- Articulated Truck:
- D400E Series II (S/N: APF1-UP)
Introduction
This Special Instruction contains information on extending the body. The rework will help prevent damage to the edge of the ejector blade from retracting past the lip of the base plate of the body. The Special Instruction outlines rework that is suggested in order to resolve the problem.
Before performing the rework that is outlined in this Special Instruction, ensure that you understand the information that is contained in the Special Instruction.
References
Reference: Parts Manual, SEBP3025, "D400E Series II Ejector Truck".
Rework of the Base Plate on the Ejector
 | |
| Illustration 1 | g01068594 |
Typical example that shows the left side of the body | |
In order to extend the length of the body, install two extensions (1) to either side of the body at the front. Installing the extensions will ensure that the ejector blade will not fall behind the lip of the base plates. This will subsequently remove any possibility that the ejector blade will clip the edge of the body on the following eject cycle. In order to fabricate the four extensions, refer to ""Fabrication of Components for the Rework of the Base Plate" ". In order to install the extension to the body, refer to ""Welding Details" ".
Weld Specifications and Qualifications
 |
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. Read and understand the manufacturer's instruction 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 electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OHSA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210. |
 |
Welders must be qualified for fillet welding and groove welding. The welder must be qualified in different welding angles. The angles are vertical, horizontal, etc. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to ISO 9606 or "American National Standards Institiute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process and GMAW process. The welders must have used the process at some time within the last six months. The welders must complete the process of certification if the welders have not used the welding processes for six months.
Proper Welding Procedure on Machines and Engines with Electronic Controls
Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:
- Turn off the engine. Put the key start switch in the OFF position.
- If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.
- Connect the ground cable for the welder directly to the actual machine component that will be welded. Place the clamp for the ground cable as close as possible to the welding area. This will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.
Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder. Do NOT use hoses as a ground point for the welder. Do NOT use the ground pole on the batteries as a ground point for the welder.
- Protect the wiring harnesses from the weld splatter.
Prepare the Area for Welding
Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.
- Oil
- Grease
- Paint
- Dirt
If the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding process.
Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal. A maximum interpass temperature of 260 °C (500 °F) should be observed.
Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the weld splatter.
Weld Specifications
Low Hydrogen Electrodes for the SMAW Process
The tables that follow list the mechanical properties of welds that are deposited by low hydrogen electrodes.
| Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.5 E10018-D2" | |
|---|---|
| Tensile Strength | 690 MPa (100076 psi) |
| Yield Strength | 400 MPa (58015 psi) |
| Elongation | 22% |
| Impact Toughness | 27 J @ -18 °C (20 ft lb @ -20 °F) |
| Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018" | |
|---|---|
| Tensile Strength | 480 MPa (69618 psi) |
| Yield Strength | 400 MPa (58015 psi) |
| Elongation | 25% |
| Impact Toughness | 27 J @ -46 °C (20 ft lb @ -50 °F) |
Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer's specifications.
The table that follows shows setting for the welding current for the electrode diameter.
| Welding Current for Low Hydrogen Electrodes | |
|---|---|
| Diameter | Amperage Rating |
3.2 mm (.125 inch) |
115-165 |
4.0 mm (.157 inch) |
150-220 |
4.8 mm (.189 inch) |
2600-275 |
Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.
Flux Cored Welding Electrode for the FCAW Process
The table that follows lists the mechanical properties of welds that are deposited by the flux cored welding electrode.
| Mechanical Properties from Flux Cored Welding Electrodes That Are Classified as "ANSI/AWS A5.20 E71T-1" | |
|---|---|
| Tensile Strength | 480 MPa (69618 psi) |
| Yield Strength | 400 MPa (58015 psi) |
| Elongation | 22% |
| Reduction of Area | 18% |
| Impact Toughness | 27 J @ -18 °C (20 ft lb @ -0 °F) |
The table that follows shows setting for the welding current for the flux cored welding electrode that has a diameter of 1.3 mm (.052 inch).
| Welding Current for Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1" | ||
|---|---|---|
| Wire Feed Rate | Voltage | Amperage |
| Minimum 5080 mm (200 inch) Per Minute |
24 | 210 |
| Optimum 6985 mm (275 inch) Per Minute |
28 | 250 |
| Maximum 8255 mm (325 inch) Per Minute |
29 | 300 |
Note: The settings for the welding current can vary due to the position of the weld. Also, the settings for the welding current can vary with the manufacturer of the welding electrode.
Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The volume of the fillet weld should not exceed 8.0 mm (.315 inch).
Arc Welding Electrodes for the GMAW Process
The table that follows lists the mechanical properties of welds that are deposited by the GMAW Process.
| Mechanical Properties of Welds from Arc Welding Electrodes That Are Classified as "ANSI/AWS A5.28 ER100S-2" | |
|---|---|
| Tensile Strength | 690 MPa (100076 psi) |
| Yield Strength | 610 MPa (88473 psi) |
| Elongation | 16% |
| Impact Toughness | 68 J @ -51 °C (50 ft lb @ -60 °F) |
The welding parameters will vary with the position of the weld and with different electrode manufacturers.
Weld Inspection
The weld should not have any of the conditions that follow:
- Cracks
- Porosity
- Undercut
- Incomplete Fusion
In order to verify the quality of the weld, refer to "American National Standards Institiute (ANSI)/American Welding Society (AWS) Specification D14.3" and ISO 6520.
Fabrication of Components for the Rework of the Base Plate
Fabricate the following components from either ASTM A572 grade 50 structural steel or ASTM A656 grade 50 structural steel.
Fabricate four extensions (1) for each body that is being reworked.
Note: Before fabricating extensions (1), fully retract the ejector blade in order to measure the gap between the edge of the ejector blade and the base plate. Use the measured dimension in order to determine if dimension (E) in Table 7 needs to be longer. Tailor the extensions in order to individually suit each machine that is being reworked.
 | |
| Illustration 2 | g01068596 |
Extension (1) | |
Fabricate extensions (1) from 10 mm (0.40 inch) thick structural steel. Refer to Illustration 2 and Table 7.
| Dimensions for Extensions (1) | |
|---|---|
| A | 20 ± 1 mm (0.79 ± 0.04 inch) |
| B | 90 ± 1 mm (3.54 ± 0.04 inch) |
| C | 10 mm (0.40 inch) Approximate |
| D | 10 ± 1 mm (0.40 ± 0.04 inch) |
| E | 20 ± 1 mm (0.79 ± 0.04 inch) (1) |
| F | 4 ± 0.5 mm (0.16 ± 0.02 inch) × 45° Chamfer |
| G | 130 ± 1 mm (5.12 ± 0.04 inch) |
| ( 1 ) | This dimension is normally sufficient. Before fabricating the extension, you are advised to check if a longer dimension is required. |
Welding Details
When you install the fabricated components to your machine, please note that you must tailor the fit of the fabricated components in order to conform to any deformation of the body that may have occurred because of use of the machine.
 | |
| Illustration 3 | g01068615 |
Typical example that shows the left side of the body | |
Position extensions (1) to the base plate of the body before tack welding the extensions in place. Ensure that the extensions are in the same plane as the base plates of the body before welding the extensions fully in position. Refer to Illustration 3 and Table 8. For more information on the specifications and qualifications for the welding, refer to ""Weld Specifications and Qualifications" ".
| Welding Information | |
|---|---|
| X | 1000 ± 2 mm (39.37 ± 0.08 inch) |
| Y | 335 ± 1 mm (13.19 ± 0.04 inch) |
| Z | 4 mm (0.16 inch) Fillet Weld |