Usage:
12H (5ZM, 4XM, 2LR, 4ER, 8MN, 2GS, 2WR),
140H (8JM, 2ZK, 8KM, 5HM, 9TN, 3AS, 9ZN, 3FR),
143H (1AL),
160H (9JM, 9EJ, 6WM, 2FM, 3GM, 2HS, 3HR),
163H (5AK) Motor Graders
- SUPPLEMENT: JULY 27, 1998
Service Magazine SEPD0411, Article 6, Page 8, April 6, 1998; "Circle Assembly Reinforcement For Severe Applications".
Disregard this article and see Service Magazine SEPD0427, Article 10, Page 11 with the same title.
--------------- END SUPPLEMENT ---------------
Reference: Service Magazine, SEPD0385; October 6, 1997; Page 44; "Proper Welding Procedure on Machines and Engines With Electronic Controls".
The following procedure and illustrations can be used to reinforce the circle assembly on machines used in severe applications.
1. Fabricate two service plates, one each for the left and right side, from 10.0 mm (.39 in) thick ASTM A572 mild steel plate using the dimensions in Illustration 1.
Illustration 1.
Service Plate [10.0 mm (.39 in) thick].
2. Read the weld instructions which follow after Illustration 2. Weld the fabricated service plates to the blade beams of the circle assembly using a continuous 8.0 mm (.30 in) fillet weld. Keep the weld 10.0 mm (.40 in) from the edge of the blade beam. Do not weld the ends. See Illustration 2.
Illustration 2.
Circle assembly with service plates on blade beams. Use 8.0 mm (.30 in) fillet weld. No weld on ends depicted with arrows. Keep weld 10.0 mm (.40 in) from edges.
NOTE: Refer to Service Magazine, SEPD0385; October 6, 1997; Page 44; "Proper Welding Procedure on Machines and Engines With Electronic Controls".
Welding Requirements
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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill.
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Read and understand the manufacturer's instructions and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electrical parts.
Refer to American National Standard Z49.1 "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125.
Refer to OSHA Safety and Health Standards, 29 CRF 1910, available from the U.S. Department of Labor, Washington, D.C. 20408.
NOTE: Welding operator personal protection should be provided to assure that the total weld fume in the operator's breathing zone does not exceed OSHA limits.
All repair welding operators must be qualified for groove and fillet welding, as outlined in the current ANSI/AWS D14.3. The qualification will be for the SMAW (Shielded Metal Arc Welding) process in the vertical welding positions. The welding operator must also have used this welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications. The alternate process for this repair could be FCAW (Flux Cored Arc Welding).
The area to be welded and the surrounding area must be at a minimum temperature of 16°C (60°F) before and during all welding.
NOTE: Since weld distortion is a possibility, minimizing the heat into the surrounding area is important.
The SMAW process shall be used with E7018 (ANSI/AWS A5.5) welding electrode. These are low hydrogen electrodes and must be stored in a electrode oven at 121°C (250°F) when not in use. If the electrodes get damp, scrap or recondition them to the manufacturer's specifications.
The weld deposited by these electrodes will have the following minimum mechanical properties:
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- * 500 MPa (72 KSI) Tensile Strength
- * 420 MPa (60 KSI) Yield Strength
- * 22% elongation in 50 mm (2 inch)
- * 27 J (20 lb ft) Notch Toughness at -29°C (-20°F)
- * 500 MPa (72 KSI) Tensile Strength
The following chart relates to the electrodes diameter and approximate current settings for welding:
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed two times the electrode diameter.
As an alternate process the FCAW process may be used with E71T-1 (ANSI/A5.20) welding electrode and the manufacturers specified shielding gas(es).
The weld deposited by the three electrodes will have the following minimum mechanical properties:
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- * 500 MPa (72 KSI) Tensile Strength
- * 420 MPa (60 KSI) Yield Strength
- * 22% elongation in 50 mm (2 inch)
- * 27 J (20 lb ft) Notch Toughness at -18°C (-0°F)
- * 500 MPa (72 KSI) Tensile Strength
NOTE: This type of electrode has limitations if it is used to carry larger weld pass volumes in the flat welding position. Due to the fast freezing characteristics of this electrode's slag system, there is a chance of trapping evolving gases in the weld melt. Precaution should be taken by controlling weld pass size.
Welding parameters will vary due to weld position and manufacturer of the welding electrode. For 1.30 mm (.052 inch) diameter electrode, typical welding parameters should be:
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed 8.0 mm (.31 inch) fillet volume.
Clean the metal of oil, grease, rust, scale, paint and dirt in the area to be welded. Any of these materials including water discharge gas when they come into contact with heat. This gas can cause porosity (very small bubbles) in the weld deposit.
Remove all oil and grease. Remove paint, rust, dirt and scale with a brush or by blasting with glass beads.
Attach the welding ground cable directly to the area to be welded. Protect all machined surfaces from sparks or splatter produced by welding, chipping and/or grinding operations.
The welds shall be free from cracks, porosity, undercut and incomplete fusion. All weld quality shall conform to ANSI/AWS D14.3.