SIS Media Number: BI646644

Media Number: SA13-009

7 May 2013

Technical Information Bulletin

Hoist Drum Cracking Occurring at Spider Weld Joint on Certain 7495

and 7495HF Electric Rope Shovels

Electric Rope Shovel

7495
7495HF

Table of Contents

Introduction ............................................................. 1
Problem .................................................................. 1
Solution ................................................................... 2

Introduction
This document is to advise customers of a method to maintain or extend the life of a component.

Problem
An instance of crack formation on the hoist drum at the welded joint of the non-drive end spider and rolled plate,
specifically on part number S064255.

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All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
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 SIS Media Number: BI646644
Media Number: SA13-009
7 May 2013
Solution

Regular inspections of the hoist drum for cracks in the area of the welded joint between the drum and the spider.

Illustration 1 – Hoist Drum

Illustration 2 – Hoist Drum Cross Section

 SIS Media Number: BI646644
Media Number: SA13-009
7 May 2013

If cracking is found, perform the following weld procedure.

Material Spec:
SD3060A, SD3523

Electrode Type:
FCAW E81T1-Ni2 0.052” Dia
Or
E8018-C1 1/8” Dia

Current: DCEP
275-375 Amps (FCAW)
90-130 Amps (SMAW)

Volts:
27-31 (FCAW)

Preheat:
o
Minimum 500 F

Notes / Materials
• Insure all electrodes are kept dry
• Do not expose electrodes to any contaminants such as grease, oil, water, or any other possible sources of
moisture
• Use temperature indicating crayon to insure preheat temperature is in according with procedure
• Magnetic Particle testing will need to be performed to ensure crack removal.

Preparation & Inspection

• Thoroughly clean surfaces to be welded of all dirt, oil, paint and grease. Any possible sources of moisture or
contaminants need to be removed
• Excavate cracks using the following air arc salvage repair technique. Ensure the material is brought to the
preheat temperature prior to air arcing.

1. Starting in sound base metal approximately 1” from each end of the crack, gouge toward the center of the
crack. The extent of metal removed should be approximately that shown in Illustration 3.

Illustration 3 – Salvage Repair Technique

2. Remove the remainder of the crack between the two gouged end areas to the same depth as the initial
gouges
 SIS Media Number: BI646644
Media Number: SA13-009
7 May 2013
3. Repeat sequence 1 and 2 in layers approximately 0.25” deep until the crack is completely removed. This
will necessitate widening the groove toward the top surface as the depth increases per end view. MT to
ensure full crack removal.

• Once it is certain that the crack is removed, shape the excavated (arc gouged) parts of weld to form a
Single-V-groove with a 2.00” minimum depth as shown in Illustration 4. Note: Make sure all gouged surfaces
are ground clean to remove carbon arc deposits before welding

Illustration 4 – Hoist Drum Cross Section

Welding Technique
• Weld groove complete using above parameters. Thoroughly chip and wire brush all welds immediately after
depositing.
• After completion of welding, let repair slow cool by wrapping with insulating blankets

Finishing and Inspection

• Grind all weld reinforcements smooth.
• Perform final M.T. to insure no cracks after grinding. Also insure no other visual defects such as slag inclusions
or porosity.