Caterpiller 306-P BoreWelder Tool Operating Manual – PDF DOWNLOAD

Introduction 3

Precautions and Rules of Safe Operation 3

Additional Welding Precautions 3
Limited Warranty 4

Product Description and Theory of Operation 4

Specifications 4

Nomenclature 5

Major Assemblies 6

Power Supply Compatibility Information 8

Set-Up Procedure 9

Initial Set-Up Procedure 9
Set-up Procedure for Wire Feeder Conduit Attachment 11
Wire Loading and Feeding 12
Final Set-up 12
Description and Use of Optional Equipment 14

Use of the Adjustable Base 14
Set-up Procedure 15
Radial Mount 16
Torch #00 and #0 16
Torches #1 Through #8 17
Trammel Torch 17
Procedure 17
Face Welding Torch 18
Procedure 18
Torch Extension Support Kit 19
Procedure 19
Auto-Skip Option 19
Maintenance 20

Daily Maintenance 20
Replacing Liners 20
Replacing #00 and #0 Contact Tips 20
Operator Training 21

Suggested Training Procedure 21
Out of Position Practice 22
Welding Pointers 22

Welding in the Horizontal 23

Practical Suggestions for Successful Horizontal Axis Welding 24

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
Separation of the Build-up from the Underlying Base Material 26
Wire Burning Back to The Contact Tip While Welding 26
Wire Feeding Stops and Wire Burns Back to Tip 26
Wire Burning Back to the Contact Tip When Welding Is Stopped 26
Welding Wire Will Not Feed Through the Off-Set Head 27
Weld Beads Are “Ropy” 27
Too Much Spatter 27
Torch Nozzle Becomes Too Hot 27
Spindle Rotation Becomes Jerky at Slow Speeds 27
Porosity in Weld 28
Steel Weld Is Hard to Machine 28
Weld Breaks Cutting Tools When Machined 28
Excessive Undercutting Into Base Material 28
Weld “Graping” When Welding in the Vertical Axis 28
Too Much Build-up Thickness 28
On Breaking Failure, the Bead Appears Made Up of Large Grains 29
Mechanical Troubleshooting 29

Machine Will Not Step 29
Machine Cannot be Retracted or Extended 29
Nothing Happens When Weld Button Is Pressed 30
Machine Moves or Welds Without Having Pressed the Buttons Which Control These Actions 30