804084 Mercury GASKET

Weld Specifications and Qualifications
Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.Welding can cause fumes, burn skin and produce ultraviolet rays.Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.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 cause death.Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125
See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.U.S. Department of Labor
Washington, D.C. 20210
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures" for additional welding instructions.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 1U-8088 Type H Respirator Gp for breathing protection.Welders must be qualified for fillet welding and groove welding. The welder must be qualified in different welding angles. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to ISO 9606 or "American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process and GMAW process. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.The power source should be able to supply 500 A or more with DC current for the welding operation. The power source should be able to gouge metal with 500 A.Use the direct current electrode positive (DC reverse polarity).The welding wire must be shielded with CO2 gas or Argon/CO2 80/20 gas.All repair welds should be done in a controlled environment. Controlled environments prevent the rapid cooldown after the repair. Controlled environments would be inside of a repair shop.All welds should be done in the horizontal position in order to make a smooth surface finish.If the vertical position must be used in the welding procedure, the operation should be performed in the "vertical up" direction, instead of the "vertical down" direction.
Table 1
Allowed Filler Material    
AWS A5.18 ER70S-6    
DIN 8559 SG3    
EN 440 G4Si1    Recommended European weld consumables: SAF Oerlikon Carbofil SG3, ESAB OK Autrod 12.64, Pittini Pitarc G9, or Thyssen® Union k56.If only manual welding is possible, use ESAB OK 48.00 with a rod diameter of 3.25 mm (0.128 inch) or the equivalent AWS A5.1 E7018 or EN ISO 2560-A E 42 4 B 42 H5.If welding quenched steel or tempered steel, the recommendation is to use specific filler metal with higher mechanical properties and lower hydrogen levels such as flux cored wire with AWS A5.20 Class E70T-5 specification. If something other than an AWS A5.20 Class E70T-5 Electrode is used, preheat to 200° C (392° F) and maintain interpass temperature at 150° C (302° F).Mask all parts prior to gouging.Proper Welding Procedure on Machines and Engines with Electronic Controls
Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:
Turn off the engine. Put the key start switch in the OFF position.
If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.
Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This connection will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.
Protect the wiring harnesses from the weld splatter.Replacement Parts
When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts. Refer to the "MCM Replacement Parts" section of the, "Parts Information" chapter of this manual for assistance in ordering the appropriate replacement parts.