding is permissible only with DC converters.

The ground terminal of the welder must be connected directly to the part to be welded at the end of the welding point.

Electrode welding

Use electrodes with cold alkaline jacketing.

Dry moist electrodes at 150°C to 400°C.

Drying time

3 h at 150°C.

1 h at 400°C.

Electrode diameter

2.5 mm

Amperage

40 A per mm electrode diameter.

MAG welding

When welding with CO2, use a wire with a thickness of 1 to 1.2 mm (300 to 350 A).

The welding material must have at least the same yield strength and tensile strength as the material to be welded.

Welding vapors

Evacuate noxious gases, vapors, dust and welding smoke in the area where these occur.

Preparation

Thorough preparation of the points to be welded is absolutely necessary to obtain a high quality connection.

Protect heat sensitive parts or remove.

The connection points on the part to be welded on the vehicle and the ground terminal on the electric welder must be as bright as possible; for this reason, thoroughly remove paint, corrosion, oil, grease and contamination, etc.

Fasten welding tongs to part to be welded.

If two parts are welded to one another, connect the negative clamp to both parts.

To avoid damage to the semiconductors disconnect vehicle battery before starting welding work.