v 1811

‘. MAINTENANCE INSTRUCF~N
a./-+,
ELECTRO-IiOTIVE DIVISION
GENERA1 MOTORS COlPORA~lON . 1A GRANGE. ILLINOIS, U. S. A.

WELDING INSTRUCTIONS FOR CARBODY REPAIR

GENERAL DESCRIPTION ends of the crack, scarifying out the

cracked area by chipping, grinding or
Procedure for the welding repair flame cutting and welding between bobs.
of the locomotive carbody will necessar- Holes drilled at the end of the crack,
ily present individual problems which should be magnafluxed to make sure
will require separate methods of pro- that the end of the crack has been
cedure for these repairs. These indi- reached.
vidual problems may be directed for
attention ,to the Service Department. In Figure 1 shows method to be used
this instruction we endeavor to cover in splicing "II" section such as center
repair which may generally be applicable sills, bolster posts, roof members and
in the majority of repairs to the car- side frame members. Diamond rein-
body. forcing plates are recommended where
the size of member permits. The center
When any welding repair is made sills are the "H" beams extending the
to a locomotive, care must be taken as length of the locomotive tying into each
not t o provide-1 ‘@current path through bolster and to which the generator
any of the working equipment of the mounting pads are welded. The bo
locomotive such as, journal boxes etc. posts are the main upright carbody faa
The ground connection should be made members forming an aroh directly over
directly to the locomotive frame. each bolster. Figure 2 shows a repair
made by removing a damaged flange
The following recommendations section and replacing with a new section.
cover typical repair methods used in
repairing damaged carbody structural Figure 3 shows a typical splice in
members. In general, all splices should the side sill “Z ” bar. Diamond patches
be made on a diagonal across the flange are recommended. The side sill “Z” bar
of the member. Diamond reinforcing is the structural member extending the
plates should be used wherever practical. length of the locomotive on the bottom
Overhead welds should be reduced to a outer side and to which the side carbody
minimum. All weld passes should be frame members are welded as shown in :;
parallel with the joint or crack and no Fig. 4.
weaving will be permitted. Multiple pass
welds should be peened after each pass If a side sill “Z ” bar, Fig. 4,
to decrease the weld shrinkage and clean Item #4 outer flange only is
the weld. Always magnaflux the first repair by straightening. I f “Z” b a r
pass. Magnaflux between subsequent flange and web is damaged, remove
layers of weld passes. Cracks in under- damaged section between framing mem-
frame members, not otherwise damaged bers such as “A” and “H, ” and spHce
may be repaired by determining the in a new section. If side sill is buckled,
extent of the crack by magnaflux inspec- as between “A” and “C ” remove gussets
tion, then drilling a hole at the end/or and detach items 1, ‘2 and 3 in the
June, 1948
September, 1e40
 OPEN TO ALLOW

IF DIAMOND REINFORCING
PLATE IS USED

A-A;
IF DIAMOND PLATE IS NOT USED
I x I

REINFORCING PLATE IF USED

ISE USE BACKUP PLATE
“&i k

I TIMES Pt%TE l-l/2 TIMES

LTHIGKNESS ROD DIA
/zA I
“/
,/,9
,‘,‘,’
----------Y-Lm-----e
/I/
-------,~,~------
///I
/;+c
\
1 //

I TIMES THICK-
N E S S O F O P L PATE

Fig. 1 - Splicing ‘H” Section

effected area, Straighten or replace “2 ” the finished panels, This condition is

bar and reweld framing members. Dam- particularly noticeable in locomotives
aged side framing members such as finished in dark paint colors. Repaired
Item 1 and 2 can be most satisfactorily panel support members usually result
repaired by replacing the damaged sec- in misalignment of batten bolts.
tion.
No attempt should be made to
A damaged flange may be straight- straighten the center sills. The damaged
ened or repaired as indicated in Fig. 3. section should be removed and replaced
Damaged side panel support members, following: instructions shown in Fig. 1.
Itam 3 of Fig. 4,, should be replaced Transverse underframe members may be
sinqe slight bends in these members repaired by straightening damaged flanges
resuits in an exaggerated wave effect in or by repair methods shown in Fig. 1 or 3.

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 M.I. 1811

Fig. 2 - “HI’ Section Flange Repair

j$

Fig. 3 - Typical “Z” Bar Repair’

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 On page 4 is given the recom- ification code and may be purchased from
mended welding electrode for various many electrode manufacturer’s. By the
applications on the locomotives and parts. use of a electrode comparison chart,
The welding rod is identified by the the AWS specification designation of a
AWS (American Welding Society) spec- particular company may be obtained.

6-Q3

Fig. 4 - Carbody Frame Repair

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“..c_-I.. -_I.-- ---

 M.I. 1811
I ‘

Part Locomotive Type Electrode - Type

Journal Box Wear Plate All AWS E-310-15 Lime

Lube Gil Tanks Galvanized AWS E-6010
Lube Oil Tanks Stainless AWS E-347-15
Fuel Gil Tanks All AWS E-6012
Water Tanks Mild Steel AWS E-6012
Water Tanks Galvanized AWS E-6010
Traction Motor Gear Cases All AWS E-6012
Coupler Pockets Passenger AWS E-6012
Coupler Pockets Switcher AWS E-6012
Coupler Pockets Freight AWS E-7010 D.C. - E-7011 A.C. .
Sand Boxes All AWS E-6010 D.C. - E-6012
Battery Boxes All AWS E-6012 - E-6013 A.C.
Spring Holder All AWS E-6012 qi
Truck Frame Passenger AWS E-7010 - 7011.
Truck Frame Switcher AWS E-6010 D.C. - E-6012
Truck Frame Freight AWS E-7010 - 7011
Spring Plank All AWS E-7010 D.C. or E-7011 A.C.
Bolsters (Carbody) Freight & Passenger AWS E-7010 D.C. - E-7011 A.C.
Cross Bearers All AWS E-7010 D.C. - E-7011 A.C.
Underframe Passenger AWS E-7010 D.C. - E-7011 A.C.-/
Underframe Freight AWS E-7010 D.C. - E-7011 A.C. I
Underframe Switcher rAWS E-6012 - E-6015 D.C.
Front & Bear Platform Passenger AWS E-7010 D.C. - E-7011 A.C.
Front & Bear Platform Freight AWS E-7010 D.C. - E-7011 A.C.
Side & Front Framing All AWS E-7010 D.C. - E-7011 A.C.
Roof & Hatches All AWS E-6012
Roof & Hatches Stainless AWS E-308-15 or 308-16,?
End Sheets - Air Ducts All AWS E-6012 - E-6013
False Ceilings All AWS E-6012: - E-6013
Pipe Clamps All AWS E -6012:
Engine & Gen. Pads All AWS E-6012:
Frog Hooks Switcher AWS E-6012
Fuel Tank Supports All AWS E-6012
Bolster Switcher AWS E-6012
Underframe Side Brgs. All AWS E-6012 ui
Air Reservoir Brackets Switcher AWS E-6012
Push Pole Pocket All AWS E-6012
End Plates Switcher AWS E-6012
Cable Cleats Switcher AWS E-6012
Step and Skirt Switcher . AWS E-6012
Hoods and Cabs Switcher AWS E-6012 ‘- E-6013
Ballast - EMD Appl. A l l AWS E-6012
Floor Plates AU AWS E-6012 - E-6020 J
Base Angles Switcher . ,. p-WS E -6012 -, E -6020
:
..
Diameter of electrodes mentioned above is governed by thickness of material to be welded.
All overhead welding shall be done with 118 ” or 5J32 ” diameter- electrode.
All vertical welds shall be done with l/8” or 5/32” diameter electrode.
Electrodes not exceeding l/4” in diameter should be used for down hand or horizontal
welds. v-y. )
a..
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