CAT Bucyrus Unit Rig Mining Truck P150 Operation & Maintenance Manual BI007312 – PDF DOWNLOAD

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© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

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~ UNrrHIG

P150 OPERATION AND MAINTENANCE MANUAL

UNIT RIG A Division of TEREX Corporation P.O. Box 3107 Tulsa, Oklahoma 74101-3107 Phone: (918) 446-5581 Fax: (918) 445-5950 http://www.terex.com

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INTRODUCTION The purpose of this manual is to provide understanding of the P-150 UNI-PRES. Although mounting and demounting instructions are provided in this manual, some users may find it necessary to modify or supplement them to make the equipment more compatible with their facilities and resources.

Various configurations of mounting and demounting adapters have evolved, but their use will remain the same regardless of physical appearance NOTE: The contents of this manual do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met in connection with installation, operation, or maintenance.

TABLE OF CONTENTS OPERATION General

.

Stand

.

Grapple Head Assembly.

1 1 1

Power pack

.

1

Operation

.

Mounting . . .

1 1 2

Demounting .

7

P-150 Tire Size Capability .

MAINTENANCE

ii

General

.

Overhaul

.

12 12

Illustrated Parts

13

Hydraulic Pump

13

Field Repair Welding Procedures

38

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SAFETY IN VEHICLE OPERATION STARTS WITH SAFE TIRE REPAIRS

Don't permit anyone in your maintenance shop to mount or dismount tires on large equipment without first providing them with proper training. Then, to minimize dangers ever present when working with jacks, hydraulic power tools, and inflated tires, follow these safety tips provided by the engineers at Motor Wheel Corp.

• Never run a vehicle on one tire of a dual tire assembly.

The carrying capacity of a single tire and rim is dangerously exceeded, and operating a vehicle in this manner can result in damage to the rim.

• Don't reinflate a tire that has been run flat without first inspecting the tire, rim, and wheel assembly. Double check the lock ring for damage; make sure that it is secure in the base rim gutter before inflating the tire.

• Clean all rims and repaint to stop the detrimental effects of corrosion. Make sure that you clean all dirt and rust from the lock ring gutter. Secure the lock ring in its proper position.

• Use a filter on the air inflation equipment to remove moisture from the air line and thus reduce corrosion.

Check the filter periodically to ensure that it is operating properly.

• Make sure that the correct parts of a tire and rim assembly are being assembled. Mixing parts of one manufacturer's with those of another is potentially dangerous. Always check with the proper technical representative man that services the fleet, the rim and the wheel distributor, or sales engineers if there are any questions.

• Double check to ensure that all components are properly seated prior to beginning inflation.

• Always place hardwood blocks under each jack, regardless of how hard or firm the ground appears.

• Do not overload the rims or over inflate the tires, Always check with the rim manufacturer if special operating conditions are required.

• Block the tire and wheel on the other side of the vehicle before you place the jack in position; always secure with adequate blocking in case the jack moves.

• Do not seatthe rings by striking with a hammer or other tool while the tires are inflated. Do not strike any inflated or partially inflated tire and rim assembly.

• Always allow all air to exhaust from a single tire and both tires of a dual tire assem bly prior to removing any of the rim components, such as the nuts and rim clamps. Make sure that the valve core is removed and all air is exhausted from the tire(s). Check the valve stem by inserting a wire through the stem to make sure that it is not plugged. Remove the valve cores from both tires of a dual tire assembly.

• Do not use undersized rims. Use the correct rim for the installation.

• Remove the bead seat band slowly to prevent it from dropping off and falling on your foot. Support the band with your thigh and roll it slowly to the ground, protecting you back and toes.

• Keep your fingers clear of rim flanges when unseating the beads Slant the demounting bead tool about 10° to keep it firmly in place. A demounting tool applies pressure to the rim flanges. If it slips off, it can fly with enough force to kill.

• Always stand to one side when you are applying hydraulic pressure to any tool.

• Check rim components periodically for fatigue cracks Replace all cracks, badly worn, damaged, or severely rusted com ponents.

• Do not inflate any tire before all side and lock rings are in place. Check the components for proper assembly again after inflating to approximately 5 psi (35 kPa).

• Never stand on or in front of a tire and rim assembly that is being inflated. Use a clip on chuck and make sure the inflation hose is long enough to permit the person inflating the tire to stand to the side of the tire.

• PJways inflate tires in a safety cage or use proper safety chains during inflation.

• Never attempt to weld on an inflated tire and rim assembly.

• Do not, under any circumstances, attempt to rework, weld, heat, or braze rim components that are cracked, broken, or damaged. Replace with new parts, or parts that are not cracked, broken, or damaged and are of the same size, type, and make.

II • Stand clear when using a cable or chain sling; ,t may suddenly snap and lash out. .

iii

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Section 1--0PERATION GENERAL

The P-150 UNI-PRES is a heavy-duty tire changing fixture designed specifically for large size off-road type tires. The fixture will handle tire sizes from 49 to 57 inch (1.25 to 1.45 m) diameter rims.

The UNI-PRES consists of a stand with a built in 150 ton (135 m. tonne) ram; a grapple head assembly with integral grapple arms; a power pack assembly; and various mounting and demounting shoes and adapters.

The fixture requires an air input into the power package of 80 scfm (2 265 liter/min) at 100 psi (690 kPa). An overhead crane or hoist with a minimum capacity of 6-1/2 tons (5 m. tonnes) is required to be used in conjunction with the UNI-PRES.

Reservoir, rotary valve, and pump in the hydraulic system.

An external air source of 100 psi (690 kPa) is applied to the power pack at the terminal block. The air is routed through the air selector valve and filter to the air pressure regulator. Regulated 80 psi (550 kPa) is provided to the two air-operated hydraulic pumps and to the air pressure gauge.

Hydraulic oil, from the reservoir, is pressurized by the pump and is routed to the rotary valve. The rotary valve provides the pressurized oil to the ram cylinder.

OPERATION

All operation of the UNI-PRES is controlled from the power pack control panel. The control consists Of the:

STAND

The UNI-PRES stand consists of the four support legs, constructed of heavy gauge steel, and the ram, with an integral hydraulic cylinder. Provisions are included to lock the grapple head assembly to the ram. Hose connections are provided for the hydraulic connection to the power pack.

The hydraulic cylinder, powered by the pump in the power pack, is used to power the ram both up and down to exert force, through the grapple head, to the rim parts.

GRAPPLE HEAD ASSEMBLY

The grapple head assembly is used to transmit force to and from the wheel, and as the lifting adapter for the tires, rims, and assembled tires and rims.

The grapple head assem bly consists of the center tube with its four rigid extension arms; the four pivot grapple arms; and the adapters for lifting the rim components.

Air valve - to supply regulated air pressure to the pump and; Hydraulic valve - to actuate the ram cylinder either up or down.

In the mounting and demounting process that follow the instructions to raise and lower the grapple head are accomplished with the hydraulic valve lever.

The proper operating sequence is as follows: 1. Connect and apply pressurized air from an external power source to the power pack.

2. With the machine at idle, adjust the air pressure to 80 psi (550 kPa).

NOTE: The air pressure should not exceed 80 psi (550 kPa).

3. Move the air valve lever to ON. The center tube incorporates lock-pins for attaching the grapple head to the ram.

POWER PACK

The power pack provides the hydraulic source for the for the operation of the ram cylinder and the controls and indicators required for system operation. The power package components are housed in a sheet metal cabinets and consist primarily of the:

4. Move the hydraulic valve lever as required to cause the desired movement of the grapple head.

-Push for UP; -Pull for DOWN; -Center for NEUTRAL. 5. To hold the grapple head in any position, move the air valve level to the OFF position..

Selector valve, filter, pressure regulator, and gauge in the air system;

1

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P-150 TIRE SIZE CAPABILITY

The P-150 UNI-PRES will accommodate the following tire and rim sizes.

Standard Tires

18.00X49 21.00X49 24.00 X 49 27.00 X 49 30.00 X 51 33.00 X 51 36.00 X 51 37.00 X 57

40.00 X 57

2

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MOUNTING

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LOWER MOUNTING SHOE

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1'\ The UNI-PRES may be used to install a tire as follows: 1.-Place the lower mounting shoes on the UNI-PRES stand and the upper mounting shoes on the grapple head assemblly.

RIM BASE ADAPTER

2.-Using the rim base adapters attached to the grapple head assembly, lift the rim assembly and place on the stand. Make certain that the rim base is prpperly engaged with the lower mounting shoes. '

3

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SIDE RING ADAPTER ~........_

••

I I

3.-Remove the rim base adapters and attach the side ring adapters to the lupper side ring.

I 4.--Lift the upper side ring and the bead seat ring and place on the upper bead of the tire to be mounted. Place the lock ring on the tire. '

O-RING SEAL

5.--Lubricate the O-ring and lower the groove into the rim with Ruglide (or equivalent). Place the lock-ring on the tire before placing the tire on the P-150 UNI-PRES. Place the O-ring around the stand and inside the rim.

4

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GRAPPLE HEAD

5.-Unlock the grapple arms. Using the grapple head, lift the tire and slid~ down over the rim base. !

I

GRAPPLE ARM LOCK PIN

........_

... ~ ..0.' ~'....

_

7.-Lower the grapple head sufficiently to engage the four grapple arm lodk pins and the four pins locking the grapple head to the ram. If necessary, force t~e tire down to the lower side ring using the ram and grapple arms.

5

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UPPER MOUNTING SHOE

S.-Align the mounting shoes to engage the bead seat ring.

BEAD SEAT RING

O-RING

9.-Using the ram, force the bead seat ring down enough to clear the two g~ooves in the rim base. Install the O-ring the lower groove and the lock ring in thel upper groove of the rim.

10.-Make sure that the lock ring is properly seated.

6

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LOCK RING

FIGURE 9.--Make sure that the lock ring is properly seated.

PRESSURE GAUGE;

11.--Raise the grapple head just enough to relieve pressure on the bead seat ring.

Leave the grapple head in this position, as a safety precaution, while inflating the tire.

12.-Using a 100 psi (690 kPa) air source, begin inflating the tire.

13.-lnflate the tire only enough to seat the tire. Complete the inflation process after the assembly is mounted on the vehicle.

Tire pressure must not exceed 5 psi (35 Kpa) with the metal band around a new tire.

7

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14.-Remove the tire and wheel assembly using the grapple head assembly. (The grapple head lock pins and the grapple arm pins must be pUlled).

NOTE: The lock pins and grapple arm remain in position when pUlled, they cannot be removed.

DEMOUNTING

DEMOUNTING SHOE

The UNI-PRES may be used to demount the tire as follows: 1.--Place the four lower mounting shoes on the UNI-PRES stand.

8

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LOWER DEMOUNTING SHOE

2.-Place the tire and wheel assembly on the stand, with the locking ring up. Be certain that the lower side ring is resting on the lower demounting shoes.

3.-Verify that the tire is fUlly deflated (pressure is 0 psi (kPa) and the valve core removed.

NOTE: The tire should have been deflated during the removal procedure.

UPPER MOUNTING SHOE

4.-Place the upper mounting shoes in the grapple head assembly. Lock the grapple arms.

5.-Lower the grapple head assembly onto the stand, making certain the upper mounting shoes engage the bead seat ring.

9

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GRAPPLE HEAD LOCK PIN

6.-Lock the grapple head assembly to the ram using the four lock pins.

7.-Using the ram, depress the bead seat ring until the lock ring and rubber O-ring can be removed.

c UPPER DEMOUNTING - - - - SHOE

8.--lnstall the upper demounting shoes.

9.-Using the upper demounting shoes, press the rim out of the tire.

10

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10.-Press the rim out of the tire.

BEAD SEAT RING DEMOUNTING ADAPTER

•

• 11.-Using the grapple head, (the pins must be pulled) lift the tire, side ring, and bead seat side ring (if necessary). Place the bead seat ring demounting adapters around the edge of the rim base. Use the four three-pronged adapters evenly spaced around the rim.

11

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SIDE RING

12.-Lower the grapple head, making certain the upper demounting shoes engage the side ring.

13.--Using the ram, (lock pins must be engaged) press down on the side ring, forcing the bead seat ring out of the tire.

BEAD SEAT RING DEMOUNTING ADAPTER

14.-Using the grapple head, (all lock pins must be pulled) lift the tire, locking ring, side ring, and bead seat ring from the rim base.

NOTE: The lock and grapple arm pins ramain in position when pUlled, they cannot be removed.

12

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Section 2--MAINTENANCE GENERAL

HYDRAULIC PUMP

Maintenance of the UNI-PRES is limited to the:

GENERAL

1. Removal and replacement of the hydraulic and pneumatic components; 2. Draining and cleaning of the air filter; 3. Structural repair of the stand and the grapple assemblies.

Use standard shop practices for the removal and replacement of the pneumatic and hydraulic components.

Make sure that all pressure is released before attempting to remove or service any component. After replacement is complete, leak check the system and refill the hydraulic reservoir.

The Haskell Liquid Pump, is an air powered, pilot operated reciprocating piston pump. It functions as a variable volume, pressure compensated pump. The pump ratio dash number on the decal indicates the practical work ratio of the air drive area to the hydraulic piston area.

The air supply and exhaust connections are in the lower end cap. Hydraulic connections are in he pump body.

Standard configuration is side inlet and side outlet. The pump is an automatic cycling device, cycled by a nondetented, unbalanced spool that is alternately pressurized and vented by the pilot system.

The air driven section consists of:

AIR FILTER 1. One or more air driven piston assemblies; The air filter can be drained by opening the drain cock in the bottom of the bowl.

To clean the filter element:

2. A cycling control valve; 3. Pilot buttons mounted in the upper and lower end caps;

1. Remove the bowl.

2. Remove the element.

4. A flow tube to direct the flow to the top side of the air piston and;

3. Clean with a "jet" of clean, dry compressed air through the filter in the direction of normal flow.

5. A pilot tube to connect the upper and lower pilot control valves.

4. Replace the element.

WELDING Use standard welding practices to make the necessary repairs to the structural members of the stand and grapple assem blies.

These are included in module M1315, Welding Process For High Strength Steel, later in this manual.

The control valve operates without springs or detents and is cycled by alternately pressurizing and venting an unbalanced operating spool. It is recommended that only O-rings and seals of proper compounds and hardness for low friction be used in the air drive section.

These seals should be acquired through the appropriate Unit Rig parts distribution sources.

The hydraulic section includes the: 1. Pump body;

OVERHAUL 2. Air drive piston and hydraulic plunger assembly; Overhaul of the UNI-PRES can be accomplished using standard shop tools and practices. The major precaution to be observed is that the disassembly of components be accomplished in a clean area. For troubleshooting procedures refer to the charts later in this manual.

3. Plunger packing and retainer and; 4. Inlet and outlet check valve assemblies.

NOTE: The check valves are of the ball type construction, designed for maximum flow and dynamic sealing characteristics.

13

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PRIMING

OPERATION

The system should be primed as followed:

The output liquid pressure can be controlled accurately by regulating the drive air pressure. As stated previously, the pump model number contains its nominal pressure ratio as a suffix.

1. Fill the hydraulic reservoir with the appropriate hydraulic fluid.

2. Open the bypass valve in the fluid outlet line.

The pump will run at approximately 100 strokes per minute at an output pressure equal to this ratio times the air pressure. It will "stall" and hold pressure indefinitely at approximately 110% of this pressure.

3. Open the suction shut-off valve.

4. Set the air pressure regulator to 0 psi (kPa).

5. Slightly open the speed control valve, to a maximum of approximately the 1/4 open position.

6. Slowly increase the air pressure regulator setting.

7. Allow the pump to cycle for approximately 3 to 5 minutes, at 20 to 30 strokes per minute.

Most air pressure regulators have 5 psi (35 kPa) or more differential between the "flow" and "no flow" air pressures. Therefore when it is necessary to pump and appreciable volume at approximately the maximum pump pressure, a high flow, precision type regulator, or the maximum pump pressure should be controlled by some other device such as a relief valve, pressure switch, or pressure operated shut-of valve.

8. The pump should now be primed and ready for operation.

9. Close the bypass valve.

'-J~'~

~----Pilot ,~---Pilot

Valve

.1+----

'4dlt+----Air Air Piston

+----Hydraulic t - - - - Hydraulic Piston Air Drive Inlet Port . . . ; - - - - Hydraulic Seal

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Hydraulic Body

FIGURE 1 PUMP (SHEET 1 OF 3)

14

Liquid Outlet

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ITEM NO.

PART OESCRlmON

UPPER CAP NAMEPLATE NAMEPLATE PLUG ~80"4 PLUG *5 6 BOLT 1 BOLT B NUT 9 LOCKWASHER 10 WASHER PLUG ~&"11 O-RING ~&"12 5/B" 0.0.1l 1/16" C.s. ~&"13 SPRING *&"14 PI LOTSTEM *&"15 O-RING 1/4" 0.0.1l 1/16" COS. *&4416 SPACER ~&4411 RETAINER lB O-RING 3/B" 0.D.1l1/16" COS. 19 O-RING 5/B" 0.0.1l 1/16" c.s.

20 PILOT TUBE 21 FLOW TUBE **22 LOWER CAP **23 PLUG -24 FITTING **25 SPACER **26 SLEEVE **21 O-RING 1" D.O.ll 1/16" C.s. **2B SPOOL **29 O-RING 13/16" D.O.ll 1/16" COS. **30 RETAINER **31 O-RING 11Illi' 0.0.1l 1/16" COS. 32 O-RING 5·3IB" 0.0.1l 1/16" COS. 33 BARREL 34 O-RING 35 DECAL, LUBE 36 DECAL, PATENT 31 O-RING 1·518" 0.0.1l 1/1li' COS. 53 NUT 54 LOCK NUT 55 MTG. BRACKET *1 2 *3

21}--------j

19~----__(:r~

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154113 UPPER CAP ASSEM. AlR CONTROL VALVE

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154114 LOWER CAP ASSEM. AlR DRIVE

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16111. SEALS KIT 16112. SEALS KIT

@-----~i 12.---_ _--.~A

HASKELPUMP MOOELAW60 PIN 154043 MODELAW35 PIN 154042

&THIS ITEMIS) AND THE PUMP BODY ARE PERMA. NENTl Y LDCTITED TOGETHER AT ASSEMBLY. 2. SEE PAGE 2 FOR PARTS INCLUDED IN INLET AND OUTlET CHECK VALVES. 1. SEE PAGE 3 FOR PACKING PUMP BODY AND PISTON ASSEMBL Y.

FIGURE 1 PUMP (SHEET 2 OF 3)

15

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INLET

154115CHECKVALVEASSEMBLY

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"PARTS INCLUDED IN SEALS KIT

RETAINER RETAINER RING

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PUMP BODY

&USE TOOL PIN 29370 TO ASSEMBlE AND

6

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DISASSEMBLE PARTS. 2. SEE PAGE 1 FOR PARTS INCLUDED IN AIR DRIVE SECTION. 1. SEE PAGE 3 FOR PACKING PUMP BODY AND PISTON ASSEMBL Y. PLUNGER. ~

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154116 CHECKVAL~ L!\ ASSEMBLY ili

THESE ITEMS ARE LDCKWIRED TOGETHER WITH 032 DIAMETER STAINLESS STEel WIRE AT ASSEMBLY. NOTE:DN PUMPS USING DISTANCE PIECE. NUTSWILL BE INDIVIDUALL YWIRED TO DISTANCE PIECE.

• PARTS UST· AND DRIVE SECTION

-SEAL

"BOUNCE RING BEARING

UMPBOOY

HYDRAULIC SEALS KIT· AW-35, 154117 HYDRAULIC SEALS KIT • AW60-154118

• PARTS LIST· PUMP SECTION

FIGURE 1 PUMP (SHEET 3 OF 3)

16

BALL SPRING RETAINER SPRING RETAINER RETAINER RING

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FIGURE 2 UNIPRESS ASSEMBLY PIN 150600 (SHEET 1 OF 6) 17

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FIGURE 2 UNIPRESS ASSEMBLY PIN 150600 (SHEET 2 OF 6) 18

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ANGLE HANGERS

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_____2.0

24____.

24

ITEMS 20 AND 24 TO BE WELDED DIRECTLY BELOW ANGLE HANGERS AS SHOWN.

FIGURE 2 UNIPRESS ASSEMBLY PIN 150600 (SHEET 3 OF 6) 19

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39

SEC TION

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SEC T ION B-B

14-.!!!o~::l=:=l-:-

POWER PACK HOSES

19

SEC TION

A-A

FIGURE 2 UNIPRESS ASSEMBLY PIN 150600 (SHEET 4 OF 6)

20

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ITM

QTY PER ASSY

COMPONENT

001

4

10005

002

8

10066

003 004

4 8

10124 10139

005

12

10141

006

8

10186

007

12

11209

008 009

4 4

12333 13002

010

4

15193

011 012

4 i

15914 16441

013

1

17023

014 016 018 019 020 021 022 023

19762 4 1

4 3 4 4 4

024

025 026 027 028 {:;")o VIO:..,

030 031 032 033 034 035 036 037 038 039 040 041

21257 150983 150495 150502 150513 150514 150515 150517

4 4

150555 150556

1 1 2

150604 150613 150630 150705 150706 150754 150768 150769 150770

4 1 4 1

1 4

4 4 4

1SG772

150774 150775 150776 150777

DESCRIPTION CAPSCR,HX,1/4-20NC X 2 GR 5 CAPSCR,HX,3/4-10NC X 2-3/4 GR 5 NUT-HEX 1/4NC NUT,HX,JAM.3/4-10NC STL GR 2 NUT,HX,JAM,1-8NC STL GR 2 WSHR,LK.HELI,1X 1.661 OD CAPSCR,HX,1-8NC X 3-1/4 GR 5 NUT-HEX,FLXLC 1-8 CAPSCR,HXSKT.1-8NC X 2-1/2 GR 8 WSHR.LK.HELI,1-1/2 X 2.430 OD SCR,DR ~2 X 3/16 LG ADAPTER.90 DEG ~6 JIC,MALE X 3/8 NPTF,MALE CAPSCR,HX,l-1/2-6NC X 6 GR 5 HOSE ASSY 242-06 32- LG W/320-06 FTGS PIN-ROLL NIPPLE-PIPE .375NPT STOP ADAPTER-RIM BASE SHOE-UPPER DEMOUNT SHOE-LOWER DEMOUNT SHOE MOUNTING(UPpER) ADAPTEP-SIDE RING EXTENSN-SHOE-8IN EXTENSN-SHOE-12IN POWER-PACK-ASSEMBLY CYLINDER ADAPTER-EL ADAPTER STRAIGHT NAMEPLATE SHOE-UPPER DEMOUNTNG NIPPLE PIPE MOUNTING SHOE LOWER HOUSING RAM STAND PRESS HEAD ASSY PIN-LOCKING. GRAPPLE PIN - GRAPPLE ARM HEEL-GRAPPLE ARM-GRAPPLE

FIGURE 2 UNIPRESS ASSEMBLY PIN 150600 (SHEET 5 OF 6)

21

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Qrr PER ITM

ASSY

042 043 044 045 046 047 048 049 050

8 4 4 4 8 4 4 4 2

150778 150779 150780 150782 150783 150784 P010529 12185 10029

051

2

10182

052 053 054

1 4

150781 151922 151786

4

COMPONENT

DESCRIPTION BAR-GRAPPLE GUIDE-GRAPPLE LOCKPIN PLATE LOCKPIN .25 PIN LOCK ADAPTER BEAD SEAT RG NUT-HEX,FLXLC 3/4-10 CAPSCR,HX,1/2-13NC X 1-1/2 GR 5 WSHR,LK,HELI,1/2 X .873 OD ANGLE SHOE-EXT. LOWER, 4ADAPTER-BD ST RNG DM

FIGURE 2 UNIPRESS ASSEMBLY PIN 150600 (SHEET 6 OF 6) 22

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COMPONENT

MOUNTING

FIGURE 3 POWER PACK ASSEMBLY PIN 150593 (SHEET 1 OF 8)

23

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-----:

AIR REGULATOR &. GAUGE PLUM81N

wITH POWER PACK OFF, ADJUST AIR PRESSURE REGULATOR, ITEM NO. 31, TO 80 PSI.

PNEUMATIC PIPING FIGURE 3 POWER PACK ASSEMBLY PIN 150593 (SHEET 2 OF 8)

24

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FIGURE 3 POWER PACK ASSEMBLY PIN 150593 (SHEET 3 OF 8)

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FIGURE 3 POWER PACK ASSEMBLY PIN 150593 (SHEET 4 OF 8)

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ADJUST RELIEF VALVE, ITEM NO. 29, RAISE PRESS HEAD ASSEMBLY AND GRAPPLE ARMS TO MAXIMUM HEIGHT AND ADJUST RELIEF VALVE INWARD UNTIL PRESS HEAD ASSY. WILL NOT FLOAT DOWNWARD. HYDRAULIC RETURN

FIGURE 3 POWER PACK ASSEMBLY PIN 150593 (SHEET 5 OF 8) 27

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"'tJ "tl

C/o) Co)

::D JJ

cc: m

Q

." ."

I

I

I

:

,()

I

.-

()

() " I

RAM DOWN

I

- -I

B.8.M. M.M.

TO TANK

I

-

.....

CHECK VALVE 151785

-..=----

I

RELIEf VALVE 151546

T

~)

TO CYLINDER

TO PUMPS

I

e1iMe

AIR/HYD.

-L

b PPI~

10.00,J

,-"' _I

~

II.'

"

""

5148

~ArVE ~ArVE

.

SELECTOR S[LEC TO R

80 CFM

AIR SUPPLY 125 PSI

~7

154042

"'\

154043 154043

.eW4e .eQMe

AIR/HYD AIR/HYD

151149

GAUGE. ~ AIR PRESSURE GAUGE AIR PRESS REGULATOR 151648

-150593PO~K

,

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ITM

QTY PER ASSY

COMPONENT

001

4

52344

002 003

1 4

150609 10163

004 0a5 006 007 008

1 1 1 1 1

10548 151857 10333 10546 24263

009

5

986219

010

7

10649

011

012

1 4

150616 10178

013

8

10179

014 015

2 2

150988 16441

016

1

17065

017

1

17141

018 019 020

3 2 3

150991 150989 17410

021 022 023 024

1 1 1

152307 150615 152706 21273

"') L.

025

1

151170

026

5

19136

027

2

151545

028

1

20148

029 030

1 1

151546 151547

DESCRIPTION

SCR,MACH,PNH,5/16-18 X 3/4 GR 2 PIPE HEX NIPPLE WSHR,FL,5/16 X .687 OD COUPLING,PIPE-1 NPT BREATHER FILTER PLUG,PIPE 1/2 NPT CPLG,PIPE,1/2NPT ADAPTER,NIPPLE,HEX 1/2 NPTF,MALE ADAPTER,90 DEG ~10 JIC,MALE X 1/2 NPTF,MALE CAPSCR,HX,5/16-18NC X 3/4 GR 5 NIPPLE-PIPE .5NPT ,HEL I ,1/4 , 1/4 WSHR ,LK ,HELl X .489 OD WSHR,LK,HELI,5/16 X .586 OD NIPPLE,3/8NPTX 3/SNPT ADAPTER,90 DEG ~6 JIC,MALE X 3/8 NPTF,MALE ADAPTER,STRAIGHT ~6 JIC,MALE X 3/8 NPTF,MALE CLAMP-CUSHION 7/8 7/8- ID TEE PLUG PIPE NUT-HEX,FLXLC 5/16-18 FLEXLOC 21FAF-518 EL,45 DEG,1/2 NPT X PIPE NIPPLE HOSE ASSEMBLY ADAPTER,90 DEG ~10 JIC,MALE X 1/2 NPTF,FEMALE HOSE ASSY 13- LG W/319-10 FTGS ADAPTER,90 DEG ~6 JIC,MALE X 1/2 NPTF,MALE HOSE ASSY SYNFLEX WI 390H-06546 EA. END HOSE ASSY 211-06 10- LG W/319-06 FTGS VALVE-RELIEF FILTER-AIR

FIGURE 3 POWER PACK ASSEMBLY PIN 150593 (SHEET 7 OF 8)

29

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ITM

PEK ASSY

031 032 033 034 035 036 037 038 039 040 041 042 043

1 1 1 1 1 1 1 1 1 1 4 1 1

151648 151785 154042 154043 151148 151149 151099 152308 152309 152310 10286 16013 152306

044 045 046

1 1 2

150707 150598 150719

. QTY

COMPONENT

DESCRIPTION REG-AIR 150593 VALVE-CHECK 2000PSI PUMP HYDRAULIC PUMP HYDRAULIC VALVE-AIR SELECTOR GAUGE-DYNAFLOAT VALVE-ROTARY ELBOW - 90 DEG, MALE CONNECTOR - FEMALE TUBE - NYLON, 1/4 88 NIPPLE-PIPE .5X3NPT NIPPLE,PIPE,1NPT X 10 HOSE ASSY 242-06 18 8 LG W/320-06 FTGS OIL RESERVOIR POWER PACK-CABINET HOSE ASSY 16 LG W/320-10 FTGS HOSE ASSY 211-1(;) 10 LG W/319-10 FTGS HOSE ASSY 211-10 12 LG W/319-10 FTGS NUT-LOCK HX(8-32NC} ADAPTER- ELBOW 90 ST. PIPE TEE BUSHING-STRAINER SIGHTGLASS STRAINER CAPSCR,HXSKT,1/4-28NF X 7/8 GR. 5 ADAPTER,STRAIGHT ~10 JIC,MALE X X 1/2 NPTF,MALE ADAPTER,STRAIGHT ~6 JIC.MALE X 1/2 NPTF,MALE PIPE NIPPLE SCR.MACH.PNH.8-32NC X X 1/2 GR 2 8

047

3

53535

8

048

1

20595

8

049 050 051 052 053 054 055

3 6 2 1 1 1 4

25128 152312 150626 150716 150713 150720 982398

056

4

986013

057

1

20647

058 059

1 3

150618 21985

FIGURE 3 POWER PACK ASSEMBLY PIN 150593 (SHEET 8 OF 8)

30

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TROUBLESHOOTING

AIR AIR DRIVE SECTION SYMPTON SYMPTON

CAUSE

REMEDY

1.

1. Will Will not not run at low air drive drive pressures pressures (10-15 psi).

(70-105 kPa) 2.

2. Pump Pump will not cycle, or slow slow cycling. cycling.

1. Excess friction of spool packings.

replacement 1. Necessitates lubrication or replacement of spool o-rings. (See instructions for removing sDool). spool).

1. Replace o-rings on flow tubes.

2. Remove ice. repair 3. Remove pilot valves, inspect and repair as necessary.

3.

3. Pump Pump will not build up pressure, pressure, or deadhead.

1. Leakage of flow tubes.

2. Iced-up exhaust or vent.

3. Indications that one or both pilot valves are malfunctioning.

4. Build-up of residue in muffler.

1. Continuous exhaust bleeding, if air supply is relatively small.

4.

4. False False or double cycling.

1. Leakage of pilot system.

5.

5. Excessive Excessive moisture or liquid liquid outside outside muffler.

1. Air filter full of water.

6. In In double double or tripple 6. head pumps-excessive pumps-excessive bleedhead out diaphragm diaphragm breather. ing out ing

1. Diaphragm seal leakage.

clean.

4. Remove muffler, disassemble and clean. follow1. Remove and replace o-rings in the following order: a. Spool o-rings. b. Air piston o-rings.

If leakage persists c. Replace sleeve o-rings. (See instruco-rings. tions for removing and replacing o-rings. control 1. Refer to Test Procedure of pilot control valves.

1. Drain air filter.

Sympton 33 in in 2. Refer to Trouble Shooting - Sympton Hydraulic Section.

1. Replace diaphragm rod seal.

HYDRAULIC SECTION HYDRAULIC 1. Pump Pump will not cycle.

1.

2. Pump Pump cycles without 2. pumping. pumping.

1. Restricted outlet.

1. Restricted inlet.

2. Suction leak.

3. Check valve malfunction.

3. Excessive Excessive moisture or 3. liquid outside outside muffler, or liquid outside distance distance piece vent outside (if applicable). applicable). (if Pump will not deadhead.

4. Pump 4.

1. Plunger seal worn out.

2. Refer to Trouble Shooting Sympton 5 in Air Drive Section.

1. Insufficient liquid supply.

2. Leakage in outlet system.

3. Check valve malfunction.

1. Check outlet valve for pluaain!l. pluooina.

1. Check for air or excess restriction in hydraulic inlet system 2. Check inlet system if hydraulic supply supply isis remote or below the pump.

3. Check both check valves for foreign matermaterial holding valve off the seat.

1. Replace seal. Check hydraulic fluid for for abrasive contaminants.

1. Check pump inlet for clogged filter.

2. Be sure entire inlet line is of required size. size.

1. Install gage at pump outlet and plug inlet. inlet. If If pump holds pressure, leakage is in some component component external to the pump.

1. With pump inlet plugged, and gage installed installed in in outlet, if gage goes up and down with cycle, cycle, outlet outlet check valve is defective. Remove and replace. replace.

2. If all above conditions check out and pump pump will will not deadhead, replace inlet check valve.

3. See Sympton 3 above.

31

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/

24

II

STROKE HARD CHROME PLATED BRZ FACE

1. RATED CAP: 200 TONS @ 7960 PSI (180m. tonnes @ 54,880 kPa)

~ ~-18NPT

2. EFFECTIVE RAM AREA: 50.26 SQ. IN. (32,425 mm 2) 3. FLUID VOLUME PER STROKE: 1205 CU. IN.(19.75 liters) 4. EST. WEIGHT 616 lb. (280 kgs) 5. STROKE: 241N. (610 mm) 6. BOTTOM PLATE NOT SHOWN

SIMPLEX CYUNDER (GREEN) REPAIR KIT-PIN 150822 NORCATH CYUNDER (ORANGE) REPAIR KIT- PIN 152062 ITEM NO

QTY

DESCRIPTION

1 2 3 4 5 6 7 8

1 1

BODY U-CUP

2 1 1 1 2 2 1 1

BU-RING O-RING RAM O-RING O-RING BU-RING RETAINING NUT BU-RING

9 10 11 12

FIGURE 4 CYLINDER PIN 150604

32

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KEY

ROTARY VALVE PIN 151099

•

• • •

• •

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

HANDLE SPRING BALL O-RING PIN- DOWELL PLATE- NAME CAPSCREW - FLAT HEAD STEM CAP WASHER - BACK-UP SCREW-SET WASHER - BACK-UP O-RING RACE - BEARING NEEDLE - BEARING SCREW - DRIVE ROTOR ASSEMBLY SLEEVE WASHER BACK-UP O-RING SPRING BODY GRIP-HANDLE DECAL

SEAL PIN • KIT 151098 RELIEF VALVE PIN 151546 KEY 1 LOCKNUT 2 CAP-END 3 PISTON 4 RING - BACK-UP 5 O-RING 6 NUT PANEL 7 BODY 8 SPRING 9 POPPET 10 RETAINER 11 CAPSCREW - SOCKET HEAD NO REPAIR KIT PARKER HANNIFIN RELIEF VALVE PIN 151546 REPUBLIC KEY

1 2 3 4 5 6 7 8 9 10

LOCKNUT PORT - PRESSURE PISTON O-RING O-RING NUT- PANEL BODY SPRING POPPET KNOB

FIGURE 5 HYDRAULIC COMPONENTS

33

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AIR PRESSURE REGULATOR

REPAIR KIT

150743

_

WILKERSON CORPORATION

PIN R·20·04·000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

FIGURE 6 AIR PRESSURE REGULATOR PIN 151648 34

KEY ADJ SCREW ASSEMBLY NUT RANGE DISK SCREW SPRING DISK SPRING DIAPHRAGM ASS'Y PIPE PLUG BODY O-RING VALVE STEM VALVE SEAT VALVE O-RING SPRING SCREEN O-RING BOnOM PLUG

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AIR FILTER

_

® ,----

@t I

L __

®

® REPAIR KIT PIN

151087 BOWL KIT PIN

151655

WILKERSON CORPORATION

PIN F-20-04-000 KEY 1 2 3 4 5 6 7 8 9 10

COVER ASS'Y a-RING CLAMP RING ASS'Y TEXTILE ELEMENT BAFFLE MECHANICAL DRAINER BOWL AUTOMATIC PETCOCK a-RING BOWLGUARD

FIGURE 7 WILKERSON CORPORATION PIN 1137-4 35

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TROUBLESHOOTING f)·100S f)·100S UN/·PRES UN/·PRES

SYMPTOM

CAUSE

REMEDY

1.

1. Machine Machine runs but will not demount tire.

1 Low oil level

2. Insufficient air supply.

w/ram up. up. Oil Oil must must be be 1. Fill oil level to sight gauge w/ram clean.

2 Air pressure should be set at 80 psi psi on on gauge gauge be 1/2' 1/2' I.I.D. D. -should be w/machine idle. Air supply line should (550 kPa kPa @ @ 2265 2265 minimum (80 psi @ 80 cfm) (550 . liters/min).

3 Strainer in hydraulic tank plugged.

months to to insure insure proper proper oil oil 3. Clean strainer every four months flow. ..

4 Malfunctioning power pack.

hydraulic rotary rotary valve valve 4 To check power pack, place hydraulic selector valve valve on. on. The The in neutral position and turn air selector to pressure pressure and and stall. stall. hydraulic pump should pum pp to If this occurs, the power pack is functioning functioning porperly. porperly. the pump pump fails fails to to crcle, crcle, If, when the air is turned on the dirve section section 00 the the there is a problem in the air dirve repair section section of of the the pump. Refer to the pump repair cycles but but does does not not manual (Fig. 2-15). lithe pump cycles in rotary rotary valve valve (See (See seals in stall, check and/or replace seals replacing seals seals in in rotary rotary Fig. 2-4) if necessary. After replacing does not not stall, stall, the the valve, repeat test. If the pum pp does section of of thepump. thepump. To To problem is in the hydraulic section repair section section (Fig. (Fig. 2-15) 2-15) repair pump refer to pump repair 111 manual.

5 Seals leaking In hydraulic cylinder

5

1. Improperly adjusted relief valve

kPa). Adjustment Adjustment 1 Adjust relief to 1,000 psi (6 900 kPa). inserting aa gauge gauge in in the the may be accomplished by inserting tuming the the relief relief valve valve hydraulic return line and tuming until proper proper pressure pressure is is adjusting screw clockwise until range is is 100-1200 100-1200 showing on gauge. Relief valve range psi (60--8275 kPa). seat valve. valve. Replace Replace 2 Check for foreign material on seat 2-5). Replace Replace relief relief seals in relief valve (See Fig. 2-5). valve if necessary. inspect for for foreign foreign 3 Disassemble check valve and inspect check for for damage. damage. material. Clean seat and check Replace check valve if necessary. necessary.

Cylinder Cylinder will not return to up position

2.

2. Ram Ram and and Grapple Head will not hold in up position position w/air drive off

2. Internal leakage in relief valve 3. Check valve malfunctioning

REPAIR

sylinder (See (See Fig. Fig. 2-7).

2-7).

Heplace seals in hydraulic sylinder Check, should should be be comcomNote: Step 3, Power Pack Check, cylinder. pleted prior to working on cylinder.

The sleeve and bumper spacer assembly may be removed as follows:

Air Drive Section

NOTE: The air drive section of all liquid pumps are prelubricated at the of assembly at the factory with Molykote "G" lubricant and require no other means of lubrication other than that listed here.

The air control valve spool may be removed as follows: 1. Remove the air exhaust muffler and fitting (30) located in the lower end cap.

2. Remove the pipe plug (23) at the opposite end.

3. Remove the spool (28).

NOTE: A 1/2 inch (13 mm) diameter wooden dowel or fiber rod should be used to remove the spool, 4. Inspect the spool O-rings (29) and remove if found to be worn.

1. Verify that the spool has been removed as outlined previously.

2. Remove the spacer (25) and sleeve (26) by tapping a wooden dowel inserted in the plug (23) hole.

A CAUTION A 5/8 inch diameter wooden dowel or special Haskell too (Haskell PIN 28584) should be used to remove and replace the control valve sleeve, NOTE: If the sleeve (26) stops moving, spacer (25) has dropped into an undercut in the body. Do not continue to drive the sleeve out. Insert a 1/8 inch (3 mm) diameter brass rod into the first set of flow holes in the sleeve and pull th sleeve out, at which time the washer will also drop out.

The sleeve and bumper assembly may be installed into the body as follows:

36

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1. Replace all sleeve O-rings (27) if required.

2. Install a 0 - 160 psi (1 100 kPa) pressure gauge in the air pressure line.

2. Lubricate the O-rings with a light coat of vaseline.

3. Apply air pressure to the inlet of the pump.

3. Install spacer (25) with the rubber facing the sleeve a The gauge will indicate full system pressure if

(26).

the pilot system has not been actuated.

4. Install the sleeve (26).

5. Install the spool (28) as outlined.

b. Correct pilot action will cause the gauge pressure to immediately increase or decrease from o psi (kPa) to the maximum pressure.

o

The spool assembly may be installed as follows:

1. Lubricate the spool O-rings with a light coat of Molykote "G".

2. Using the 1/2 inch (13 mm) dowel rod used for removal, install the spool into the body.

3. Install the pipe plug (23).

A slow increase in the gauge pressure indicates c. A leakage in the lower pilot valve. d. A slow decrease in the gauge pressure indicates the upper pilot valve is faulty and repair is necessary.

The air drive piston O-rings (34) and air barrel o-rings (32) may be replaced as follows:

4. Replace the muffler, fitting (30), and pipe plug (23).

1. Remove bolts (7).

The pilot control valve may be disassembled as follows: 2. Remove the upper cap (1).

1. Remove plug (11).

3. Remove the air barrel (33).

2. Remove the pilot stem (14), O-ring (15), spacer (16), and retainer (17).

3. Inspectthe pilot stem and seat for foreign material.

Replace if found to be worn, bent, or damaged.

A CAUTION The stems in the upper and lower caps are not interchangeable.

NOTE: Unless excessive leakage occurs it is not advisable to replace the O-ring on the shank of the stem as replacement of this O-ring requires complete disassembly of the air section.

1.1 nstall the pilot stem (14), O-ring (15), spacer (16), and retainer (17).

2. Remove plug (11).

NOTE: If afterassembly, the pump will not cycle the, the following test procedure will determine which ofthe pilot valves is at fault.:

4. Remove the piston assembly.

5. Remove the air barrel O-rings (32).

6. Clean the air barrel with clean solvent and dry with dean, dry compressed air.

7. Relubricate the inside of the air barrels with Molykote "G" or equivalent to within 1/2 inch (13 mm) of each end.

8. Replace the air barrel O-rings (32).

NOTE: Do not lubricate these rings.

9. Replace the air barrel (33), air piston assembly and upper cap assembly in the reverse of the order removed.

NOTE: Care must be take during the disassembly and assembly processes that the flow and the pilot tube O-rings be on the flow and pilot tubes prior to assembly.

Torque the bolts (7) evenly in an alternative pattern.

The pilot control valve can be tested as follows: 1. Remove the 1/8 inch (3 mm) diameter pipe plug (4) in the upper end cap.

37

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FIELD REPAIR WELDING PROCEDURES These instructions are mandatory guidelines for the field repair and remanufactured processes of Unit Rig structures. The procedures are based on the shielded metal arc welding process using low hydrogen electrodes and flux cored arc welding. They provide welding guidelines on both Unit Rig Products - Lectra Haul and Dart.

ELECTRODE SPECIFICATIONS

ROLL OVER PROTECTIVE STRUCTURE (ROPS)

NOTE: The material has excellent cold weather impact properties and provides the required tensile strength.

To avoid violation of the R.O.P.S. certification, do not weld to or modify the ROPS in any way without the prior written permission of Unit Rig. The R.O.P.S. may not provide sufficient protection if it has been altered, damaged, or previously involved in a roll over. Contact your Unit Rig Service Advisor or Factory Service Department for assistance with R.O.P.S. related questions.

1.

All shield metal arc welding (stick) electrodes must conform to AWS E8018 C3 or approved equivalent.

Welding should be DC, reverse polarity. Alternate electrodes require Unit Rig Engineering approval.

2. Flux core arc welding (FCAW) must conform to E71T-1 AWS A5.20. The approved electrodes are Uncoln outer shield 1/16 (.052 and .045) - dual shield 1170. Gas flow rate 35 to 45 CFH (1 to 1.3 m3 /hr).(External shielding gas shall be C02 or a mixture of 75% Argon, 25% C02. For further detailed information refer to your electrode supplier or Unit Rig Specification 02-150.

MATERIAL SPECIFICATIONS

1. All plate material must conform to constructional alloy steel ASTM-A514, Type A.2 on trucks built prior to 1985; after 1985, Unit Rig specification 02-560, 561, 562 - similar to Bethstar 80.

Note: Some dump bodies still use a 514 Type A material. Contact a Unit Rig Representative for material specification.)

2. The main frames of Lectra Haul trucks and Dart products plus many of the other major structural components are now being fabricated from a HSLA (High Strength, Low Alloy) steel. This material has a minimum yield strength of from 55 to 80 ksi (55 TO 80 MPa), depending on thickness and where used, and is very similar to Bethstar 80, except with a lower allowable sulphur content and is produced by the "controlled rolled" process. The result is a superior quality steel with very favorable weld characteristics and good fatigue qualities.

However, in order to take advantage of these characteristics it is still necessary to carefUlly follow the weld and repair procedures. Further questions should be directed through the Unit Rig Engineering or Technical Service Departments or a Service Advisor.

38

3. Innershield ( a trademark name of Lincoln Electric) electrode must conform to AWS Class E71 T-11 per AWS A5.20. Approved electrodes are NR211-MP, Size 5/64 inch or NR203-M AWS E71-8,size 5/64 inch. All shielding, slagging and oxidizing materials are in the core of the tubular wire. No external shielding gas or flux is required.

NOTE: Innershield electrodes are self-shielding, flux cored continuous electrodes used in semi automatic and automatic welding processes.

ELECTRODE CARE (STICK)

1. All electrodes must be purchased in hermetically sealed containers. Immediately on opening the container, the electrodes must be removed from container and transferred to a ventilated holding oven at 250 - 300°F (125 - 150°C).

2. If the electrode container has been damaged so as to allow electrode exposure to air, or if it is not of hermetically sealed type, the electrode should be baked at the temperature and for the time as specified by the electrode manufacturer. One to one and a quarter hours at 700 - 800°F (271 427°C) is common. They should then be returned to the holding oven as in Step 1.

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3. Heating electrodes at a low temperature, 250 300°F (125 - 150°C), for several hours is not equivalent to using specified temperatures as outlined in Step 2.

4. Stick electrodes contaminated with oil, grease, water, or with damaged coating must be discarded.

5. No more than a 15 minute supply of electrodes should be removed from oven at one time. Unused electrodes out of oven more than 30 minutes must be discarded or reconditioned as outlined in Step

5. PJr arcing is required when removing weldment and removing cracks in welds and parent material. The maximum size air arc electrode recommended is 1/4 inch (6.35 mm) in diameter. Scarfing or gas gouging is not permitted. Air arcing should begin 1/2 inch (12 mm) past propagating end of crack.

After air arcing, remove carbon deposits by grinding metal until bright, including all cavities. A die grinder with a carbide burr is recommended for all grinding. Complete removal of crack should be verified by NDT, such as dye penetrant or magnetic particle inspection.

2.

ELECTRODE CARE (WIRE REELS) 1. Welding wire must be maintained free of dirt, oil and other contaminants.

2. Wire that has been accidentally contaminated must be scrapped.

3. Wire reels should not be removed from shipping box until ready to use.

WELDING PREPARATION 1. Clean the surface prior to making repairs. Use a gas torch, buffer, or grinder to remove paint, rust, oil, and/or dirt.

2. For proper electrode grounding, attach ground cable directly to part being welded: For example, superstructure-to-superstructure, frame-to-frame, and axle box-to-axle box. This will avoid current passing through bearings.

3. To protect the truck's electrical system; refer to General Electric TI PS, Issue 34, Oct. 1989, or later information.

DO NOT pull any control cards or remove panel connectors. This practice can cause more damage than it prevents. It puts unnecessary cycles on the connector pins and may cause loose or dirty pins which could result in a control system failure.

4. If the truck has a Detroit Diesel engine equipped with DDEC II controls or an Allison transmission with ATEC controls, the ECM power must be disconnected either by a suitable switch or disconnecting the power plug. The MASTER SWITCH must be kept in the OFF position.

6. An oxygen and gas cutting torch is recommended for web plate cut-outs and preheating. Correct tip size compatible with metal thickness is important to avoid over-heating metal edges. Flame-cut surfaces having burn marks deeper than 1/16 inch (1.6 mm) will require grinding.

WELDING PRECAUTIONS 1. The weld joint plus a three inch (75 mm) area either side must be preheated to 213°F (101°C) (minimum) prior to welding. A temperature crayon, such as tempilstick, can be used for checking the tem perature.

2. Interpass temperatures should not exceed 400°F (204°C). Discontinue work until surface cools to approximately 250°F (118°C).

3. All welds must be made with stringer passes. No weaving of welds is acceptable; however, a slight oscillation may be necessary, but movements should never exceed 1/8 inch (3 mm) maximum width or 1/16 inch (1.5 mm) per side of oscillation.

4. When cold weather welding, the overall temperature must be above 50°F (10°C) on the truck or component parts. Cold climates require covering the work piece and using heaters to raise the temperature above 50°F (10°C) and maintaining this temperature control throughout the welding process.

5. Preheat and interpass temperature control are recommended for optimum mechanical properties, crack resistance and hardness control. This is particularly important on multiple pass welds and heavier plate. Job conditions, prevailing codes, high restraint, alloy level and other considerations may also require preheat and interpass temperature control.

M1315

39

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WELDING APPLICATION AND TACK WELDS

1. Preheating is required for all tack welds, regardless of size.

2. Cracks that occur in tack (or skip) welds must be removed.

3. Tacks must not leave an uneven finished weld profile on a single or multiple pass weld.

Dual Shield 1170 is an all position flux cored electrode that displays exceptional impact properties in both the as welded and stress relieved conditions. Arc characteristics are smooth and splatter level is low. It is recommended for the wide range of low and medium carbon steels used extensively in the construction, shipbuilding, rail car and heavy equipment industries.

Shielding Gas - 75% Argon/25% C02

4. Tack welds should be consumed in the final weld or removed by grinding 1/64 inch (1 mm) into the parent material.

5. It is very important that each weld bead be thoroughly cleaned before the following bead is deposited. Pneumatic or hand chipping must be done with a blunt tool after each pass. Wire brushing after chipping is required. Air must never be blown on weld area.

6. In multiple pass welding all starts and stops must be staggered.

7. Welds must be finish ground as specified in current Unit Rig T-drawings and blueprints.

WIRE APPLICATIONS

1. All welds should be made with stringer passes.

2. Flux Core Arc Welding (FCAW)

a Dual Shield 1170 - All Position

M1315

40

3. Innershield Electrode Semi-Automatic (FCAW) NR211-MP (AWS Class E71T-11) or NR203M (AWS Class E71T-8) Innershield operates in all positions including vertical up and overhead and is acceptable to use in drafty locations. Innershield process is job proven on many applications including repair welding, machinery fabrication, assembly welding, ship and barge building, field welding and erection of structural steel.

4. Proper AWS classification of filler material, f1uxcore can be applied in the vertical-up position. All welds should be made with stringer passes. Flat position is preferred as this improves melted metal flow, bead contour and shielding gas coverage. All starts and stops using multi-pass welding should be staggered wherever possible. A pneumatic chipping hammer is used to clean each weld bead and remove the slag covering.

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ELECTRODE CHART (OUT OF POSITION WELDS) ELECTRODE SIZES AND APPLICATIONS ~TICK ELECTRODE

APPLICATION FLANGE REPAIR WEB PLATES TACK WELDS ORIGINAL WELDS OVER 10" LONG

APPLICATION WRAPPER REPAIR* WEB PLATES TACK WELDS ORIGINAL WELDS

DESCRIPTION

DIAMETER

1" PLATE BELL CUT-OUTS

3/32"-1/8" 3/32"-1/8" 3/32"-1/8"

ALL UNDER 10" LONG 1/8"

DESCRIPTION 1" PLATE BELL CUT-OUTS

3/32"-1/8" E-8018 C3

FLUX CORE WIRE DIAMETER

ALL

.045-1/16" .045-1/16" .045-1/16"

UNDER 10" LONG OVER 10" LONG

.045-1/16" .045-1/16"

SHIELDED MANUAL ARC WELDING (SMAW) E-8018 C3 E-8018 C3 E-8018 C3 E-8018 C3

FLUX CORE ARC WELDING (FLAW) E71T-DUAL SHIELD 1170 E71 T-DUAL SHI ELD 1170 E71 T-DUAL SHI ELD 1170 E71 T-DUAL SHI ELD 1170 E71T-DUAL SHIELD 1170

*(Note: Do not exceed 400°F (205°C) Interpass Temp.

41

BI007312