Caterpiller 306-P BoreWelder Tool Operating Manual - PDF DOWNLOAD

NEHS0665 December 1997

TOOL OPERATING MANUAL Operator’s Manual for the 306-P BoreWelder

Table Of Contents

Separation of the Build-up from the Underlying

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wire Burning Back To The Contact Tip

Base Material . . . . . . . . . . . . . . . . . . . . . . . . . . . .

While Welding . . . . . . . . . . . . . . . . . . . . . . . . . 26

Precautions and Rules of Safe Operation . . . . . . . . 3

Wire Feeding Stops and Wire Burns Back

Additional Welding Precautions . . . . . . . . . . . . . . 3

to Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wire Burning Back to the Contact Tip When

Product Description and Theory of Operation . . . . . 4

Welding Is Stopped . . . . . . . . . . . . . . . . . . . . . 26 Welding Wire Will Not Feed Through the

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Off-Set Head . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Weld Beads Are "Ropy". . . . . . . . . . . . . . . . . . . . 27

Major Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Too Much Spatter . . . . . . . . . . . . . . . . . . . . . . . . 27

Power Supply Compatibility Information . . . . . . . . . 8

Torch Nozzle Becomes to Hot . . . . . . . . . . . . . . 27 Spindle Rotation Becomes Jerky At

Set-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Slow Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Initial Set-Up Procedure . . . . . . . . . . . . . . . . . . . . 9

Porosity In Weld . . . . . . . . . . . . . . . . . . . . . . . . . 27

Set-up Procedure for Wire Feeder Conduit

Steel Weld to Hard to Machine . . . . . . . . . . . . . . 28

Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Weld Breaks Cutting Tools When Machined . . . 28

Wire Loading and Feeding . . . . . . . . . . . . . . . . . 12

Excessive Undercutting Into Base Material . . . . 28

Final Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Weld "Graping" When Welding in the

Description and Use of Optional Equipment . . . . . 14

Vertical Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Use of the Adjustable Base . . . . . . . . . . . . . . . . 14

Too Much Build-up Thickness . . . . . . . . . . . . . . 28

Set-up Procedure . . . . . . . . . . . . . . . . . . . . . . . 15

On Breaking Failure, the Bead Appears Made Up

Radial Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

of Large Grains . . . . . . . . . . . . . . . . . . . . . . . . 29

Torch #00 and #0 . . . . . . . . . . . . . . . . . . . . . . . . 16

Mechanical Troubleshooting . . . . . . . . . . . . . . . . . 29

Torches #1 Through #8. . . . . . . . . . . . . . . . . . . . 17

Machine Will Not Step. . . . . . . . . . . . . . . . . . . . . 29

Trammel Torch . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Machine Cannot be Retracted or Extended . . . . 29

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Nothing Happens When Weld Button Is

Face Welding Torch . . . . . . . . . . . . . . . . . . . . . . 18

Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Machine Moves Or Welds Without Having

Torch Extension Support Kit . . . . . . . . . . . . . . . . 19

Pressed the Buttons Which Control These

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Auto-Skip Option. . . . . . . . . . . . . . . . . . . . . . . . . 19

The Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Off-Set Head Dovetail Adjustments . . . . . . . . . . 31

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . 20

Suggested Method for Setting the

Replacing Liners . . . . . . . . . . . . . . . . . . . . . . . . . 20

Wire Feeder Drive Rolls . . . . . . . . . . . . . . . . . . 32

Replacing #00 and #0 Contact Tips . . . . . . . . . . 20

Wire Feed Drive Roll Pressure and

Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . 21

Wire Seizing . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Suggested Training Procedure. . . . . . . . . . . . . . 21

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Out of Position Practice . . . . . . . . . . . . . . . . . . . 22

306-P BoreWelder . . . . . . . . . . . . . . . . . . . . . . . . 34

Welding Pointers . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Wire Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Welding in the Horizontal. . . . . . . . . . . . . . . . . . . . 23

Wire Feed Conduit . . . . . . . . . . . . . . . . . . . . . . . 40 Torches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Practical Suggestions for Successful

Trammel Torch . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Horizontal Axis Welding. . . . . . . . . . . . . . . . . . . . . 24

Radial Facing Torch . . . . . . . . . . . . . . . . . . . . . . 46

Common Welding Problems and Their Cures . . . . 25 Lack of Fusion to the Bore Surface. . . . . . . . . . . 25 Lack of Fusion to the Previous Weld Bead of the Same Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lack of Fusion at the Root and General Ability to Control Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2

3. Any parts needed for special applications,

Introduction

alterations, repair or servicing must be approved by Caterpillar or the OEM.

The Bortech 306-P BoreWelder was conceived of and designed for the repair and maintenance of

4. To make sure that nothing gets caught in

heavy earth moving equipment. The BoreWelder

rotating members, avoid wearing loose fitting

was the answer to the obvious need for a machine

clothing and keep hair back or in a cap when

to rebuild worn holes on large parts. This design

operating the machine.

combines optimum features for both ease of use

5. Turn off the input power before changing

and simplicity in manufacture.

torches or working on the machine.

6. Read and follow all instructions for the power supply unit you have chosen to use with the BoreWelder.

Additional Welding Safety Precautions 1. The operator and any personnel observing the machine, when in use, must use a protective shield with a filter and cover plates which conform to ANSI Z87.1 standards.

2. The operator needs protective clothing such as heavy shirts and cuffless pants of a durable flame resistant material for protection from sparks and flame. Other personnel in the area need to be protected from the arc rays by a screen and/or a warning not to watch or otherwise expose themselves to the rays or to any hot spatter.

Illustration 1. 306-P BoreWelder

3. Practice "good housekeeping" in the area around the BoreWelder. Keep combustible material or any other fire hazards well away from the work area. For in-shop use, have a fire

Precautions and Rules for Safe Operation

extinguisher readily available.

4. Welding may produce gases and fumes that are dangerous to breathe. Sufficient ventilation

The 306-P BoreWelder is designed for safety and

is needed to remove smoke while the machine

ease of use. As with the operation of any

is in use. The operator should keep his head

machinery, safety depends on the operator. The

out of the fumes.

BoreWelder requires thoughtful, careful operation to produce optimum results and optimum safety.

5. Make the electrical installation in accordance with the National Electrical Code and all local

It is important that the operator read and

codes where applicable. Also, ground the

understand the specific instructions for set-up and

control box in accordance with the above

operation of the 306-P BoreWelder found in this

mentioned codes by powering it only from

Tool Operating Manual as well as the following

properly grounded three prong outlets.

safety information.

6. Caution must be taken with regard to potentially

1. Set-up, maintenance, and operation of the

dangerous electric shock. Do not ever contact

BoreWelder should re done only by qualified

electrically live parts. Your hands can be

individuals.

insulated with dry, hole-free leather gloves.

When working in any damp areas or on metal

2. Alterations to this machine will void the warranty.

floors, you must insulate yourself from the ground and the work, making sure you have complete protection if you are sitting or lying on the ground to operate the machine.

3

To obtain additional details on safety precautions,

Product Description and Theory of Operation

we highly recommend "Safety in Welding and Cutting", American National Standard ANSI Z49.1, which can be purchased from the American Welding Society, Inc., 550 N.W. Lejeune Road, Miami, Florida 33126. Their ordering number is

The 306-P BoreWelder is an automated welding

1-800-443-9353.

device that uses a rotating and axially stepping torch in conjunction with the MIG process to build-up the surface of a bore by depositing

Limited Warranty

contiguous weld beads around the bore s

The OEM warrants new equipment, not classified

accommodated by torch selection, and/or

as expendable, against defects in workmanship

adjustment of an off-set head. During the set-up

and material for one year of normal use from the

phase, the operator is required to align the

date of receipt by the end user. The following

BoreWelder to the bore, determine the proper

conditions shall be met in order for this warranty to

torch/bore clearance, and to make the initial

be enforced:

control settings. During welding, operator input is

circumference. Differences in bore diameter are

required to start and stop the machine, and to

1. Equipment has been stored, operated, and

visually remain in contact with the welding process

maintained in accordance with the OEM s

in order to make the minor adjustments in the

instructions.

rotational speed, voltage and wire speed

2. Equipment has not been partially or completely

necessary to maintain good weld quality.

disassembled, or otherwise tampered with without proper authorization.

Specifications

3. Equipment is owned by the original purchaser.

It shall be the warrantee s responsibility to prove

Description

compliance with the above conditions of warranty

Specification

Welding Process

Metal-inert-gas (MIG)

replace any components or parts of the

Wire Diameter Range

0.8 to 1.2 mm (.030 to .045 in)

BoreWelder that are determined by the OEM to be

Build-Up Diameter Ranges

defective.

Bore:

enforcement. The OEM has the option to repair or

.

2.2 to 68.8 cm (88 to 27 in)

Outside:

0 to 35.6 cm (0 to 14 in)

Face:

0 to 50.8 cm (0 to 20 in)

Unsupported Torch Reach

1.5 m (60 in)

Length of Stroke

15.2 cm (6.3 in)

the buyer, shall not exceed the cost of correcting

Step Range

1 to 5.1 mm (.04 to .20 in)

defects in the equipment or replacing defective

Maximum Continuous Welding

175A

parts. When the period of warranty expires, all

Current

Goods returned are done so at the customers risk and expense, including all transportation and packaging costs. The liability of the OEM with respect to supplying said equipment or its use by

such liability shall terminate.

Welding Power Required

Constant Voltage

Expendable items referred to above, include, but

Control Box Power

120 VAC 50/60 Hz

are not limited to torches #00 and #0, and all tips,

Requirements

nozzles, diffusers, and liners.

Remote Voltage and

Provided

Contactor Control Typical Voltage Operating

16 to 17.5 Volts

Range (short arc/.035 wire) Component Weights

4

BoreWelder

9.4 kg (22 lb)

Control Box

4.5 kg (10 lb)

Wire Feeder

14.5 kg (32 lb)

Nomenclature

Illustration 2. BoreWelder Component Identification.

5

Power Cable.

Major Assemblies

Provides for the transmission of welding current

Standard Base.

from the power supply to the BoreWelder. (Cable

Provides support for the BoreWelder by the use of

and power supply end are optionally purchased.

a base weldment which can be clamped to a table,

Use #2 Welding Cable).

or other suitable surface, and a mounting rod

Welding Power Supply.

which the BoreWelder attaches to. The standard

Provides the current necessary for the welding

base does not provide for leveling, or centrality

process. (Optionally purchased).

adjustment of the BoreWelder.

Control.

Adjustable Base.

Controls all the welding functions. It contains the

Provides support for the BoreWelder while also

motor controllers for the wire feeder, step, and

allowing leveling and centrality adjustment.

rotation motors. The control also connects with the

BoreWelder.

welding power supply to operate its contactor and

Provides the circular and axial motion required to

control its voltage output.

accomplish bore build-up. It also provides for the

Control Cables.

passage of current, welding wire, and shielding

Connects the control with the wire feeder, welding

gas to the welding torch.

power supply, and BoreWelder.

Off-Set Head.

Carrying Case.

Part of the BoreWelder, the off-set head provides

Provided to assure safe transporting, and storage

the torches with 2.5 cm (1.00 in) of radial

of your BoreWelder.

adjustment. This allows adjustment for diameter.

Orientation Fitting.

Fitting for coupling torches to the off-set head member. The orientation fitting allows for rotational positioning of torches after connection to BoreWelder.

Torches.

Attach to the off-set head, and are sized to allow the welding of holes from 2.2 to 68.5 cm (.875 to 27 in) diameter.

Torch Extensions.

Allow torch entry into deep, or remotely located holes. (Options)

Wire Feed Conduit.

Allows the passage of wire and shielding gas from the wire feeder to the BoreWelder.

Wire Feeder.

Supports a standard 30 cm (12 in) wire roll, and feeds the wire into the wire feed conduit. The shielding gas is also introduced into the wire feed conduit at this point.

Gas Hose.

Allows for the quick connection and remote location of the shielding gas tank.

Gas Regulator.

Determines the flow of inert gas. (Option)

6

Notes

7

Power Supply Compatibility Information

Chart A. Power Supply Control Cable 137-2707 (Control Provides Contactor Current) Amp. Conn.

Purpose

CDR Color

11

AC Hot

N.C.

3

Interlock - A

N.C.

potential of the 306-P, a continuous welding

9

Arc Voltage Wiper

Black

current of about 200 amps should be possible.

2

Interlock - B

N.C.

5

Weld Solenoid Switch

N.C.

14

AC Neutral

Blue

13

Arc Voltage Pot - Leg A (min)

Red

control cable with a connector on one end for

12

Arc Voltage Pot - Leg B (max)

Green

attachment to the control box. The other end must

8

Weld Solenoid Switch

White

4, 6, 7, 10

N.C.

1

Key Pin

Numerous weld power supplies can be used with the 306-P BoreWelder. In order to utilize the full

The power supply must be of the constant voltage (CV) type (the type suitable for MIG welding), and it should have remote voltage control capabilities.

The 306-P comes equipped with a power supply

be attached directly to the power supply, or to a connector that will mate properly with the power supply to be used.

The 306-P is capable of interfacing with power supplies providing contactor actuation current, and

Chart B. Power Supply Control Cable 137-2706 (Power Supply Provides Contactor Current)

those that do not. It is important to know the requirements of the power supply to be interfaced

Amp. Conn.

with the 306-P before attachment is attempted.

Charts A and B show the function of each

Purpose

CDR Color

11

AC Hot

N.C.

Attachment of the power supply control cable to

3

Interlock - A

N.C.

the power supply, or connector should only be

9

Arc Voltage Wiper

Black

2

Interlock - B

N.C.

5

Weld Solenoid Switch

Blue

14

AC Neutral

N.C.

13

Arc Voltage Pot - Leg A (min)

Red

12

Arc Voltage Pot - Leg B (max)

Green

attempt connection or use until necessary

8

Weld Solenoid Switch

White

information is obtained from the manufacturer or

4, 6, 7, 10

N.C.

1

Key Pin

conductor in the power supply control cable.

attempted by a licensed electrician, and only after a thorough appreciation of the theory of operation of the power supply has been gained by studying this manual and appropriate power supply information. If adequate information is not available regarding the operation of the remote contactor circuit of the power supply, do not

other reliable source.

The WHITE and BLUE wires connect to the power supply contactor terminals.

The RED, BLACK, and GREEN wires

Be certain that you are using the correct cable for your power supply. connect to the power supply voltage control terminals.

Improper connection of the Bore Welder may result in dangerous electrical shock. Damage to the power supply or to the BoreWelder control may also result.

Note: If you purchased a power supply from Bortech, both power supply cable ends are installed.

8

Set-Up Procedure

Note: The torch socket in the off-set head

The standard base does not provide for leveling or

6.4 mm (.25 in) from center. This means

sliding member is not central, but is off-set that if the slide were centered, there would

centrality adjustment, and therefore is normally

be a 12 mm (.5 in) radial difference

used for build-up of bores in parts small enough to

between a torch nozzle facing in and one

be adjusted to the BoreWelder set-up. If you have

facing outward. This is due to the fact that

purchased the adjustable base option, refer to the

in the first instance, the shank of the torch is

use of the adjustable base section when indicated

actually 6.4 mm (.25 in) behind center, and

below.

in the second, the shank is 6.4 mm (.25 in) ahead of center. Therefore, there is a 12.5

Leveling provides for parallel alignment of the axes

cm (1.0 in) difference in diameter between

of the BoreWelder, and the bore. Centrality

the two possible torch positions, extending

adjustment is necessary to make the center of the

the range of each torch by 2.5 cm (1.0 in).

bore the same as the center of rotation of the BoreWelder.

Initial Set-Up Procedure Also see the "Operator Training" section.

1. Clamp or tack weld the base plate to a suitable non-combustible surface. (If applicable see adjustable base).

2. Screw the support rod into the base plate and tighten.

3. Slip the BoreWelder over the support rod and secure in place with the hand knob.

4. Connect the three control cables and control box power cable as shown in Illustration 4.

Switch the POWER switch located on the side of the control to the on position to insure operation. Illumination of the LED next to the FUNCTION button indicates that the control box functions are now operable. Before proceeding, switch the POWER switch off and turn the control off.

5. Attach the torch and the extensions to the BoreWelder orientation fitting, as shown in Illustration 4.

Illustration 3. Torch And Extension Orientation.

a. Orient the torch in a direction parallel to the off-setting travel of the off-set head member by rotation of the orientation fitting.

6. Reach Adjustment. The BoreWelder should be positioned axially on its support rod so that the

b. Secure in position with the 38 mm (1-1/2 in) nut. Please note that there are two possible positions for orientation.

axial torch travel will reach to both extremes of the welding that is to be done in the bore. Jog the Quill, by using the QUILL JOG EXTEND/RETRACT switches to check for the proper BoreWelder placement and slide the BoreWelder up, or down as necessary to position the stroke.

9

Illustration 5. Connection for the BoreWelder.

10

7. Aligning the BoreWelder. (If applicable, see adjustable base). Adjust by moving or shimming the part to be welded to be level and central to the BoreWelder. Small metal wedges are sometimes handy. Check adjustment by rotating the spindle (using the ROT JOG switch), and moving axially (using the QUILL JOG RETRACT/EXTEND switches). Please study the more detailed instructions on this subject in "Use of Adjustable Base".

8. Adjust the radius of the torch to the bore by turning the adjustment knob on the off-set head. If necessary, loosen the two clamp screws (Illustration 4) - leaving the binder screws snug. This should allow movement of the off-set head by hand.

NOTICE Never use a wrench or pliers to adjust the torch radius because damage may result.

(This adjustment can be made easier by grasping the off-set head with the left hand in such a way that a pressure is exerted between

Illustration 4. Adjusting Torch Radius On Offset Head Assembly.

thumb and fingers that tends to shift the head in the desired direction while turning the knob).

Leave approximately 3 mm (.12 in) clearance between the torch nozzle and the bore to

head, the two clamp screws may be

Set-up Procedure for Wire Feeder Conduit Attachment

retightened if desired.

1. Attach the BoreWelder end of the wire feed

assure no interference when the spindle is rotated. Following adjustment of the off-set

conduit to the swivel connector located at the

Note: Torches #00 and #0 have "live" copper

top of the BoreWelder by engaging the

nozzles and therefore it is particularly important

attachment nut. A wrench should not be

to leave clearance when using these torches.

necessary as the seal is obtained with an O-ring. Hand tight is usually adequate.

The usable travel of the head is limited to 2.5 cm (1.0 in). If the sliding member radially

2. Open wire feeder case. Back off thumb screw.

protrudes past its holder, gas leakage

Attach the wire feeder end of the wire feed

and/or damage to the liner may occur.

conduit by inserting the end into the wire feeder adapter to a positive stop, and securing it lightly with the thumb screw.

11

Wire Loading and Feeding

Final Set-up

1. Place the roll of wire on the spool holder such

1. Axial Start Position

that the wire will feed from the bottom of the

Jog the torch axially until the nozzle is

roll. Straighten about 10 cm (4.o in) of wire at

positioned properly to start welding at the end

the end of the roll.

of the hole farthest from the BoreWelder.

Welding always progresses towards the

2. If wire feeder is equipped for the push/pull

BoreWelder.

option, there will be a toggle switch inside the

2. Angular Start Position

wire feeder case attached to the side rail near the front (and the wire feeder serial number will

Push and hold the ROT INIT switch on the

have a "1" in the next to the last digit place).

control panel, until the torch stops rotating.

This switch should be in the NORMAL position

This will be the angular starting position for the

(switch handle towards the back of feeder)

weld. Starting here assures a complete

unless the pull feeder is being used (if the

revolution of the torch before any axial

BoreWelder is so equipped).

movement occurs, thereby providing complete build-up at the very end of the hole.

3. Weld Power Cable Attach the weld power cable to the BoreWelder power connector, and the power supply. Use #2 Welding Cable.

4. Ground Cable.

Attach the power supply ground clamp to the part to be welded. The surface to which the ground clamp is attached should be clean bare metal, and should be located such that there is a good conductive path to the bore being welded. As with any welding process, a poor ground is detrimental to weld quality, and increases the risk of electrical shock.

Illustration 5. Wire Loading and Feeding

5. Shielding Gas. a. Attach the gas hose to a regulated source 3

of shielding gas. A flow of 1 m /hour (35

3. Disengage the feed pressure rolls on the wire

cfh) is good.

feeder by flipping the two levers from over the roller holders. Thread the wire through the 3.8

Note: Avoid excessive flows as this creates

cm (1.5 in) hole in the wire feeder cavity, and

turbulence and could cause poor shielding.

into the feed guide tube. Push the wire past

If poor shielding is suspected, check for a

the feed rolls, and on into the outlet guide.

dirty nozzle or an obstructed gas flow from

Reposition the feed roll pressure levers over the

the diffuser.

rolls so they will engage the wire. With the control ON, press the WIRE JOG switch and

b. The other end of the gas hose should be

the wire will be pushed through the wire feed

attached to the wire feeder quick

conduit, the BoreWelder, and to the torch.

disconnect.

4. It may be necessary, especially with the #00

c. Push the PURGE button on the control

torch, to feed the wire through the BoreWelder.

panel for approximately 15 seconds. This

With the torch detached, push the wire through

will assure that only shielding gas will be

the torch with pliers, and then attach the torch

present throughout the system during

to the off-set head. (If the wire is filed to point

welding.

before installing torch, automatic feeding through torch may be possible).

12

6. Final Adjustments. Adjust the STEP SIZE, WIRE

7. Start.

SPEED, ARC VOLTS, and ROTATION SPEED

Welding is initiated by pushing the WELD

on the Control Panel according to the charts C,

switch on the control panel. Pressing WELD

D, and E.

again halts welding.

8. Adjustment Modifications.

As with any arc welding process, visual observation should only be made when using

Chart C. Approximate Rotation Dial Setting

an appropriate light shield. Modify the

Torch Setting

Torch Range cm (in)

Suggested Dial Setting

00

2.2 - 4.4 (.875 - 1.75)

8.0

0

4.4 - 7.6 (1.75 - 3)

7.0

1

7 - 14 (2.75 - 5.5)

5.5

2

11.4 - 19 (4.5 - 7.5)

3.5

3

15.2 - 22.9 (6.0 - 9.0)

2.5

4

20.3 - 27.9 (8.0 - 11.0)

2.3

5

25.4 - 33 (10.0 - 13.0)

2.0

6

30.5 - 38 (12.0 - 15.0)

1.8

7

35.6 - 43.2 (14.0 - 17.0)

1.5

8

40.6 - 48.3 (16.0 - 19.0)

1.3

adjustments made in "9" above as necessary, using the judgment process as would be used

See "Welding Pointers" and "Welding In The Horizontal". for MIG welding.

9. Keyways, Holes, Etc. If there are certain locations within the bore where build-up should not occur:

a. Depress the ARC INTERRUPT switch on the control panel when the torch approaches such an area, and welding will stop.

b. Welding will resume when the ARC INTERRUPT switch is released. Please note that this procedure must be repeated for each revolution until the area where weld is not to be deposited is passed, and should be visually observed by using an

Chart D. Current Range and Step Size (Suggested Value in Parentheses)

appropriate light shield.

Wire Size

Current Range

Step Size

0.8 mm

100

100

(.030 in)

(65 - 120)

(.090 - .120)

0.9 mm

130

.130

(.035 in)

(100 - 160)

(.110 - .150)

10. Stop.

Welding is stopped by again pushing the WELD switch on the control panel.

Determination of when the welding should be stopped should only be judged while looking at the welding through an appropriate light shield.

Chart E. Setting of Rotation Dial Circumferential Inches per Millimeter (Inches per Minute) Dial Setting

Spindle RPM

254 (10.0)

381 (15.0)

508 (20.0)

635 (25.0)

762 (30.0)

889 (35.0)

10

6.000

13 (0.5)

20 (0.8)

27 (1.1)

34 (1.3)

40 (1.6)

47 (1.9)

9

4.290

19 (0.7)

28 (1.1)

38 (1.5)

47 (1.9)

57 (2.2)

66 (2.6)

8

2.500

32 (1.3)

49 (1.9)

65 (2.5)

81 (3.2)

97 (3.8)

113 (4.5)

7

1.710

47 (1.9)

71 (2.8)

95 (3.7)

118 (4.7)

142 (5.6)

165 (6.5)

6

1.270

64 (2.5)

95 (3.8)

127 (5.0)

159 (6.3)

191 (7.5)

223 (8.8)

5

1.090

74 (2.9)

111 (4.4)

148 (5.8)

185 (7.3)

223 (8.8)

260 (10.2)

4

0.920

88 (3.5)

132 (5.2)

176 (6.9)

220 (8.6)

264 (10.4)

308 (12.1)

3.5

0.880

92 (3.6)

138 (5.4)

184 (7.2)

230 (9.0)

276 (10.9)

322 (12.7)

3

0.750

108 (4.2)

162 (6.4)

216 (8.5)

270 (10.6)

323 (12.7)

377 (14.9)

2.5

0.710

114 (4.5)

171 (6.7)

228 (9.0)

285 (11.2)

342 (13.4)

399 (15.7)

2

0.630

128 (5.1)

193 (7.6)

257 (10.1)

321 (12.6)

385 (15.2)

449 (17.7)

1.5

0.550

147 (5.8)

221 (8.7)

294 (11.6)

368 (14.5)

441 (17.4)

515 (20.3)

1

0.410

197 (7.8)

296 (11.6)

394 (15.5)

493 (19.4)

592 (23.3)

690 (27.2)

0.5

0.230

352 (13.8)

527 (20.8)

703 (27.7)

879 (34.6)

1055 (41.5)

1230 (48.4)

13

Description and Use of Optional Equipment Use of the Adjustable Base This base is normally used when it is most practical to align the BoreWelder to the part.

Illustration 6.

14

NOTE: A good way to check parallelism is to

Set-up Procedure

thread a torch extension into the offset head of the

1. Weld a 12 mm (.5 in) diameter mounting bolt of

BoreWelder. Then using at least one radial

suitable length to a spot approximately 28 mm

mounting extension, position the BoreWelder so

(1.1 in) from the center of the bore to be built-up. The bolt should be welded at the

the torch extension is up against the side of the

head end, with the axis of the bolt

bore. Adjust the first two set screws until the

approximately parallel with the axis of the hole

extension is parallel. Then move the BoreWelder

to be built-up. In some instances, uneven or

and extension to the other quadrant of the bore

angled surfaces adjacent to the bore will

and adjust the single set screw until the extension

require tack welding or clamping blocks or

is parallel.

sub-plates for support of jack screws in order to provide a suitable adjustment surface.

2. Place the adjustable base plate on the adjustment surface with the 1/2 inch (12 mm) bolt protruding through hole, shown in Fig. ?.

Orient the base such that the mounting rod will be in-line with the mounting bolt just installed and the center of the hole to be worked on.

The spring, washers, and nut provided with the adjustable base should be placed over the 1/2 inch (12 mm) bolt, and the nut turned finger tight, plus a turn or so with the 3/4 inch (19 mm) wrench.

3. Screw the support rod into the slider hole as shown and tighten.

4. Adjust the base leveling screws until the support rod is parallel with the bore axis. It is important to note here that the two forward leveling jacks should be adjusted (as a pair) first ignoring the other axis, then adjust the single rear screw. In this way, the rear jack makes the base pivot on the forward jacks, not affecting the other axis as already set.

Illustration 8. Adjust Centrality.

NOTE: To attain centrality, first adjust the axis in line with the base by checking the nozzle gap at the point closet to the mounting rod and at the point 180 degrees from the mounting rod. Adjust by either turning the screw on the Adjustable Base by using the articulating effect to the Radial Mounting Extension(s). Then adjust the other axis in a similar method by swinging the BoreWelder on a mounting rod.

Illustration 7. Adjust Parallelism First.

5. Tighten the 12 mm (.5 in) hold-down nut. A torque of 2 kg-m (15 lb ft) should be sufficient.

6. Slip the BoreWelder over the support rod and secure in place with the hand knob so that the BoreWelder spindle is approximately in line with the hole.

15

7. Connect the control cables as described in the

Radial Mount

set-up procedure.

This accessory is used to extend the reach of the

8. Attach the torch and extensions to the

BoreWelder when doing build-up on large diameter

BoreWelder as described in the set-up

holes, or when attachment near the bore is

procedure.

impossible. Each radial mount used extends the reach by 12.7 cm (5 in). Use as follows:

9. Centrality to the bore is obtained by working in the two axes (we will call them X and Y) each

1. Attach the radial mount to the support rod by

separately, one at a time. If the BoreWelder

slipping the open end over the rod, and

has been set up properly on its mounting rod,

tightening the knob.

there will be facilities present for positioning the BoreWelder in each of these axes.

2. The BoreWelder then attaches to the radial mount in the same manner as it attaches to the

One axis, which we will refer to as X, is adjusted

support rod.

by loosening the two clamping knobs on the adjustable base and moving the slider by

3. If additional reach is required, another radial

turning the adjustment screw. This moves the

mount can be used by clamping the second to

mounting rod towards and away from the work

the first, and then clamping the BoreWelder to

hole.

the second. This method also allows substantial flexibility in the radial positioning of

The other axis, we will call this Y, is at 90

the 12 mm (.5 in) mounting bolt by use of the

degrees to X and is adjusted by loosening the

articulating or knuckling action of the two radial

BoreWelder clamping knob and swinging the

mounts.

BoreWelder on the mounting rod. The resulting arc is largely in this Y axis.

Torch #00 and #0

Successfully centralizing the BoreWelder to the

These torches are used to build-up bores ranging

bore requires rotation of the torch to assure that the nozzle is the same distance from the bore at

in diameter from 2.2 to 4.4 cm (.88 to 1.75 in), and

all angular positions. It is usually best to also

4.4 to 7.6 cm (1.75 to 3 in) respectively.

check centrality at another axial location to be

1. These torches have "live" copper nozzles,

sure of parallelism. Use control panel switches

making clearance between the nozzle and the

ROT JOG for rotation, and QUILL JOG

bore particularly important.

RETRACT/EXTEND for axial motion.

2. Although not usually required, it may be

At this point it may be necessary to make

necessary to feed the wire through the

further refinements to the parallelism adjustment

BoreWelder with the torch detached, push the

by use of the leveling screws. It is usually best

wire through the torch with pliers, and then

to center the BoreWelder in the X axis first

attach the torch to the off-set head. Filing the

(using the adjustment screw), and then center

wire to a point may help automatic feeding of

the Y axis (by swinging the BoreWelder). After

the wire.

which a small adjustment may be required to the first axis. Each axis is checked for center

3. Change tips by loosening the set screws

by rotating the torch to a point, noting its

holding the tip and the liner, and removing both

proximity to the bore surface, rotating 180

tip and liner from the torch body. Insert the

degrees, and noting the proximity at this new

liner into the new curved torch tip and the

point. Centering should not require more than a

combination into the torch body through the

couple of minutes to accomplish.

nozzle. Once properly located, tighten the set screws to prevent movement. (If the torch is held horizontally, the tip tends to fall correctly into its seat). Position tip axially to a point slightly below center to the nozzle opening.

Keep in mind that the wire is curved on exiting the tip and therefore the point of contact with the work is higher than might otherwise be expected, and the tip should be positioned slightly towards the end of the nozzle to compensate.

16

4. After rotating torches for set-up, hole location, or screwing into an extension, jog the wire through the torch until it exits the tip in a stable condition, producing a clean spiral of wire.

This is to relieve the torsional stresses built-up in the wire (because wire was not being fed while rotating) so that the weld will get off to a good start.

Torches #1 through #8 Use as follows:

1. These torches use standard tips and nozzles.

2. While less likely than with the smaller torches, it may be necessary when threading the wire to push it through the torch with pliers before attaching to the off-set head.

Chart F. Torches #1 through #8 Torch No.

Range of Diameter

1

2.75 in - 5.5 in (7 cm - 14 cm)

2

4.5 in - 7.5 in (11.4 cm - 19 cm)

3

6 in - 9 in (15.2 cm - 22.9 cm)

4

8 in - 11 in (20.3 cm - 27.9 cm)

5

10 in - 13 in (25.4 cm - 33 cm)

6

12 in - 15 in (30.5 cm - 38 cm)

7

14 in - 17 in (35.6 cm - 43.2 cm)

8

16 in - 19 in (40.6 cm - 48.3 cm)

Illustration 9. Radial Facing Torch.

Procedure 1. After attaching the Trammel torch to the BoreWelder, adjust the radius clamp by loosening the clamping screw, and sliding the radius clamp on the hub weldment to the proper radius to weld the bore.

2. Adjust the nozzle holder rod to the proper distance from the hub weldment to allow a

Trammel Torch

natural sweep of the hose from the hub fitting to

This torch uses standard tips and nozzles, and can

loosening the set screw on the end bushing

be used for both bore build-up, and OD build-up.

and moving the torch head rod.

the nozzle holder. This is accomplished by

The diameter range of the Trammel torch when

3. Check to see that the nozzle is still aligned at

used for bore build-up is 23 to 46 cm (9 to 18 in).

approximately 45 degrees from the bore axis, and in the Trammel torch plane.

4. Minor radial adjustment should be made with the off-set head.

The diameter range of the Trammel torch when used for OD build-up is 0 to 36 cm (0 to 14 in). Torch limitations when doing OD build-up restrict such build-up to about 25.4 cm (10 in) from the end. Procedures for OD build-up are the same as for bore build-up except that the torch is turned inward. It is generally best to use the 45 degree head on OD build-up.

17

1. Before attaching the face torch to the

Face Welding Torch

BoreWelder, check to make sure that there is

This torch is used to apply weld build-up on faces

enough radial clearance to allow the torch to

up to 50.8 cm (20 in) in diameter. It welds in a

rotate. If not, add an additional radial mount to

spiral pattern starting at the outside, and working

provide clearance. Also, check to make sure that adequate space exists between the

inward 4.2 mm (.166 in) with each revolution of the

BoreWelder and the work to allow attachment

torch.

of the torch. If not, use a longer than standard BoreWelder mounting rod or a mounting rod extender.

2. Attach the face torch and, after centering the BoreWelder, rotate the bevel gear until the torch nozzle is in the proper position to begin welding. Adjust the extension of the torch rod so as to allow the radial torch movement necessary (the hose must allow maximum radial position and yet the hose should not be unduly curved). In order to accommodate the position of the torch rod, it may be necessary to use the extra long liner and hose provided with the torch. For faces smaller than approximately 10 cm (4 in) or larger than approximately 41 cm (16 in), it may be necessary to add a radial extender.

3. Adjust the torch to give the proper angle to the face. Angles in the range of 40 to 60 degrees from the face are usually appropriate to provide adequate fusion with the previous bead and the work piece. (Must be done in conjunction with the adjustments made under item "B" above).

4. Attach the Tommy Rod to the bevel gear. If the Tommy rod does not extend far enough to reach the mounting rod or other stationary object, its reach can be extended by slipping a tube over the end. Once extended to a

Illustration 10. Radial Face Welding Torch.

stationary object, it may be necessary, if doing a horizontal axis build-up, to secure the Tommy

Procedure

Rod with a wire tie or other means.

Note: If the part geometry dictates the use of an outwardly spiraling welding pattern, contact Bortech or your Bortech representative.

Be sure that the Tommy Rod is only making contact with "ground" through its insulated section.

5. Switch OFF the BoreWelder step function.

Control of the step function is determined by the step switch located on the same end of the control box as the control cable connectors.

18

6. Set the proper rotation speed on the rotation

Auto-Skip Option

dial. Initially this speed should correspond with the setting suggested in Chart C for the

This allows the BoreWelder to be set so that it will

maximum diameter of the face to be welded.

not weld in certain portions of the bore. Two cam

This speed should be adjusted upward after

disks on the top of the BoreWelder determine

several revolutions, with the upward adjustment

where in rotation welding is to be suspended. A

repeated thereafter as necessary as the spiral

keyway or a slot are examples of when the

becomes smaller.

auto-skip option might be used. To use:

1. Rotate the two cam disks on the top of the

Torch Extension Support Kit

BoreWelder s red shroud so that the auto-skip limit switch is depressed by the disks during

This is used to provide extension/torch support

times of welding.

when the distance from the BoreWelder to the torch is far enough to make torch stability

2. Begin the weld build-up operation as usual.

questionable and alignment difficult.

3. If no arc interrupt is desired, position the disks so that the limit switch is never released.

Illustration 11. Torch extension support kit.

Procedure 1. Slip the support body over an extension located close to the bore to be welded, and at a location where the extension support rod can be clamped or tack welded to provide necessary support.

2. Orient the support block such that the shoulder screws are both at right angles to the torch extension.

3. Once centrality of the support body with the bore is obtained, attach the extension support rod to an appropriate foundation as described above.

4. Attach the off-set head provided with the torch extension support to an extension on the bore side of the support body. Adjust the torch radially with this new off-set head as with the off-set head described in "set-up procedure" above. The original off-set head should remain aligned with center mark.

19

Maintenance

Note: When replacing the liner in a wire feeder

Daily Maintenance

circle and push the liner in so that it contacts the

conduit, coil the conduit into a 24 inch (60 mm) outer wall of the conduit.

The BoreWelder is relatively maintenance free.

Then secure in place with the set screws while in

The most important maintenance is the daily

this coiled position. This procedure is very

maintenance, and is mostly common sense.

important to the proper operation of the

Daily maintenance consists primarily of keeping

BoreWelder. Do not over tighten the set screws

the BoreWelder clean and protected. The

when securing the liner.

BoreWelder has been designed to survive in industrial environments which are usually dusty

Replacing #00 and #0 Contact Tips

and gritty, but the BoreWelder is a machine tool with close fitting parts and like most machine tools, it will last longer it taken care of. The BoreWelder should be wiped down after each use - particularly

When replacing the contact tips of the #00 and the

sliding parts like the quill and the off-set head. It is

#0 torches, it is important that the contact tip be

a good idea to lightly coat these parts with a dry

positioned correctly in the nozzle. The tip should

lubricant such as WD-40 , wiping off any excess

not be centrally located. Instead, the tip should be

lubricant with a clean cloth. This will keep the quill

secured so that its exit end is closer to the end of

and off-set head sliding freely while protecting

the torch nozzle as shown in Illustration 12.

them. Avoid using an excessive amount of a sticky lubricant which may trap dirt and cause the limit switch failure with resultant machine damage. If the BoreWelder is in some sort of permanent set-up, it should be wiped down frequently, and covered when not in use.

Longer term maintenance should include cleaning or replacing the liners, and inspecting the control cables for wear. Occasionally, inspect the torch and extension ends where they mate for "dings" and burrs. These parts require good surfaces for a gas seal.

If at some point it becomes difficult to insert the conduit into either the wire feeder or the

Illustration 12. Contact tips of the #00 and the #0 torches.

BoreWelder, the "o"-rings may have become dry or worn. If worn, replace. It may be helpful to apply a small amount of "o"-ring grease to the rings. The unit was shipped with lubricated "o"-rings.

Replacing Liners Liners in the BoreWelder and related parts seldom require replacement. When liners are suspected, usually the actual cause is that the wire is seizing in a hot contact tip. However, there are occasions when liner replacement is called for. In these cases, it is important to observe a simple, though not obvious, procedure.

If the liner is being installed in a portion of the BoreWelder in which it will form a curve, it is important to preload the liner. That is, press the liner into the torch or conduit until the liner is felt to be contacting the outer wall of the bend in the torch or conduit.

20

Operator Training

Suggested Training Procedure

We at Bortech feel that it is important for the users

Become proficient with BoreWelder usage using

of the Bortech BoreWelder to have had adequate

mild steel before any other alloys are used. 70s-6

experience in its use prior to using the equipment

or 70s-2 wires are good.

The BoreWelder is not a "turn key" piece of equipment. Although it

Use a wire with a large "cast". Cut about 6 feet

should not take long for operators to become

form an arc. The diameter of this arc should be as

proficient in its use, to start out with a real job can

large as possible. Typically we like to see a cast of

be a frustrating experience. Additionally, the

at least 40" diameter. Casts below 30" are likely to

operator may end up with a false sense of

cause difficulties. Consult with Bortech if unable to

competency if the first few jobs are completed

find large cast wires.

on an actual work piece.

from the roll of wire and toss it on the floor. It will

successfully. This can lead to frustration or failure

Read the "Set-Up Procedure" in the BoreWelder

on later jobs.

manual. It is a relatively short section and the

On a real job, the operator does not feel as though

information is useful - particularly items F and I.

he can alter machine settings just "to see what

Also read the "Use of the Adjustable Base" in the

happens" - he does not want to have to redo the

Optional Equipment section. There are several

job so he leaves the settings alone.

lines marked with an "*". These paragraphs are

Experimentation is a necessary part of the training.

particularly important. There is also a figure in the

The operator must learn how to recognize when the

back of the manual that should help with

build-up is not going well. It is possible, for

parallelism and centrality adjustments.

instance, to complete a build-up job only to

Practice in the vertical axis position first. This

discover that the build-up did not fuse to the bore

position should be mastered before any other is

surface. If an operator had no training, the job

attempted. Short sections of heavy wall pipe make

might progress to the point of boring the hole

good coupons. The bore surface should be clean.

before discovering such a problem. If it were a

It is a good idea to bore the coupons to be sure

time-critical job, then this would be a big problem.

they are round and clean. This is so that the

It is surprising how many times we learn of totally

trainee can focus on learning the operation of the

inexperienced operators being sent out to use the

machine without complicating the issue with dirty

BoreWelder on time-critical jobs. We hear of them

material. Try the dirty material later if desired -

because things did not go well and they need

after some experience has been gained.

bailing out. We of course do bail them out, but the job is usually delayed as a result of their

The operator should re-find the center each time a

short-sightedness.

coupon is welded rather than just place the coupon in a "jig" which holds the piece in a

Try to choose an operator who is good at finding

centered position. This way the operator gets

most of the options available and thinking

needed practice at this task. If this is done, it won t

problems through. Try to avoid operators who tend

be long before the operator is able to center the

to stop thinking at the first available solution to a

machine in less than 1 or 2 minutes - particularly if

problem. If possible, the operator should be the

the suggestions in the manual on centering are

kind of person who takes pride in doing a job well,

observed.

does not blame his equipment for his own failed thought processes, and who has a respect for

Bore some or all of the coupons to be sure of

machinery. Such an operator will probably learn

proper fusion etc.

very quickly, and perhaps more importantly, he will

Perform multi-layered build-ups.

continue to learn while on each job. The BoreWelder will also last longer and have fewer

When learning, it is probably best if the operator

problems, not only because of the increased care

measures the step and times the rotation and wire

that the BoreWelder will receive, but because of

speeds and writes them down. In this way he can

the increased understanding the operator will have

compare the measurements with what the manual

of the use of the machine and of its capabilities.

suggests and he will know how to repeat successful build-ups.

21

Note: Measure the step with a dial indicator or a

Finally, set the angle to 90 degrees (horizontal) and

scale. Measure the wire by jogging the wire for 10

begin welding. If difficulty is experienced that can

seconds and measuring the amount pushed by six

not be corrected, reset the inclined angle back to

to get ipm. Spindle rotation is

the last successful angle. Look for the same

(Dia * Pi * 60)/SecPerRev = ipm travel speed.

undesirable condition almost happening and try adjusting parameters to make it happen and make

While performing the build-ups, the operator

it go away. When it is felt that the mechanism for

should try varying each of the controls to see how

failure is understood, try the horizontal again.

it effects the build-up operation. Experimentation is a key element to an operator becoming

As stated elsewhere, the beginning of a horizontal

proficient. In addition, try to use Bortech s

build-up is critical. If done incorrectly, the welding

suggested parameters and try to learn to

thereafter can be difficult. Please read the section

recognize the build-up they produce. Once this is

on horizontal axis welding in the Bortech manual as

done, then feel free to find other parameters.

this should be helpful.

Once the vertical axis has been mastered, the

If the operator of the Bortech BoreWelder is trained

operator should build a jig to hold the BoreWelder

in this or a similar fashion, then he or she should

and the work coupons in proper alignment for

become very competent in a very short time. Our

welding (see sketch). It should be made in such a

experience has shown that this type of effort is well

fashion that the unit can be tipped at angles from

worth the investment.

vertical through horizontal. While the following may seem like an unnecessary extravagance, it will probably prove to be a worth while effort. Without

Welding Pointers

this effort, an operator will probably have little knowledge of how to control the weld puddle and

The Bortech BoreWelder has been designed to use

why failure occurs. About 60° to 75° of inclination

solid steel wire using the MIG welding process.

is an interesting angle because it is much easier to

The length of time that the BoreWelder can be

"recover" from a problem (e.g. "graping") than it is

used continuously is mostly dependent on spatter

at 90°. At 90°, conditions are more of an "either it

build-up in the welding nozzle. Therefore, a main

works or it doesn t" situation and when it doesn t,

objective when deciding what kind of wire, gas,

recovery is very difficult unless the operator knows

and power supply to use is usually to choose the

what to do to correct the failure. At 75°, the

combination that produces the smoothest and least

operator can more easily slip into the undesirable

violent arc action. Such a combination typically

condition and work his way out again - studying the

produces less spatter build-up and longer welding

bead behavior and the results of parameter

times.

adjustments. The operator can learn to recognize a trend toward a problem. Without this knowledge,

Wires with higher deoxidizer contents usually work

the operator will not be able to recognize when he

best. Wires E-70S-2 and E70S-6 work well, with

is close to the edge of failure.

E-70S-2 probably being the better choice due to finer spatter and less glass build-up in multi-layer build-ups. Any commonly used inert gas can be

Out of Position Practice

used, but those with high argon contents are to be

Weld several coupons at an inclined axis angle of

preferred. A mixture of 92% argon, 8% CO2 works

about 30° from vertical. This should be very similar

well as does 75% argon, 25% CO2. The former is

in operation to the vertical position.

generally preferred. Straight argon or helium should not be used for steel and straight CO2

Weld several more at an inclined angle of 45

produces a lot of spatter.

degrees. At 45 degrees, one begins to see what is going to happen at the horizontal position.

In addition, the welding wire should have a large

Although this position is very manageable, the

"cast". Cut about 6 feet of wire from the reel and

operator should try to study the weld puddle

throw it on the floor. The cast of wire is the

characteristics at various parameters.

diameter of the circle that the wire makes on the floor when it settles. A cast of 40" or more is

Steepen the angle to between 60 to 75 degrees.

desirable because it will reduce or eliminate the

Weld, experiment, and observe.

effect of the "wire flip" that can occur at each rotation.

22

If "wire flip" is a problem, you might try the following

At the beginning of the welding process, the first

to try to eliminate it: Try to avoid an "S" shape in

circular bead has no previously laid bead to rely on

the conduit. Position the wire conduit in such a

for support and is therefore a different shape than

way that the conduit makes only one continuous

those that will follow. It is best if the first step (at

curve. That is, the conduit should begin curving at

the end of the first revolution) be made slightly

its attachment point on the top of the BoreWelder

smaller than those that follow. In this way

and continue this curve for about 270° (3/4 of a

compensation will be made for the fact that the

turn) and then straighten out as it heads toward the

edge of the previous bead is probably slightly far

wire feeder. (Illustration 5 hints at this

away. An alternative might be to use a slightly

configuration). This method works particularly well

slower rotation speed or slightly higher wire speed

with long conduits. If the wire has a tight cast and

during the first revolution.

it still flips even in this configuration, you might try

The rotation surface speed in inches per minute

"tightening up" the curve somewhat (even though it

(IPM) can be checked by using the following

is probably counter to what you might think).

formula:

However, long torch extensions tend to negate any

(Diameter x Pi x 60)/IPM = seconds per revolution.

benefit that this conduit shape may have.

For example, for a 6" bore at 20" per minute:

Try to resist the temptation to use high welding

6 x 3.14 x 60/20 = 57 seconds per revolution.

voltages. The globular transfer that this produces is generally undesirable. Using a low voltage usually makes for a steadier, quieter, less violent

continuous welding between nozzle cleanings.

Welding in the Horizontal Axis

Also, if your welding power source has several

Welding in the horizontal axis requires that the

ranges, choose a range in which the lower end of

operator pay more attention to the machine

the scale will be used. This usually gives better

settings than when welding with the axis vertical.

results by providing a more stable welding arc.

In the horizontal axis, the weld bead must travel

Welding wire usually contains some silicon as a

through the flat, vertical-up, overhead, and

deoxidizer. During the welding process, this

vertical-down positions. The first half of the

changes to silicon dioxide (glass) and solidifies in

following discussion should make this task easier

clumps on the surface of the weld. These normally

by giving the operator insight and some solid

do not cause a problem, but it the step size

footing to stand on when he is trying to better his

becomes too small and the rotational speed too

skills in the horizontal. The second half presents

low, the glass clumps might become large enough

some practical suggestions.

arc. This produces less spatter and smaller diameter spatter beads allowing longer periods of

to interfere with the welding arc, producing small glass inclusions. (This does not normally occur).

Likewise, when many layers of build-up are applied one on top of another, the glass from the lower level is remelted and added to the new glass, forming larger glass clumps. It is therefore a good practice to clean the glass from the bore after several layers have been applied before applying more.

During welding, check to make sure that the step setting is providing appropriate axial movement each revolution. If the step is too great, the bead will appear ropy and possibly have spaces between the beads. If the step is too little, the surface of the weld may appear smooth and flaw free, but may in fact have fused poorly to the base metal. Make sure that the arc is directed slightly above the intersection point between the base metal and the previous bead.

23

Flat and overhead positions of the bore present no

So the remedy for most problems in horizontal bore

problems for the BoreWelder. When the torch is

build-up is to increase the rotation or decrease the

welding vertical-up, the weld of course has a

current or both. If the rotational speed becomes

tendency to run back downwards. If controls are

too great, the weld may also not flow in well and

set correctly, the solidifying weld metal forms a

may tend to undercut or hump into a stringy bead.

shelf that helps support the molten metal and

Using a wire size of .035" is fine unless problems

vertical-up is done as easily as flat. The fact that

are encountered. A wire size of .030", with less

welding is done against not only the bore surface,

current, and a smaller step is very manageable.

but the previously laid weld bead, also greatly

Although, if "wire flip" is present, "tie-in" is more

helps due to the small "V" created. Therefore, it

difficult with .030".

may be more difficult to obtain a well shaped first bead than the ones that follow. If the welding current (current is controlled by the wire speed) is

produces undercutting at the edge of the weld

Practical Suggestions for Successful Horizontal Axis Welding

bead. Increasing the rotational speed of the

Use the short arc MIG weld process. In most

BoreWelder helps to cool the weld, but only helps

instances, it is the only practical mode in which the

to a point. Decreasing the weld current (by

BoreWelder can successfully be used for

slowing the wire speed) should keep the weld

horizontal welding. It should be emphasized that

metal in place. Using a smaller wire and

an operator should master vertical axis bore

proportionately lower currents will produce a more

build-up before attempting the horizontal axis. The

manageable bead. A wire size of .030" should be

horizontal procedures follow:

too high, the arc may be too forceful and gouge the base metal. The gouged out metal will flow and form globules or "grapes", or in less severe cases, it may form a humped bead. This also

easy to manage and after some use one should be

The first few beads are the most critical. If the first

able to master .035" wire horizontally. The .035"

bead is not against a shoulder (or a previous

wire is the preferred wire size in most instances.

bead), the operator must use special care to insure

On the vertical-down side, the problems are

that this first bead is smooth and even. At the

different, but the cure is the same. The deposited

start, a reduced current is advisable (about 95

metal has a tendency to flow down hill with the

amps for .030" and 110 amps for .035" wire). A

welding arc. If the deposited metal does not

normal to slightly fast rotational travel speed is

solidify quickly enough, it will follow or even run

appropriate in order to promote fast freezing.

ahead of the arc, and in the process, use up all its

It is also advisable to set the step to a lower value

deoxidizers (the welding wire contains elements to

for the first step because the first bead is smaller

cleanse the weld). This produces porosity. Ones

and flatter than what will follow. After the first step,

normal reaction at such point is to increase the gas

increase the step size, but still to a value less than

flow, but this will probably not help. The remedy is

the full step. The reduced steps allow the first

to make the weld metal solidify in place quickly by

beads of build-up to attain the thickness of the rest

either speeding up the BoreWelder s rotational

of the build-up. The third bead should bring the

speed, decreasing the welding current, using a

thickness up to normal so the step can now be set

smaller wire size or a combination of the three.

to a normal value.

A second problem of the molten metal running

If the beginning of the weld is treated in this

ahead of the arc, is that the arc then "plays" on the

manner, the weld can then be deposited into the

molten metal rather than the base metal, resulting

"V" formed by the bore surface and the previously

in a lack of fusion to the base metal. This problem

deposited weld metal. This "V" helps the weld

is one that can easily go undetected until

bead to stay in place by:

machining the bore to size, at which time large

1. Providing increased heat sink area to freeze the

sections of the weld may be pulled away from the

weld.

base metal. The remedy for this problem is the same as for porosity.

2. Force the bead into a more controllable shape so that its surface tension will be more able to hold it in place.

24

Once the build-up is started in this way, the weld

Common Welding Problems and Their Cures

current can be increased. It is not uncommon to be able to weld smoothly at 140 amps using .035" wire.

A shielding gas of 75% Ar/25% CO2 helps to control the weld puddle by increasing the freeze rate. The CO2 increases the penetration into the deeper, giving the weld a head start at solidifying.

Lack of Fusion to the Bore Surface

When building up a horizontal axis bore, it is

This is usually caused by the step being too small.

important to minimize any dirt or rust in the bore,

If the welding arc is being directed mostly against

particularly the latter. Rust tends to make the

the previously deposited bead, then it is likely that

puddle more fluid and harder to control. In

the newly deposited weld metal will "cold lap" up

addition, rust is a poor conductor of electricity and

against the bore surface. It will be well fused with

therefore if the rust is particularly heavy, the arc

the weld metal cylinder, but not the base metal.

may have difficulty reaching the base metal evenly.

Set the step so as to direct the arc precisely at or

This causes "tie-in" problems which are

slightly above the intersection between the bore

accentuated in the horizontal axis.

surface and the previously laid weld deposit.

The inductance of the power supply plays a part in

Another possibility is that the rotation travel speed

horizontal build-up also. If the power supply has

is too slow for the wire speed being used. If

an inductance control (or "pinch" on some power

rotation is too slow, the welding arc will be directed

supplies) increasing the inductance will help flatten

on top of the currently melted weld puddle. If this

out the bead, make it blend in a bit better, and

puddle is too large and deep then the melting of

most importantly, keep it from piling up on the up

the base metal must be caused solely due to the

hill side and forming a tall narrow bead. These tall

heat of the weld puddle. Being only a little over

narrow beads tend to spill and expose new base

3,000° F, this is seldom enough. Instead the arc

metal for the arc to gouge and spill again. Note

itself, with a temperature of about 10,000° F and a

that if the control is labeled "pinch", higher pinch

very high heat density as well, will insure that the

values represent lower inductance.

base metal is melted before metal is deposited on

work piece thus depositing some of the heat

top of it. Slow rotational speed can also produce a

As usual, do not allow the arc voltage to climb too

bead thickness that is too great. This will

high. An arc voltage of 17 volts is about right. A

contribute to cold lapping as well.

high voltage will make the weld bead difficult to control, especially on the down hill side. On some

Lack of Fusion to the Previous Weld Bead of the Same Layer

occasions, it may be necessary to reduce the voltage to 15 or 16 volts for the first revolution. In order to attain reasonably flat, well-tied-in beads, continued welding at this lower voltage is usually not desirable.

Usually caused by too much step. The welding arc is playing too much on the bore surface and not enough on the previously deposited bead. Direct the arc at the exact intersection of the previous bead and the bore surface.

Also possible is that the arc voltage is too low.

Generally, it is unwise to use voltages below about 16V, but also resist the temptation to use voltages above about 18-19V. A voltage of about 17-1/2 is normal.

25

Lack of Fusion at the Root and General Inability to Control Bead

The cure for this underbead crack is usually to

Arc voltage too high for the current density. In a

HAZ. It also increases the thickness of the HAZ

increase the preheat of the work piece. Another possible cure is to slow down the rotation speed.

Either of these lessen the quench effect of the heat affected metal and thus reduce the hardness of the

bore, when the arc becomes too long (arc volts

making it less abrupt, reducing the stress riser

bears a direct relationship to arc length), the arc

effect.

tends to form a cone around the desired point of heating - the root. This cone can be hollow at its

Wire Burning Back to the Contact Tip While Welding

center. It is a shorter distance to most points at the periphery of this cone than it is to the root and therefore, it is the periphery that gets heated. The bead often "splits" into two distinct beads - one on

Refer to "Wire Feeding Stops And Wire Burns Back

the base metal and one on the previous bead.

To Tip".

Lowering the arc voltage will cause the arc to become more concentrated and heat the root.

Wire Feeding Stops And Wire Burns Back To Tip

This is usually most noticeable during any sort of spray transfer - pulsed or not. Unless the currents are very high (over the capacity of the 306-P),

This is usually caused by a mechanical blockage

there must be at least an occasional crackling

of the welding wire. It can be caused by a pile up

sound or the voltage is too high. A constant

of debris at the "cone" entrance to the contact tip.

crackle is more appropriate.

This debris gets jammed between the wire and contact tip bore. When the wire stops and the

Separation of the Build-up from the Underlying Base Material

welding power supply remains on, the wire burns

Separation of the weld from the base material

too hot, the wire may seize to it. If this is the case,

generally falls into two classes.

it probably means the arc voltage is too high and

back to the contact tip and the contact tip melts as it becomes the electrode.

Additionally, if the contact tip is allowed to become

lowering it should prevent the seizing and may

1. The weld did not fuse to the base metal, but

improve the welding as well.

instead merely "cold lapped" on to it. See "Lack of Fusion to the Bore Surface" above for further

Changing the liners is usually not necessary in

discussion.

cases of wire stoppage. Sometimes the liner right at the torch nozzle has become too hot and should

2. The weld did fuse with the base metal, but it

be replaced, but generally speaking the liners will

has now separated. This is often confused with

last a long time if blown out occasionally.

the cold lap described above, but it is usually caused by "underbead crackling". The weld fuses, but then due to excessive hardness, the

Wire Burning Back to the Contact Tip When Welding Is Stopped

stresses, combined with the stress riser formed from the different hardness s, causes a crack to form underneath the weld that propagates along the fusion line or HAZ (heat affected zone). Almost always the HAZ has become too

Burn back time of control box is set too long. A

hard to do its share of yielding to shrinkage

time of about 75 milliseconds is about right for both

stresses. In addition, the part configuration is

short arc and pulsed spray.

usually quite rigid forcing the weld to absorb most of the shrinkage forces and the sudden change in hardness at this HAZ, makes it a stress riser. The result can be an underbead crack.

26

Welding Wire Will Not Feed Through The Off-set Head

Too Much Spatter The usual cause for too much spatter is that the arc volts are too high. The arc should have a nice

This could be caused by a kink in the liner within

even sound that is not violent. A setting of 15-1/2

the off-set head. If so, it is best to find the cause of

to 18 volts is about right. Above 18 volts, the arc

the kink before proceeding. There are usually two

will become much more uneven and labored and

possibilities for causing this condition.

the transfer will become globular. This range is to

1. On the older style off-set head, there was no

be avoided.

physical stop to limit head travel. On these

The shielding gas also has a marked effect on

older machines, moving the head radially past

weld spatter. A shielding of argon with less than

the body could kink the liner.

15% CO2 is recommended (we use 92% Ar/8%

2. If the wire has become jammed and it is

CO2 a lot). More CO2 than his tends to cause

pushed too hard, the liner will be unable to

excessive spatter.

support the wire and the liner will collapse within the hollow off-set head space. This is

Torch Nozzle Becomes to Hot

usually only an issue with the "top mount" push-pull feed option. This option can be set to push the wire very hard. It is important to set

Usually the result of using an arc voltage that is too

the drive rolls loose enough not to cause this

high. If short arc is used, keep volts between

condition. A reading of about 2.0 on each of

15-1/2 and 18 volts. If pulse spray is used, adjust

the pressure rolls is about right. You should be

the parameters so that you can hear at least a

able to block the wire travel at the contact tip

slight crackle or use our recommended "Low

and have the system survive. In addition, the

Voltage Pulsing" method.

wire that was in the system should be as it entered it - straight.

Weld Beads Are "Ropy"

Spindle Rotation Becomes Jerky At Slow Speeds

To make the beads wet out more and become less

It is possible that the bronze rotatable power

ropy, an increase in the arc voltage up to about 18

couplings need to be resurfaced. This condition is

volts may help. But probably the most wetting will

usually the result of excessive currents. Please

be obtained by increasing the inductance of the

call Bortech and arrange to have them resurfaced.

system. Most welding power supplies have an inductance control. Watch what happens as you rotate the inductance knob. More inductance

Porosity In Weld

tends to spread out the weld puddle. Please note

Porosity is caused by impurities gassing in the

that as you rotate the inductance knob, the arc

weld. Although the welding wires used contain a

volts probably needs to be altered somewhat to

substantial amounts of deoxidizers and cleaners,

obtain optimum performance. (Lincoln power

there is a point at which these included substances

supplies have what they call a "pinch" control. This

can not keep up with the impurities. Some of the

is inductance, but it is labeled backwards with

reasons for porosity are listed below.

higher numbers being less inductance).

1. Problem with shielding gas. This might include

If the power supply does not have an inductance

a restriction in flow due to spatter build-up etc.

control, you can add inductance by wrapping

Or it could be that the gas flow is too high

either welding cable around a steel core. A piece

causing turbulence. A flow rate of 20 to 40

of heavy wall - 4" pipe or a 4" solid works nicely.

CFH is recommended. If the weld is not

Try one wrap at a time while welding. Typically 2

shielded from the atmosphere, the oxygen and nitrogen will react with the weld metal causing

to 5 wraps should be sufficient.

porosity.

A sign of too much inductance is difficulty in starting the arc - the wire tends to "stub" and has difficulty recovering. Also, if the electrode tends to stub excessively while welding and the arc volts are not too low, then you should suspect too much inductance.

27

2. Dirty bore surface. Although the BoreWelder

Weld Breaks Cutting Tools When Machined

usually handles these problems rather well, excessive oil, or other organic compounds could tend to cause porosity. These may be on

If tungsten carbide cutting tools are being used,

the surface or imbedded in crevices or grease

the cutting edge should be honed. Obtain a copy

holes. A thorough cleaning should be done

of "Welding With Machining in Mind" from Bortech.

prior to welding. Sometimes sand blasting or even premachining may be in order. In certain cases, preheating before build-up is done will

Excessive Undercutting Into Base Material

drive out the grease.

Steel Weld Too Hard to Machine

Usually not a problem with short arc transfer. If this problem occurs with pulsed spray, try increasing the wire speed and/or decreasing the

Assuming that the wire is a mild steel wire (i.e.

apparent arc voltage. It may be appropriate to

70S-Series), the ability to harden must be coming

decrease the rotational travel speed in order to

from the base material - mild steel will not respond

allow the weld to wash up and fill the area cut

to heat treatment. The base material must contain

away by the intense arc. Usually caused by

enough carbon and possibly other alloys to cause

excessive current.

it to be susceptible to heat treatment hardening.

When the welding wire is deposited on this base

Weld "Graping" When Welding In The Vertical Axis

metal, some of the base metal is melted and mixes with the welding wire. Thus, if there is enough carbon added to the deposit, it will also become

Generally, to prevent hardening, slow down the

During The First Several Revolutions

cooling rate. This can be accomplished by

During the first revolution, the weld bead must be

increasing the preheat of the part, and/or

applied to the vertical cylinder bore. During this

decreasing the rotational travel speed of the torch.

first time around, there is not yet a previous weld

Fast travel speeds produce a rapid quench of the

bead to act as a shelf to help support the bead.

weld beads.

For most normal work, this is not a problem. If it is

heat treatable.

a problem, use lower currents and voltages for the

One other thing to keep in mind, is that once the

first revolution. Often it may be advantageous to

weld bead is hardened, it can be tempered to

increase the travel speed slightly.

soften it. For this to happen, the weld must have

During The Rest Of Build Operation

cooled to below about 400°F and then be reheated to less than about 1250°F. The welding arc can often be used to accomplish this. Slow travel

If graping is experienced during the rest of the

speeds allow the welding arc to reheat the

build-up operation, it is probably due to the weld

previous beads thus having a tempering effect.

current being too high, although it could be that the

This can work surprisingly well. In addition,

travel speed is too slow. The bead becomes so

sometimes it can be advantageous to deposit

large that its weight overcomes the surface tension

another layer of weld on top of the hard layer solely

that holds it in place and the bead spills. It also is

to temper it.

possible that if the step is too great or too little,

If the build-up is still too hard, it can be postheated

graping will occur. In these cases, the bead will

after welding. If the build-up is brought to a

be unsupported and its surface tension will no

temperature of about 1000 to 1100°F, it will be

longer hold it in place.

However, it is important that the part be allowed to cool to below 400° F before the reheating is done. It is

Too Much Build-Up Thickness

also important not to allow any part of the weld to

Increase the rotation to 20 ipm. Set the step so

be raised above the critical temperature (about

that the arc is centered at the intersection of the

1300°F), even for a short time, unless you are

previous bead and the bore surface (this should be

prepared to do a full anneal with the associated

about a .120" to .140" step size). Keep weld

heat soaking and slow cooling.

currents within range of the BoreWelder - up to 150

machinable after cooling.

amps.

28

Note: In steel short-arc mode, the wire speed

Mechanical Troubleshooting

bears a direct relationship to the weld current.

Using .035" 70S-6 wire, 92% Ar/8% CO2 shield gas, the following currents can be obtained with the approximate wire feed rates shown:

Machine Will Not Step

100 amps. @ 16V = 170 ipm (inches per minute) 125 amps. @ 16-1/2V = 200 ipm

1. Step switch on the side of the control box may

150 amps. @ 17V = 280 ipm

be in the OFF position. This switch will also prevent the BoreWelder from initializing.

On Breaking Failure, the Break Appears Made Up of Large Grains

2. Step limit switch in BoreWelder may not be working properly. Check pins 3 and 14 of the BoreWelder s AMP connector for continuity.

Rotating the BoreWelder spindle by hand so that the step switch drops into the detent

This indicates that the grain on the steel was

should cause continuity. If it does not work,

probably allowed to grow too large. The weld

remove the red shroud and check the switch

metal itself will probably still have a fine grain

directly - the wiring may be at fault. Also, be

because of the grain growth inhibitors added to the

sure that pin 3 shows no continuity to the

welding wire.

BoreWelder frame.

At somewhat under 1400°F, steel reforms its grain

3. Control cable may be damaged. Check for

structure to a fine grain. The higher the

continuity between pin 14 at BoreWelder end

temperature above 1400°F and the longer this

and pin 8 at control box end. Then check for

temperature is held, the larger the grain of the steel

continuity between pin 3 at BW end and pin 9

will grow. Therefore, it is not a good idea to heat

at control box end. Both should have continuity.

steel to temperatures above about 1300°F for long

4. There may be a problem with the control box. If

periods if one is concerned with grain size. If a

all of the above check out, then it is likely that

large section of the part being welded is at a red

the control box is at fault.

heat, there will probably be grain growth.

Large grain does not appreciably weaken the steel

Machine Cannot be Retracted or Extended

in a tensile test, but it does adversely effect its ability to stand up to repeated loading and yielding. A large grained steel is susceptible to

1. Motor failure. Can you hear the motor operate

fatigue failure if vibration or repeated heavy

when either RETRACT or EXTEND is pressed?

loading, especially shock loading, is encountered

If yes, then skip to step 4. [There should be

in service.

continuity between BoreWelder pins 1 and 9 (through the motor armature). If no continuity, it is possible that a light tap on the side of the motor will restore operation.

If so, then please contact Bortech for a new style of motor brush.]

When the BoreWelder is used properly, grain growth is seldom a problem.

2. Wiring problem. There should be continuity between BoreWelder s AMP connector pins 3, 6, and 13 when the quill is not at an extreme end of stroke.

3. Control box problem.

4. Worm roll pin sheared. If motor operates, but quill does not move, then it is likely that the roll pin is sheared. This is usually due to a quill travel limit switch failure caused by dirt and grease restricting limit feelers. Be sure this is corrected before putting machine back in service.

29

Nothing Happens When Weld Button Is Pressed

The Control Box

1. Machine is completely retracted. Press

governs all welding parameters and can be

The control box has been designed so that it

EXTEND to move the quill off its limit and try

brought close to the hole to be built-up. It controls

again.

the BoreWelder, the wire feeder, and the welding power supply.

2. Control box failure.

The control is made to allow axial jogging of the quill both during set-up and while welding. The

Machine Moves Or Welds Without Having Pressed The Buttons Which Control These Actions

travel of the quill has two speeds. When the BoreWelder is not welding, pressing either of the jog buttons moves the quill at the faster of the two speeds. This is for rapid movement as in set-up.

When the BoreWelder is welding, the quill movement is at a slower speed - that of the step

1. Membrane switch panel or cable damaged -

speed. This is because it is unlikely that one would

usually by spatter.

wish the quill to move rapidly while welding, but rather finer adjustments would be more desirable.

2. Control box failure.

The BoreWelder has limit switches to monitor the quill travel and prevent its over-travel. Jogging the

Wire Flip

quill in either direction to a limit will halt its travel in that direction. When the BoreWelder is welding, and the upper limit is reached, the control shuts down the welding and stops rotation just as if the operator had pressed the weld switch again.

The motor controller for the wire feed motor is contained in the control box. It has been designed to bring the wire feeder up to speed slowly (about 1/4 to 1/2 of a second) instead of snapping it into action. This "soft start" may make the wire feeder appear "spongy" or non-responsive, but it is actually operating as intended. Soft start has been designed into the wire feed control to make welding starts more reliable. When welding is first

Illustration 13. Position BoreWelder Conduit In This Position To Help Prevent Wire Flip.

begun, the wire speed is slower than the set speed. With a slower wire speed, the set arc voltage seems slightly high and the initial arc length is therefore longer than would normally be

If wire flip is a problem, try to avoid having an "s"

used for that wire speed. This helps prevent

shape curve in the conduit. Position the conduit as

stubbing of the wire on starts. After the arc has

shown in Illustration 13 with a continuous curve

been initiated and a puddle established, the wire is

from the top of the BoreWelder and then

brought up to speed. The set voltage is then

straightening out before going into the wire feeder.

presumably correct for the wire speed and the arc

This method works particularly well with long

length is therefore then of an appropriate length.

conduits. If the wire has a tight cast or continues

The control incorporates a burn-back timer to

to flip, try making the radius of the curve smaller.

prevent the wire from welding to the puddle when

As more torch extensions are added, this method

shutting down. If welding in the spray or

becomes less effective.

pulse-spray transfer modes, it may be desirable to reduce the burn-back time to zero to prevent the wire from fusing to the tip during shut-down. If this is the case, contact Bortech. There is also a timer on the gas solenoid to provide post flow of shielding gas.

30

The step size is governed by varying the time

Control Box Preservation

duration of the step. The step speed is fixed so the

The control box should be shielded from welding

angle of ramping to the next bead is constant.

spatter or located where spatter does not strike it.

ARC INTERRUPT stops the welding while

Failure to do so could result in damage.

continuing the other functions such as rotation and step. This persists as long as the button is

The control box is provided with rubber feet for

depressed.

physical protection, to keep it from sliding easily, and to electrically isolate it. Failure to electrically

When held depressed, ROT INIT (rotation initialize)

isolate the control box could cause welding current

jogs the spindle rotate motor until the switch is

to flow into the box, thereby damaging

activated that would begin the stepping action (if

components. It is therefore important that the

the unit were actually welding). At this point,

rubber feet not be removed and that the isolator

rotation is halted. In this position of rotation, the

pad provided with the machine be placed beneath

ROT INIT, if pressed again, has no effect. If it is

the control box at all times.

desired to rotate using this button again, it would be necessary to jog the rotation (using ROT JOG)

Note: The control box does not have to be

to a new position off of the stepping switch and

"powered up" or welding in order for damage to

press ROT INIT button again.

occur.

If the BoreWelder s mounting plate is not electrically connected to the work piece, the

Adjustments

control panel s arc voltage meter will not register.

In such case, it will be necessary to attach a small

Off-Set Head Dovetail Adjustments

wire between the BoreWelder mounting plate and the ground clamp.

The dovetail of the off-set head must be adjusted

The control box is capable of operating the two

so that the sliding member presses snugly against

types of welding power supply contactors. The

its seat and yet can still slide from side to side.

power supply control cable used determines which

Adjustment is made by tightening the two 10-32

mode the control operates in. In one mode, the

socket head cap binder screws (use 5/32 inch

power supply supplies contactor coil current and

hex wrench) that secure the side plate (Illustration

the control box merely completes the circuit to

4). They should be adjusted so that the head can

activate the welder. The A-1061 Cable supports

slide but with difficulty - it should require external

this mode of operation. In the other mode, the

hand pressure in addition to the turning of the

control box supplies 110 VAC contactor coil

knob. If the head is not tight enough, the gas seal

current to activate the welder contactor. The

between the members might fail contaminating the

A-1063 Cable supports this mode of operation.

inert gas. Additionally, looseness will add

IMPORTANT! To summarize: The A-1061

electrical resistance causing heat at the interface.

completes a circuit, and the A-1063 provides

In deep hole horizontal welding, the weight of the

switched current to the contactor.

torch and extensions tend to pry the off-set head from its seat. To prevent a gas leak, after being adjusted, the head may need to be clamped tightly in place using the two clamping screws also located on the side plate (Illustration 4). One should consider the use of the torch extension

Do not tighten the binder screws in such situations. support kit in such situations.

31

Suggested Method For Setting The Wire Feeder Drive Rolls

The welding wire is pushed by the wire feed drive rolls through the various liners of the BoreWelder system and exits the system at the contact tip.

With the wire feeder s conduit attached at the wire

Within these liners, the welding wire can be

feeder, but not attached to the BoreWelder, jog

thought of as a column that is expected to support

welding wire until it exits the free end of the

the "weight" of the feed rolls pushing on the wire. A

conduit. Clip off any excess wire flush with end of

column is very strong provided that it remains

the conduit fitting. Hold the free end of the wire

straight and that its load rating is not exceeded

feed conduit up to a hard surface (like that of a

(like the ones in your basement used to support the

table edge) and jog the wire feed rolls. The rolls

floor). As soon as the column becomes bent, its

should slip on the wire. Then allow the wire to exit

load capacity diminishes enormously. If the

from the conduit freely and jog the wire until the

column became bent due to overloading, then

entire length of wire that was in the conduit has

suddenly the column would no longer be able to

been expelled from the conduit. The wire that was

support anywhere near the loading that caused the

inside the conduit should not have any "sine wave"

bending, and there would be an immediate and

effects - it should be "crinkle" free. If present, the

total collapse.

effects will begin where the wire was near the feed

Relate the above to your BoreWelder. Although the

rolls - perhaps 10" away from them.

welding wire is often guided through a curved path

Tighten the feed rolls slightly. Then recheck for the

as it goes through the BoreWelder, it is able to

sine wave effect as above. Repeat this until the

retain its "column" properties because it is

effect appears. Then back off the pressure on the

supported by the liner and the curves it goes

rolls until the effect disappears. This will be the

through are relatively gentle. As the wire is pushed

correct roll pressure. In other words, the wire

through these curves, it bears against the outside

feeder drive rolls should be set so that when a

of the curve, pressing against the outer wall of the

stoppage occurs the wire feed rolls slip and the

guiding liner. This is how it should be.

wire does not crinkle. Note the markings on the roll tensioners for future reference. For .035" diameter

Now, it the wire is pushed too hard and its column

wire, the rolls will probably be set for a marking of

strength is exceeded, then the wire column tries to

about 2 to 2-1/2 on the adjuster barrel.

collapse. Instead of a total collapse as would be expected of a basement column, the wire becomes

Wire Feed Drive Roll Pressure And Wire Seizing

supported on all sides by the guide liner. The wire bends one way and then the other repeatedly into

Often when any sort of wire feeding problem

a sine wave shape of a "crinkling". What this

occurs, an operator s first instinct is to increase the

means is that a substantial portion of the axial

pressure of the wire feed drive rolls. His hope is

loading on the wire is transferred to a radial force

that pushing the wire harder will solve the problem.

trying to expand the liner. This radial force can be

This will not help. Instead, the feed rolls should be

quite severe and the result is great friction that

set correctly and if wire feeding problems are

translates into enormous resistance to the axial

encountered, the real cause should be found and

travel of the wire. This resistance to travel is in

corrected. It is my hope that the following

addition to the original resistance that was present

discussion will show why this temptation to over

before the sine waving occurred. Once the wire

tighten the feed rolls should be resisted.

loses its column, the harder the wire is pushed, and the tighter it locks itself in the liner.

32

There is at least one more reason that a sine wave in the wire is detrimental to feeding. In addition to the axial locking effect described above, once the wire loses its column properties, it becomes axially springy. Some of the axial force can be diverted into radial movement - stealing from the axial movement. This is a problem in that it allows small increases in wire feeding resistance to stop the wire travel while the springiness of the wire absorbs the axial movement. Then the wire jumps ahead suddenly as the stored energy is released from the spring. The springiness of the wire will encourage what is called a "stick-slip" situation where the wire repeatedly first sticks in the system, then slips.

The feeder drive rolls should be set so that they push the wire with enough force to feed, but not so much force so as to wave the wire. That way a slight momentary stoppage (which is bound to occur from time to time) can go by unnoticed. So,

do not over tighten feed rolls.

As said at the beginning of this discussion, if wire feeding problems are encountered, rather than over tightening the feed rolls, the real cause of the

Illustration 14. Wire feed drive roll pressure and wire seizing.

problem should be found and corrected. Most wire feeding problems are from foreign material jamming in the contact tip or the contact tip becoming too hot, which results in the wire seizing

From the preceding paragraph, it should be

within it. If the later is the case, it probably means

evident that as long as the loading remains, it will

the arc voltage is too high and lowering it should

be useless to try pushing the wire through the liner

prevent the seizing and may improve the welding

once it has lost its column and formed the sine

as well.

wave bending. Since much less of the axial force will actually be available to push the wire through the system, the result will be a stoppage of wire movement. This indicates that it is important not to exceed the column strength of the wire or a shutdown of the equipment will occur. If the wire feeder drive rolls are set too tightly, then even a momentary seizing of wire in the contact tip may set off an irreversible trend to sine wave the wire which will lead to a shutdown. If the wire becomes crinkled, its resistance to being fed will multiply due to its loss of column, adding greatly to the resistance that made it crinkle in the first place.

33

Parts 306-P BoreWelder

34

306-P BoreWelder Parts List Part No.

306-P BoreWelder Parts List

Item

Qty.

Item

Qty.

1

1

External Retainer Ring

42

1

Nut

2

1

Washer, Spindle Spring

43

1

Retractile Cord

3

1

Spring, Thrust

44

2

Bracket, Motor Cover

4

1

Bearing, Thrust

45

1

Cover, Rotation Motor

5

1

Isolator, Rot Power Coupling

46

4

Screw

6

1

Rot. Power Coupling, Slip

47

1

Cover, Step Motor

7

1

Screw

48

3

Screw

8

1

Rot. Power Coupling, Pulley

49

1

Cover, Gear Train

9

1

Screw

50

1

Thrust Shim, Gear Train

10

1

Cable, Welding #2

51

1

137-2685

Gear, Worm

11

1

Screw

52

1

137-2686

Pinion, Rack

12

1

Connector, Power Quick Cpl

53

1

Dowel Pin

13

1

Washer, Power Quick Cpl

54

2

Screw

14

1

Washer, Power Quick Cpl

55

1

Roll Pin

15

1

Nut, Power Quick Cpl

56

1

Motor, Step

16

1

Shroud

57

1

Worm

17

7

Screw

58

2

Screw

18

1

Liner

59

1

Plate, Motor Adapter

19

1

Screw

60

1

Screw

20

1

Stem, Swivel Connector

61

1

Screw

21

2

Bearing, Swivel

62

1

Positioner, Quill

22

1

Seal

63

2

Bearing, Quill

23

1

Body, Swivel Connector

64

2

Bushing, Insulating

24

1

Fitting, Spindle Conduit

65

1

Tube, Quill

25

1

Liner

66

1

Spindle, Main

26

1

"V" Belt, Rotation

67

1

Body, Off-Set Head

27

1

Pulley, Motor

68

1

Side Plate, Off-Set Head

28

1

Screw

69

4

Screw

29

1

Screw

70

1

Screw

30

1

Terminal Strip

71

1

Adjuster, Off-Set Head

31

4

Screw

72

1

Rack, Off-Set Head

32

4

Flat Washer

73

1

Screw

33

1

Screw

74

1

Slide, Off-Set Head

34

6

Screw

75

1

Orientation Fitting

35

1

Switch, Step Limit

76

1

Nut, Orientation Fitting

36

1

Screw

77

2

Screw

37

1

Mount, Motor

78

1

Pin, Clamp Locator

38

1

Motor, Rotation

79

2

Feeler, Rack Limit

39

1

Screw

80

2

Spring, Quill Limit

40

1

Clamp, Nylon Cable

81

2

41

1

Flat Washer

82

1

137-2682

137-2681

137-2683

Part Description

35

Part No.

137-2684

Part Description

Switch, Quill Limit Block, Travel Limit Mounting

306-P BoreWelder Parts List Item

Qty.

83

2

Part No. Screw

Part Description

84

1

Bolt, Clamping

85

1

Washer

86

1

Tubing, Step Motor Wire

87

1

Grommet

88

1

Cover, Switch

89

6

Screw

90

1

Receptacle, BoreWelder

91

2

Screw

92

1

Rack,

93

1

Knob

94

1

Insert (Short), Cable Clamp

95

1

Insert (Long), Cable Clamp

96

1

Pin, Worm Guide

97

1

Shim, Inner Gear Train

Quill

36

Notes

37

Wire Feeder

38

201 Wirefeeder Parts List Reference Number Part Number Used Number

201 Wirefeeder Parts List Reference Number Part Number Used Number

Part Description

Part Description

1

2

Plug, Tubing (1 x 3)

41

2

Washer, Wire Feed Roll

2

2

Plug, Tubing (.75 x .75)

42

2

137-2688

Roll, Wire Feed (.024/.030)

3

1

Support, Reel (Includes:

42

2

137-2689

Roll, Wire Feed (.035/.045)

43

1

Terminal, Male Insert,

44

1

Terminal, Male Insert

Screw, Flat, and Lock Washer)

6.4 mm (.250 in) 4

1

Frame, Wirefeeder

5

2

Grommet

6.4 mm (.250 in)

6

2

Isolator, Screw

45

1

Inlet Guide

7

2

Washer

46

1

Bracket, Pull Feeder Switch

8

2

Screw

47

1

Switch, CPDP

9

1

Receptacle, 9 Pin with Wires

48

2

Nut

10

8

Screw

49

2

Screw

11

1

Plug, Quick Disconnect

50

1

AMP Receptacle, 4 Pin

12

2

Screw

13

1

Valve, Solenoid

15

1

1/4 Hose to 1/8 Male NPT

16

8

Nut

17

2

Screw

18

1

Choke, 56 mH

19

6

Screw

20

6

Feet, Rubber

21

3

Screw

22

1

Cover, Right

23

3

Rivet

24

1

Latch, Draw

25

3

Screw

26

1

Cover, Left

27

1

Tubing

Female 51

28

1

Fitting, 1/4 Hose to 1/8 NPT

29

1

Thumb Screw

30

1

Screw

31

1

Liner

32

1

Fitting, Feeder Conduit

33

1

Lock Nut

34

1

Guard, Gear

35

2

Nut

36

2

Washer

37

1

Isolator, Feeder

38

1

Feed Mechanism

39

1

Screw

40

2

Screw, Wire Feed Roll

39

2

Hose Clamp

Wire Feed Conduit

40

Wire Feed Conduit Parts List Item

Qty.

1

2

Part No. Screw

2

1

Nipple, Nipple (Wire Feed End)

3

2

4

2

Two-Ear Hose Clamp

5

1

Hose, Hydraulic

6

1

Liner

7

1

Fitting, Conduit to Spindle

8

1

Nut, Conduit to Spindle

9

1

Stabilizer, Liner

3J-1907

Description

014 O-Ring

41

Torches

42

Torches Parts List Item

Qty.

1

1

137-2699

Part No. Tip #00

Description

2

1

137-2682

Liner

3

1

Screw

4

1

#00 Torch Body

5

1

Screw

7

1

137-3586

Tip, #0

8

1

137-2682

Liner

9

1

Screw

10

1

#0 Torch Body

11

1

Screw

12

1

137-3387

Nozzle

13

1

137-2704

Tip (.035)

14

1

137-2705

Diffuser

15

1

137-2682

Liner

16

1

Screw

17

1

#1 Torch Body OR ONE OF THE FOLLOWING: #2 Torch Body #3 Torch Body #4 Torch Body #5 Torch Body #6 Torch Body #7 Torch Body #8 Torch Body

43

Trammel Torch

44

Trammel Torch Parts List Item

Qty.

1

1

Part No.

2

1

Screw

3

2

1/4 Tube to 1/8 Male NPT

4

1

Screw

5

1

Hub Assembly

6

1

Radius Assembly

7

1

8

1

9

1

Screw

10

1

Rod, Torch Head

11

1

Thin Spacer

12

1

137-3386

Holder, Nozzle

13

1

137-2705

Diffuser

14

1

137-2704

Tip (.035)

15

1

137-3387

Nozzle

16

1

Alternate Style Welding Head

17

1

Screw

18

1

Thick Spacer

137-2682

Description Liner

Screw 140-0459

Hose, Gas

45

Radial Facing Torch

46

Radial Facing Torch Parts List Item

Qty.

1

1

2

Part No.

Radial Facing Torch Parts List Item

Qty.

Liner

40

1

Screw

1

Screw

41

1

Thin Spacer

3

1

Hub, Radial Torch

42

1

Shim

4

1

Gear, Bevel

5

1

Spacer, Gear

6

1

Block, Hub

7

3

Screw

8

1

Screw

9

1

Pinion, Bevel

10

1

Rod, Guide

11

1

Screw

Screw

12

1

Square, Guide

13

1

Rod, Tommy

14

1

Block, Travel

15

1

Washer

16

1

Screw

17

1

Acme Nut

Nut

18

2

Screw

19

1

Block, End

20

2

1/4 Tube to 1/8 Male NPT

21

1

Radius Assembly

22

1

Screw

23

1

24

1

Screw

25

1

Rod, Torch Head

26

1

Thick Spacer

27

1

137-3386

Holder, Nozzle

28

1

137-2705

Diffuser

29

1

137-2704

Tip (.035)

30

1

137-3387

Nozzle

31

1

Extender, Radial

32

1

Screw

33

1

Screw

34

1

Washer

35

1

Screw

36

1

Washer

37

1

Washer

38

1

Cable Assembly

39

1

Alternate Style Welding Head

137-2682

140-0459

Description

Hose, Gas

47

Part No.

Description

For information on service tools or shop supplies contact Caterpillar Service Technology Group on:

Caterpillar Service Technology 100 N.E. Adams Street Peoria, Illinois 61629-9110 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6618 (Fax)

or

Caterpillar Service Technology Caterpillar Overseas S. A. P.O. Box 6000 1211 Geneva 6 Switzerland 41 (22) 849 40 36 (Geneva Phone) 41 (22) 849 45 44 (Geneva Fax) 413323 (Geneva Telex) CATOVERSEA (Geneva Cable) 36CSTG (COSA E-Mail Address)

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