as CRAWLER HOOK CASTING WELD REPAIR augens July 23, 2003 MATERIAL SPEC. SD3520E ELECTRODE TYPE E8018-C1 1/8" Dia. or E8OTI-Nit 3/32" Dia. (FCAW) CURRENT DCEP 90-130 AMPS. 350-550 AMPS (FCAW) TRAVEL SPEED 2-6 LPM, 8-16 L.P.M. PREHEAT Minimum 400°F Maximum 500°F MATERIALS * Insure all electrodes are kept dry according to Bucyrus Int! Welding Standards. Do not expose electrodes to any contaminants such as grease, oil, water, or any other possible sources of moisture. Use electric Dry Rod holders to store electrodes on repair site. Follow Weld Standards, section WS801, as a guideline for drying time and temperature, * Perform MT according to Quality Standards QS6810. PREPARATION & INSPECTION 1. Thoroughly clean surfaces to be welded of all dirt, oil, paint, and grease. Any possible sources of moisture or contaminants need to be removed. 2. Fit-up hook casting (D002067) using drawing numbers £002182 and E002707. See weld joint detail below from drawing details, note backgouging and finishing symbol.as CRAWLER HOOK CASTING WELD REPAIR sugynus July 23, 2003, Grind Smooth WELDING TECHNIQUE 3. Uniformly preheat repair area to 400°F. Do not let temperature fluctuate during repair, always maintain this minimum temperature. 4, Weld joint using above parameters. Thouroughly Chip and wire brush all welds immediately after depositing. Backgouge second side of joint to sound metal. 5. After completion of welding let repair siow cool by wrapping in insulating blankets (such as kaowool).. FINISHING AND INSPECTION 6. Blend Grind per drawing weld symbol, Perform Visual inspection to WS 1201 and drawing. Random UT according to WS1202 page 1. 7. Certain dimensions may require stock before stress rel.. Perform full dimensional audit to insure that all effected machining dimensions are within specification including the outside lower roller bores. 8. Local stress rel. hook casting weld at 1100F for 3 hours using procedure SD3902. 9. MT weld repair again after stress to insure no cracks, 10.Machine according to drawing dimensions, use forms BA-02, BA-O1, AA-02, AA-04 to document. Edward E. Spadoni Welding Engineer