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New Holland EC240 Excavator SN 724002-Up Excavator-691-720

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71 views30 pages

New Holland EC240 Excavator SN 724002-Up Excavator-691-720

Uploaded by

leogerguz
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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REPAIR WELDING TECHNIQUES 3.2 Cracks in hub connections Fig. 7 shows the connection of a hub to a box-type section which is accessible only from one side. Fig? 1 Hub 2 Web plate 3 Square-edge butt joint 4 Fillet-weld backing, welded before closing of the box-type section, ‘The weld is characterized by a fillet-weld backing on the outer edge and the chamfered web plate. ‘The following defects may occur: 3.2.1 Cracking along the center of the seam (fig. 8) Fig ‘A possible cause is a broken fillet-weld backing, Counter-measures: Gouge out the crack carefully (fig. 9). Weld the gouged joint (fig. 10) Gouge out the web plate (2) in the area of the filet-weld backing round the hub (1) and down to its collar (fig. 10). Weld the gouged joint (fig. 11) Fao 1_| Fig. 10 1_| Piatt Page 25 REPAIR WELDING TECHNIQUES 3.2.2 Sharp, exactly radial crack along the unchamfered edge ‘A possible cause is a lack of fusion in the uncham- fered edge of the joint (see arrow in fig. 12). Fig 12 Counter-measures: Gouge out the crack carefully (ig. 12) Weld the gouged groove (fig. 14) Fig. 18 Page 26 REPAIR WELDING TECHNIQUES 3.3 Welding on of a metal cylinder by the back-step technique The following example describes the welding of a machined cylinder onto an undercarriage. Welding by the back-step technique can always be employed where as distortion-tree a weld as possible Is required, ‘This applies to circumferential seams as well as to longitudinal seams. Fig. 18 shows how to execute the weld between the web plate of the cylinder and the base plate. Fig 15 A. Outer side of cylinder B Inner side of cylinder Welding Is carried out in the normal operating post- tion, Welding position: horizontal Correct positioning of the electrodes avoids defects from incomplete fusion (9, fig. 16) at the web plate edges. 33.1 Working sequence 1. Position and align the cylinder in accordance with the drawing. Tack the cylinder solidly on the ‘outside and carry out a dimensional check after tacking. A Wy’ Pat? 2. Welding of the 1st pass from the inner side of the oylinder (fig. 17). For this work use rod electrode © 3.20 mm, Weld in accordance with the back-step proce- dure, step length: approx. 250 mm Fig. 18 shows an example for the back-step technique. Fig 16 Fig 18 Page 27 REPAIR WELDING TECHNIQUES 3. Grind weld joint clean working from the cylinder outside. Remove any slag residues from the ist ass and completely grind out any cracked tack welds, Do not weld over cracked tack welds! Fig 19 4, Weld the full seam on the cylinder outside. The example in fig. 19 shows a cylinder wall thick- ness of 15 mm. For other plate thicknesses, the build-up of the weld has to be planned and executed accordingly. Rod electrode 2nd pass: Rod electrode 3rd and 4th pass: 03.20mm 4 0r5mm Weld all beads in the back-step procedure and stagger starting and end points of each new layer. Example: Seam welded Fig a7 ‘A. Joint propared Joint welded Double-V butt weld (fig. 50). Seam accessible from 2 sides after turning of the component Q B © Root gouged out from the under-side D_ Root capped V-butt weld (fig. 48). Seam accessible from 2 sides after turning of the component © VANYADAS ZS A B c D DAZWINRMNE| 2 Oo Fig. 50 ‘A Joint prepared B Root welded © Plate tumed, root gouged out D Seam welded Fig 48 A Joint prepared B Joint welded © Plate turned, root gouged out D_ Root capped Page 36 REPAIR WELDING TECHNIQUES 3.6.1.3 V-butt weld with backing strip accessible from 1 side A Rud MES Fig st ‘A. Backing strip attached B Joint prepared and 1st root bead welded © 2nd root bead welded D_ Seam welded \V-butt weld with backing strip 30x6 (fig. 52). Seam 362 TJoints 3.6.2.1 Toints (fig. 53), accessible from 2 sides TTY Fig. 53 ‘A Web and chord plates tacked B__Single-bevel weld deposited © Root gouged out D Seam welded 3.6.2.2 Toints with backing strip (fig. 54), acces- A B QsS A B c D a Pitt c D RS, aS ‘A Weld-backing strip attached B Joint prepared © Joint gouged out (grinding) D Seam welded ‘A Backing strip welded B 1st root bead welded © 2nd root bead welded D Seam welded Page 37 REPAIR WELDING TECHNIQUES 3.7 Closing of working openings, renewal of component areas Openings (fig. 55) should be as small as possible but Weld seams [2] and [3] alternately and use the so- as large as necessary in order to allow the unimped- called "back-step procedure" for the long seams. ed use of tools. Back-step welding: Experience: Openings 300 mm long and 200 mm high are normaly sufficient. 3.7.1 Closing a working opening Wold seam [4] in the same way as seam (1) Fig 55 ‘The following example (fig. 55) is suitable for plate thicknesses up to 25 mm. Fig. 56 shows a backhoe stick. The diagram of mo- ments clearly shows the areas of highest loads and thus of greatest stresses. Seam [1] is therefore the ‘seam that lies in the area of high chord stresses, Weld seam [1] from the middle outwards to the left land right to the midpoint of the corner curvatures. Finish upper beads or passes approximately 15 mm before reaching the end of the underlying bead or pass. Allow the completed weld seam to cool down to approximately + 50°C. Fig. 56 Page 38 REPAIR WELDING TECHNIQUES 3.7.2 Closing a web-plate opening Fig 57 1 At the web-plate (2, figs. 57 + 58), chamfer the edges to be welded with approximately 10° Width b of the chamfer in reldtion to the plate thickness can be seen in fig. 70, page 42 2 A Cc Prepare backing stip (8) from flat steel 30 x 4 bent on edge or burn out of 4 mm thick plate. Do not tack-weld backing strips trom flat-steel bars for lack of cover at the rounded comers. 4. Attach backing stip (3) 0 the web plate (2) by means of screw clamps (ig. 60). Do. not tack- wold but rather weld with a S mm filet seam running all around (fig. 61), SSS Zr Ny Fg.60 ‘After welding the filet seam, clean the contact ‘surface for the cover plate by removing all races of weld spatter (arrow, fg. 61). AB cD 2 1 4 Fig 58 2. Gouge out the longitudinal seams between chord 3. plate (1) and web plate (2) over a distance of approximately 100 mm (fig. 58). Attach backing strip (3, fig. 59), but only to the web-plate edges. WG, F Fae Page 39 REPAIR WELDING TECHNIQUES 5. Prepare cover plate (6, fig. 62) for the repair ‘opening. For this purpose, use a new plate of the same thickness and’ chamfer as_shown, Press cover plate (5, fig. 64) against backing sttip by using screw clamps. In workshops, this ‘ean be done with box-lype section widths of up tee ioeat a tartee ee \t ‘ 6. Attach cover plate (5, fig. 63) and check for perfect weld joints, The cover plate must be in full-face contact with the backing stip. In case of distortions due to welding, the backing strip has to be straightened, aa) ne Fig. 63 If the use of screw clamps is not possible, the cover plate should be fastened by so-called “hold-down strips" (6, fig. 65). Attach the hold- down strip (6) to the web plate (2) with a fillet weld, Fix the cover plate (5) by driving wedges (7) between plate and strip, After welding of the cover plate, remove hold- down strips by flame-cutting, Grind welded areas smooth and clean, Do not knock off hold-down strips with a ham- ae 666 5 3 2 Fig. 65 Page 40 REPAIR WELDING TECHNIQUES 7. Weld on cover plate (fig. 66) (x. ght a 2 ad. 5 {a} co 2 2 c 1 D vos Itis essential to observe the welding sequence shown. The symbols used have the following meaning: Sequence a Start e———-> End Weld seam {1] approximately to the midpoint of the corner curvature. Place the first bead exactly between cover plate (6) and backing strip (3). The upper bead must end approximately 15 mm before the end of the underlying bead. After welding of seam [1], the cover plate may shrink. Proceed by welding seams [2] and [3]. Make sure that the seams interiock properly with the ends of seam [1] (prepare by grinding). Weld the other ends through to the chord plate. The end of seams [2] and [3] at the chord plate are to be ground as shown in fig. 68, so as to obiain the Same shape of the welding joint as. the one between web and cover plate Finish the sequence by welding seam [4]. The tends of welds (2} and [3] must not come to lie against interruptions or starting points of seam [4]. If possible, weld seam [4] with continuous stringer beads from one end to the other. Finish by grinding the surfaces of seams (1), 2], and (3] flush with the adjacent plates (fig. 67), Page 41 REPAIR WELDING TECHNIQUES 3.7.3 Replacing a chord-plate section 3.7.3.1 Salient chord plate In a box-type section with 2 web plates (fig. 68), a cchord-plate section Is to be replaced by a new one. Fig 68 Fig 69 1. Chamter welding bevels at 10°. Width b (fig. 69) can be read from fig. 70 below. PLATE THICKNESSt | CHAMFER WIDTH b 8 20 10 20 R 25 5 3.0 20 35 25 45 30 55 35 65 40 70 45, 80 50 9.0 Fig. 70 2. Work out the longitudinal seams between web plate (2, figs. 68 + 69) and chord plate (1) over a length of approximately 100 mm from the point at which the new piece is to be fitted. 100 1 AB cD fam tl os 3 (att D \ a) 2 Fart Page 42 REPAIR WELDING TECHNIQUES 3. Attach backing strips (3, 4, figs. 72 + 73) at the two remaining ends of the chord plate (1). Fit the Weld the backing strips (3, fig. 75) with filet seams to the web plates (2) plates properly and without any gaps, i 30 | / / | 3 > a |A2 3 aN) 4 Fa 75 ad 6. Tack-weld backing strips (4, fig. 76) to the outer side of web and chord plates 1 a 34 if NV, 7 \ 1 2 Cort 4 ~ “p23 2 4 for cow For the backing strips (3,4) use flat steel 25 x 4 mm. Fit backing strip (3) exactly between the two web plates (2). Adapt extemal backing strips (4) to the joints of the web plates (2) and allow them to extend outwards by approximately 30 mm. 4. Tack-weld backing strips (3) between the web plates. If distortion occurs due to welding (fig 74), the backing strips have to be straightened. Fig 76 7. Tackweld run-off tabs (5, fig. 77) to backing strips (4). Ct. also the section "Ends of butt welds". Fig 74 Fig? Page 43 REPAIR WELDING TECHNIQUES 8. Fit the new piece of chord plate (6, fig. 78). The Old piece of chord plate previously removed must not be used again. Make sure that the new piece of plate rests properiy on its support. Fig. 78 8. Weld the two filet seams (fig. 78) as shown, without interruptions and without any tack points Fig. 78 10. Weld in the new piece of chord plate by strictly ‘observing the welding sequence shown (fig. 80). The symbols have the following meaning’ Sequence o Start @_> End Seam {1} ~ transverse seam in the area subject to high chord-plate stresses. Weld seam com- pletely ‘Seams (2+ [3] - weld longitudinal seams in the direction indicated by the arrows, ‘Seam [4] = weld transverse seam com- pletely ‘Seams [5]+[6] - weld longitudinal seams in the direction indicated. by the arrows. Weld seams [1] and [4] with stringer beads and continue the weld onto the 50 mm long run-off tabs (4). Remove the run-off tabs after welding with @ clean cut ‘The surfaces of the transverse seams must be ground clean and flush with the adjacent plates. Work out properly the longitudinal seams in the area of the transverse seams. The grinding drag lines must run parallel to the longitudinal lines of force. If possible, the transverse seams should be subsequently subjected to ultrasonic testing Practical hint In welding the longitudinal seams [2] [3] [5] and [6] there must be no welding starts or stops in the area of the transverse seam (backing strip). 13 5 3 1 en aS Page 44 REPAIR WELDING TECHNIQUES 3.7.32 Recessed chord plate The following example shows how to fit a new re- cessed piece of chord plate by welding it into a box-type section with 2 web plates (fig. 81) S> S LY Fig.at Working sequence: Fig 82 4. Chamfer welding bevel at 15°, Width (b, fig. 82) can be taken in fig. 70, page 42. 2. Work out longitudinal seams between web plate (2, fig. 83) and chord plate (1) over a distance of approximately 100 mm beyond the cutting edge Of the chord plate. KY ] HU H ‘Attach backing strips (3, figs. 84 + 85) to the two remaining ends of the chord plate (1). For the backing strip (3) use flat steel 25 x 4 mm. Fit in backing strip (8) properly and without ‘any gaps between the two web plates (2). Fig 63 Fig.08 Page 45 REPAIR WELDING TECHNIQUES Weld in new piece of chord plate by strictly ‘observing the welding sequence shown (lig. 87) ‘As to the welding of the seams, cf. 10 on page 44 4, Tack backing strips (3) between the web plates (fig. 85 + 86). If there is any distortion due to welding, the backing stips have to be straight- ened. RSS SSS ZZ} SSE "BH mn Fig. 86 F.87 Page 46 REPAIR WELDING TECHNIQUES 3.7.3.3 Possible causes of damage to chord plates: The following faults may occur in chord plates of box-type sections: 1. Transverse cracking ‘The chord plate may crack open transverse to the ‘component in the chord plate, Fig. 88 Reason for the damage: Expansion of the component obstructed by non-opt mally dimensioned or welded component elements such as bearing blocks, ribs, reinforcing plates etc. Measures: ‘The component can almost always be repaired by welding. For a durable repair, the component must be opened to allow the welds in the component ‘areas subject to maximum stress to be capped. 2. Plate parting ‘The plate may crack open almost exactly at the centre of the plate, as shown in the diagram (fig. 89). Fig. 88 Reason for the damage: There are non-metalic inclusions from the pool (seg- regation defects), distibuted over the entire plate dimension, atthe centre of the plate Measures: The plate cannot be repaired by welding For durable repairs, the damaged plate must be re- placed, It is to be assumed that areas of the plate Not yet cracked open would. eventually also crack open as a result of the dynamic stress on the compo- nent 3. Longitudinal cracking The chord plate may crack open in longitudinal direc- tion of the component parallel to the adge of tha plate (fig. 90) NN Fig.60 Reason for the damage: The component is not adequately stable. The chord plate is deformed under changing loads, resulting in ‘material distortions at the weldichord plate transition. Measur The chord plate cannot be repaired by welding, For a durable repair, the plate must be replaced in the cracked area. The new plate must be thicker than the cracked one to reduce deformation to a tolerable level Page 47 REPAIR WELDING TECHNIQUES 3.7.3.4 Repair of a boom with a salient chord ‘The top chord of the boom is cracked (arrows, fig. 91). 4. Remove support eye (1, fig. 91). 3. Repair the damage inside the box-type section and in the side walls. 4. Weld on new top chord (fig. 99). Increase plate thickness by 5 to 10 mm, Figg 2. Remove top chord in the area of damage (fig. 92) ecommendation: Remove the curved section of the top chord completely. F983 Weld support eye back in place (fig. 94). Machining of the severed parts is generally not required if fiting and welding are carried out caretully, Fig 82 Fig 98 Page 48 REINFORCING OF STEEL COMPONENTS 4, Reinforcing of steel components. The reinforcement of components by welding can be done in the following ways: + Covering up a damaged area after repair by re- inforcing plates, with the aim of reducing the me- chanical stresses G (Nimm) in the repair area, + Eliminating deficiencies caused by changes in shape, 9. the problematic case of “open sec: tionsiciosed sections", shape of stiffening ribs, Configuration of frame comers, ete. + Eliminating deficiencies by means of changes in shape by bulld-up welding, e.g. on cast-steel pars, The necessity of a component reinforcement should, if possible, have been proved by a simple analysis. 4.1 Reinforcing plates 4.1.1 Dimensions + Length of reinforcing plates The ends of reinforcing plates are places where metallurgical and shape-induced notches occur Which may lead to damage by the concentration of stresses (Part A, fig. 1). + Thickness of reinforcing plates ‘The thickness of reinforcing plates should be max. 60 % of the thickness of the plate to be reinforced (fig. 2) 50,6 xty ty te Fig? ‘An analysis shows that thicker reinforcing plates ‘cannot be connected to the plate to be reinforced as the welding seams required would be too large. Thicker plates moreover lead to large shape-in- duced notches and make the component heavier than is really necessary. + Width of reinforcing plates Fiat Reinforcing plates should therefore be dimen- sioned in such a way that they end in areas with low basic stresses (Part B, fig. 1) In stool components, stresses are often highest near the ages. The reiforeing plate should A therefore be as wide as the plate to be reinforced (A fig. 3), 3 t 23 @ ze A $3 a ovl B g © Pe 4 con Bg ras Na] FOr practical reasons, reinforcing plates of less than'8 rem tetnwes’ can not be. chamfered. fn such cases, the reinforcing plate (B, fig. 3) must be narrower to leave enough space for a fillet weld, ‘The upper edges (arrow, fig. 3) of the plate to be reinforced and of the reinforcing plate should not bo-molied away Page 49 REINFORCING OF STEEL COMPONENTS 41.2 Shapes of reinforcing plates Reinforcing plates should, if possible, have simple shapes with straight edges (figs. 4 + 5). To relieve the transverse seams of stresses, welding slots should be provided (fig. 4), Fig ‘Another possibility consists in welding on strips of plate. In this case, the longitudinal seams must be welded continuously. Advantages ‘The edge zones, where high stresses normally prevail, are reinforced. Another advantage is the reduction of weight (fig. 8). Figs ‘Small plate strips, flat-steel or wide flat-steel bars, can be more easily fitted and bent (fig. 5). Fas Non-linear plate shapes (figs. 7 + 8) are difficult manufacture and do not offer any advantages with regard to the distribution of forces. Fa Page 50 REINFORCING OF STEEL COMPONENTS Fie 4.1.3 Welding slots In addition to the welding seams along the outer edges, the seams in welding slots are equally intended to enhance the connection of reinforcing plates (figs. 9 and 10) Fig. Finish the ends of the slots by diiling stopper holes (tig. 9) Slot width = 2 x plate thickness (fig. 9) 2b CD Ue SSssss ‘The welding seams in the welding slots are ideal thrust connections between the reinforcing plate and the plate to be reinforced. Circular welding holes are disadvantageous (fig. 11): Fig tt The parts of the seam transverse to the lines of forces cannot bear any loads and can therefore not be considered for analysis, ‘The reinforcing plate's cross-section is strongly re- duced. ‘The hole edges are subject to stress concentrations. Page 51 REINFORCING OF STEEL COMPONENTS 4.1.4 Fitting of reinforcing plates: Reinforcing plates should be in full-face contact with the plate to be reinforced, i.e. they should lie as closely as possible against the base plate. The air {gap should, if possible, be nil For relatively small components and thin plates, the reinforcing plates should be squeezed against the base plate by means of screw clamps (fig. 12) After tack-welding, the welded-on stud may only be knocked off. The area in the base metal where the studs have been removed must be carefully prepared by grinding before the sit is welded. SES Fig 12 For larger components and thicker plates, the reinforcing plates should be held in place by wedges (fig. 13). ‘This is, however, only possible at the edges of plates. Welding and cutting of the wedge holders must be done properly. Never knock off wedge holders with a hammer, rT OF i | i mn Fig. 18 ‘The central area of plates can be pressed into position by means of bolting (fig. 14) ‘This is particularly recommended for large plate sections. The studs can be favourably placed near the welding slots, Page 52 Fig ta 41.5 Weld seams of T-joints Reinforcing plates in T-joint areas should be welded in such a way that a connection between all 3 plates is formed (fig. 15). Fig 15 REINFORCING OF STEEL COMPONENTS 4.2 Shaping plates for repairs ‘The plates needed for repair or reinforcement pur- poses can be shaped in different ways. Problems which may arise in the different shaping methods: + Edge folding (Fig. 16) cold shaping: ‘observe minimum bending radius; watch for longitudinal cracking in the bending Fig 16 + Pressing (Fig. 17) cold or warm shaping; with cold shaping, observe minimum bending ra- dius and watch for longitudinal cracking in the bending area, Fig. 17 + Rolling (Fig. 18) ‘cold shaping; no problems to be expected after shaping, 4 On Fg1@ + Multi-edge bending (Fig. 19) ‘cold shaping Cracking at the lines where the tools act on the plate edges is to be expected; ‘chamfer plate edges approx. 2 x 2 mm at top and bottom after mult-edge bending, = ' veecese ———————————— AB Fig. 19 Page 53 REINFORCING OF STEEL COMPONENTS 43 Reinforcing by shape improvements 4.3.1. End of ribs ‘The terminal section of ribs ending on highly stressed parts of components is to be shaped as shown in fig 20. This applies equally to ribs of minor importance, b Fig.20 tyelo], feyeyulyu OO et*«ts|[olo|o|»| «2 wo f«]e [ole] |) 2 wz] s |e | 0 | wo] 20 | 0 | = |e |e | | wo] 0 | | w ze [2 | 0 | | 2 | oo | 2 a fe [2] fw fo | | 2 3 [| 15 | 10 | 200 | 30 | 70 | 2 ‘Areas where overlapping takes place should be ground smooth (fig. 21) Atel 7 na Make sure that the welding seam as such is not ground off. Fig.21 43.2 Open sectionsiclosed sections The moment of torsion resistance of a closed section is approximately 500 times greater than that of an open section of otherwise similar dimensions. This leads to stress peaks in the zone of transition from the opened to the closed section. These peaks are caused by deformation impediments and con- straints (ig. 22) q Ele E Figee T Torsional moment © Open section G Closed section Page 54

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