VOLVO CONSTRUCTION EQUIPMENT

SERVICE BULLETIN
Language Code Group Product No. Version Date Page
GB 711 ART 39 K 1 2012-05-24 1/10
Applies to models
A35E, A35E FS, A40E, A40E FS

ONLY FOR DISTRIBUTORS / DEALERS

Repair instruction, rear section front frame

WARNING
Please pay attention to the safety instructions in the Operator's
and Service Manuals concerned.

This Service Bulletin is to be considered as technical information

only and is not subject to any reimbursement programs outside
normal warranty.

Cause
Cracks have been detected in weld joints at the rear section of
the front frame

Action
Inspect the area with respect to cracks. Recommendation is that
this is done the first time after 6000 operating hours and then after
each 2000 operating hours. If crack/s are seen at inspection, this
must immediately be corrected.

Models Ser. No.

A35E, A35E FS All
A40E, A40E FS All

Fig.1
1 Areas where cracks have occurred
2 In some cases where cracks are seen in the
upper part of the rear section cracks also
have occurred in this areas

Volvo Construction Equipment Customer Support

Carl Lihnells väg, SE-360 42, Braås, Sweden
Language Code Group Product No. Version Date Page
GB 711 ART 39 K 1 2012-05-24 2/10

Work instructions
1 Place the machine in service position
NOTE!
Take necessary precautions before doing any welding. Follow the
instructions concerning this in the Service manual and Operator’s
manual. Make sure the connectors are removed from all ECU’s.

2 Separate the front unit from the rear unit in the steering joint.
See suitable instruction in service manual A40F, operation
742-040. Even though the instruction is from the F-model,
the operation is applicable also on the E-model.

Repair of frame at upper steering joint

3 Remove the paint, in this case in the upper steering joint and
inspect the area.

Fig.2

Fig.3
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4 If cracks are found in the weld seam in the area marked in

figure, grind out the cracks to locate how deep they are.

Fig.4

5 If it is discovered during the inspection that the cracks

penetrate into the horizontal plate. Contact your region's
technical support group, with clear digital photos, and
description to show the fault in detail. You will be given
guidelines, how to proceed. This information can be
submitted in Techline.

Fig.5
1 Vertical plane
2 Horizontal plane

Fig.6
1 Vertical plane
2 Horizontal plane
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Upper steering joint outer part

6 Cracks located in the marked area must completely be
removed by grinding. In the marked area, see fig. 7 and 8,
the existing weld seam should be removed by grinding and
a preparation of the vertical plate should be done, so that a
45° angle can be measured between the plates, left and right
hand side.

Fig.7

Fig.8

Upper steering joint center part

7 Cracks located in the marked area must be removed
completely by grinding.
8 Repair is also required if cracks are discovered in the vertical
plate.

Fig.9

NOTE!
The crack must be completely ground out to base metal prior to
re-welding and elimininated from the affected area.
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9 To prevent further cracking; drill an 8 mm (0,31 In) hole at

the end of the crack.

Fig.10
1 Crack, grinded out to base metal
2 Hole, 8 mm (0,31 In)

10 After welding preparation, carefully clean the area around

the steering joint.
To achieve a good result, it’s essential that all contamination,
such as paint, grease, moisture, etc. affecting weld repair
are removed.

Fig.11

NOTE!
Take necessary precautions before doing any welding. Follow the
instructions concerning this in the Service manual and Operator’s
manual. Make sure the connectors are removed from all ECU’s.
Make certain the welder ground wire is as close as possible to the
area to be welded.
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11 With a gas torch, preheat the welding area, the temperature

must be between 140°C (284 °F) and 180°C (356 °F) ,
maximum 200°C (392 °F) during the welding operation.

Fig.12

12 It’s essential that the welding rods that are used during the
operation are kept moisture free.
After that the package has been opened, the welding rods
should be stored in a dry storage container, type ESAB PK-1
or equivalent during the welding process. The temperature
in the container should be between 50-80 °C (122–172 °F).
After the work is complete the remaining electrodes, if they
are to be used in later operations, must be stored in a
temperature of 150 °C (302 °F). If not, they should be
scrapped.
Recommended welding rods: OK 48.00 2,5 mm or
equivalent.
Fig.13

Welding lower ear upper steering joint outer part

13 Start with the root bead, it’s essential to after each weld bead
remove the slag, and if the weld are uneven, grind the weld
seam and clean the area so that the next weld bead is given
the right conditions. When the last weld seam are done, the
weld toes, upper and lower should be grinded (rotary
grinding die) to radius 5 mm (0.2 In).
Throat size: a5 mm (0.2 In)
Penetration 11 mm (0.43 In)

Welding sequence
Fig.14 1 Root bead
1 Weld toes 2 Second weld bead
3 Third weld bead
4 Fourth weld bead
5 5-N: Fifth weld bead
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Welding lower ear upper steering joint, center part

14 Start with the root bead, after each weld bead it’s essential
to remove the slag, and if the weld is uneven, grind the weld
seam and clean the area so that the next weld bead is given
the right conditions. When the last weld seam has been
done, the weld toes, upper and lower should be grinded
(rotary grinding die) to a radius 5mm (0.2 In).
Throat size: a5mm (0.2 In)
Penetration 2 mm (0.07 In)

Welding sequence
1-n. = Root bead
Fig.15 n+1.= Second weld bead
1 Weld toes n+2.= Third weld bead

Repair of frame at lower steering joint

15 If cracks are seen in the lower steering joint an operation
where the backing bar located in the joint between the rear
frame section and the frame beam, partly have to be
removed. The purpose with this operation is to tie the parts
together with weld seams.

Fig.16

Fig.17
1 Rear frame section
2 Backing bar
3 Frame beam
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16 Locate the backing bar by smoothly grind the side of the

bottom plate on the frame (location see fig) until the end of
the backing bar appears.

Fig.18

Fig.19 Grinded area

17 With a rotary grinding die, grind out/remove the weld bead

left and right side of the backing bar.

Fig.20
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18 Grind away the weld bead between the backing bar and the
vertical plate and remove the end of the backing bar

Fig.21
1 Vertical plate

19 Prepare for welding by grinding the area so that there is a

smooth transition between the rear section of the frame and
the frame beam.

Fig.22
1 Rear section
2 Frame beam

20 Start the repair weld with the weld bead marked in the figure.
After welding, remove slag and clean the area for next weld
bead.
Recommended welding rods, OK 48.00 2,5 mm or
equivalent
Throat size: a5mm (0.2 In)
Penetration 2 mm (0.07 In)

Fig.23
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21 Continue by filling up the area with weld beads. After each

weld bead, remove slag.

Fig.24

22 When the last weld seam is finished, the weld toes, upper
and lower, should be grinded (rotary grinding die) to a radius
5 mm (0.2 In).
Grind the welded area.
23 Clean and paint the surface as required.
24 Reassemble the machine, use suitable instructions in the
service manual A40F op. no. 742-040
25 Restore machine from service position, test run and make
sure that machine works according to specification.

Fig.25
1 Weld toes