REVISION 01

PROCEDURE NO: PR060041

Disconnect 3 connectors from VECU

Disconnect 3 connectors from CECM

Disconnect connector A 83 under Volvo Link
module

Page 15 of 27

REVISION 01

PROCEDURE NO: PR060041

2.30

Location: Pneumatic accessory panel inside right
console
Remove the access panel on the right console
(R.H. side of dashboard)
Disconnect both I/O B modules

2.40

Location: Condenser Compartment

Disconnect connector A 137

Page 16 of 27

REVISION 01

PROCEDURE NO: PR060041

2.50

Location: Evaporator Compartment
Disconnect A 54 module located
evaporator compartment, on the door.

2.60

2.70

REVISION 01

inside

the

When all the previous steps are done, you can do ENSURE THAT THE WELDING GROUND
RETURN CLAMP IS WELL SECURED AND
welding on the vehicle.
MAKES A GOOD ELECTRICAL CONTACT
WITH A LARGE METALLIC AREA OF THE
CHASSIS LOCATED NEAR THE WELDING
POINT AS MUCH AS POSSIBLE.
When welding is completed, reconnect all the BE CAREFUL TO MAKE THE PROPER
modules.
CONNECTIONS, IF NOT, SOME SYSTEMS
Make sure that the connectors locking tab are well OR COMPONENTS MAY NOT BE USABLE.
engaged!

Page 17 of 27

Appendix C

IT750004
Weld Inspection

Page 18 de 27

WORK INSTRUCTION
TITRE: WELD INSPECTION
PROPRIÉTAIRE: Sébastien Guévin

MAJOR DEFECTS
TYPE OF DISCONTINUITY

NO: IT750004A

MATERIAL THICKNESS
CC1

NONE

t > 3.2 mm

NONE

t ≤ 3.2 mm

NONE

REPAIR
Gouge or grind to
sound
metal
at
craked locations and
reweld.
Contact the welding
technician.

NONE

NONE

NONE

Gouge or grind to
sound metal and
reweld.
Contact the welding
technician.

NONE

NONE

NONE

Gouge or grind to
sound metal and
reweld.
Contact the welding
technician.

No unfilled crater allowed.
FOR
THICKNESSES
LESS THEN
3.2MM

NONE

NONE

Hole accepted at
the end of the
seam if diameter
less than 0.5 mm.

Fill with welding

No
unfilled
crater allowed.

Note : If presence of
cracks in the crater,
grind and weld

NONE

Grind to eliminate
stress concentration
or hammering to
remove the sharp
corner.
Reweld if possible.

Page 19 of 27

WORK INSTRUCTION
TITRE: WELD INSPECTION
PROPRIÉTAIRE: Sébastien Guévin

TYPE OF DISCONTINUITY

NO: IT750004A

MATERIAL THICKNESS
CC1

t > 3.2 mm

t ≤ 3.2 mm

REPAIR

Unless otherwise stated on the shop drawing, all welded
joints must be so to cross the corners
Visually check that :

Add weld.

Minimum covering : 3 mm
Desirable covering : 5 mm

Max. depth :
NONE

0.5 mm

Max. depth :

NONE

Max.
10%
of
weld
seam
length

Grind if required
(MAX
10%
of
material thickness)

Make an additional
weld seam, adhering
to the weld profile.
DOWNWARD
WELDING
is
forbidden
with
FCAW et MCAW
processes.

Check the depth
using the profile gauge.

NONE

NONE

Page 20 of 27

NONE

Grind and weld an
additionnal bead.

WORK INSTRUCTION
TITRE: WELD INSPECTION
PROPRIÉTAIRE: Sébastien Guévin

NO: IT750004A

MATERIAL THICKNESS
TYPE OF DISCONTINUITY

RÉPARATION

CC1

t > 3.2 mm

t ≤ 3.2 mm

NO overflow having a less than 90 degree angle.

Grind or weld.

REFUSED

NONE

NONE

NONE

Grind or fuse with
weld
bead,
minimum
length :
10 mm.
Blend
bead.

Page 21 of 27

with

weld

WORK INSTRUCTION
TITRE: WELD INSPECTION
PROPRIÉTAIRE: Sébastien Guévin

NO: IT750004A

MATERIAL THICKNESS
TYPE OF DISCONTINUITY

REPAIR

CC1

NONE

t > 3.2 mm

t ≤ 3.2 mm

NONE

Grind

NONE

For a skewed weld to be acceptable, it should not exceed
the following criterias:
Max. length: 10 % of weld length

Grind and reweld

Max. skew distance. : 1.5 mm
Not to be located at the end of the weld seam: (12 mm)

The repair must meet
the quality criterias.

No cut line, cracks or other defects on parts.

Contact the welding
technician to see if
the repair is possible,
to be analyzed for
exemption request.

Excessive thickness :
The
extra
thickness
should not exceed 2 mm.

of

the

Note : Repair if presence of porosity or undercut.

collapse

Grind
Porosity or undercut:
Grind and weld

Page 22 of 27

WORK INSTRUCTION
TITRE: WELD INSPECTION
PROPRIÉTAIRE: Sébastien Guévin

NO: IT750004A

DIMENSIONAL INSPECTION OF WELDS
MATERIAL THICKNESS
TYPE OF DISCONTINUITY

REPAIR

CC1

t > 3.2 mm

t ≤ 3.2 mm

Visually check and control with a dimensionnal gauge to
make sure that weld profile is acceptable.
The dimension of a continous fillet
weld may be 2 mm less than required
without correction if it is present on
less than 10% of weld length.

As
noted
drawing.

on

Weld or grind as
required.

UNACCEPTABLE

Max 3.2 mm

Max 3.2 mm

Max 1.6 mm
Grind
welding.

excess

Bead must be convex.
Weld
to
material.

Page 23 of 27

add

WORK INSTRUCTION
TITRE: WELD INSPECTION
PROPRIÉTAIRE: Sébastien Guévin

NO: IT750004A

MINOR DEFECTS
MATERIAL THICKNESS
TYPE OF DISCONTINUITY

REPAIR

CC1

t > 3.2 mm

t ≤ 3.2 mm

NONE

NONE

NONE

Remove with a flux
hammer

Remove projections which do not fit the acceptable
profile.
For carbon and stainless steels,
non adhesive projections are not permitted.
Maximum projections allowed without repair:
2

2

Grind.

6 projections per 625 mm (1 po )

NONE

NONE

Page 24 of 27

NONE

Remove

Appendix D

Welding Procedure

Page 25 of 27

Appendix D

WELDING PARAMETERS
Volt : 19 – 22 V
Amp. : 130- 190 A
Wire speed. : 360- 500 in/min
Position: Overhead
Welding Wire: ER308 LSI 0.035 ’’
Shelding Gas: 98% AR – 2%CO2 or 90%He- 7.5% Ar- 2.5 CO2
Welding Speed: 15- 22 in/min

_____________________________
CRACK REPAIR
Weld cracks on the mounting ears must be grinded to the root and welded.
If the crack is visible;

Grind to the root of the crack

Fillet Weld according to "welding
parameters" above

Page 26 of 27

Appendix D
If grinding reveals that the crack goes all the way through;

You can groove for 2mm;

Fillet Weld according to "welding parameters" above;

Groove the other side;

Fillet Weld according to "welding parameters" above

Page 27 of 27