Silver Eagle Model 2006 VAST-20NU - 1200 Galvanized ... 18810 Parts Book.pdf · Vehicle Make: Silver Eagle Model Year: 2007 Date: 9-Aug-06 Updated: K. Fulp & G. Gaussoin QUANTITY:

(503) 281-0727 - (800) 547-6792 Rev: 12/15/2006 5825 NE Skyport Way – Portland, OR 97218 10:28:42 AM www.silvereaglemfg.com

VAST-20NU CONVERTER DOLLY PARTS AND SERVICE MANUAL

As Built for

UNITED PARCEL SERVICE

Silver Eagle Model 2006 VAST-20NU - 1200 Galvanized Dollies

Appropriation Number: 06-74 Car Numbers: 898027 - 899226

Serial Numbers: 1U3JU78117B316107 - 7306

December 14, 2006

SILVER EAGLE MANUFACTURING COMPANY


GENERAL INFORMATION

SILVER EAGLE MANUFACTURING COMPANY

5825 NE Skyport Way Portland, OR 97218

(503) 281-0727 (800) 547-6792

(503) 335-2171 Fax

www.silvereaglemfg.com

Hours:

Mon – Thu 7:00a.m. – 5:00p.m. (PST) Fri 7:00a.m. – 12:00p.m. (PST)


TABLE OF CONTENTS

GENERAL INFORMATION SPECIFICATIONS & WARRANTY

VAST20-NU (18810) Warranty

MAINTENANCE PROCEDURES Drawbar Replacement Kit - pending Drawbar Eye Removal & Installation Fifth Wheel: Operation, Alignment & Jaw Wear Laser Axle Alignment ProTorq Wheel End Assembly Procedure Phillips Electrical

PARTS LISTING 18810 VAST-20NU Frame Fifth Wheel Suspension & Table Assembly Axle Assembly - PENDING Air System Electrical


TABLE OF CONTENTS (cont.)

APPENDIX Welding & Hot-Dip Galvanizing Sealco Emergency Brake Pressure Protection Valve

No. 110257 Sealco Emergency Control Valve

No. 110376 Bendix Service Data: SD-03-1063

R-12P Pilot Relay Valve Bendix Service Data: SD-03-2201* (formerly SD-03-66)

In-Line Single Check Valves Bendix Service Data: SD-03-3611* (formerly SD-03-61)

Push-Pull Type Control Valves: PP-1 Bendix Service Data: SD-03-4020

SV-4 Synchro Valve Bendix Service Data: SD-13-4757

WS-20 Antilock Wheel Speed Sensor Bendix Service Data: SD-13-4834

MC-30 Trailer ABS Controller Assembly Bendix Technical Bulletin: TCH-013-007

EC-30T ECU Product Recall Campaign Bendix – Troubleshooting MC-30 Trailer Antilock System Bendix Fuse Adapter Kit & ID Guide


SPECIFICATIONS

VAST20-NU (16810) Warranty

Vehicle Make: Silver EagleModel Year: 2007Date: 9-Aug-06Updated: K. Fulp & G. Gaussoin

QUANTITY:Beginning Ending

UPS DOLLY NUMBERS: 898027 899226MFG. SERIAL NUMBERS: 1U3JU78117B316107 1U3JU78117B317306UPS SPEC NUMBER: APPROPRIATION 06-74SILVER EAGLE PART # 18810

GENERAL:MAKE & MODEL: VAST-20NULENGTH: OVERALL: 119"WIDTH: 96" 71-1/2" trackFIFTH WHEEL HEIGHT: 47-1/2"DRAWBAR LENGTH: 78" Centerline Eye to AxleHITCH HEIGHT: 17"OPERATIONAL USE: HIGHWAYGAWR: 20,000# GVWR: 20,000#TARE WT: 2950# maximum

FRAME:DRAWBAR: 1/4" A572-50 Steel drawbars - Huck bolted - Gr. 8, 12mm & 20mm

SIDEFRAME: 3/8" A572-50 Sideframe, crossmembers, and tailframe

SHOCK HSG: Split rectangular type - Huck bolted Gr. 8, 12mm

EYE: Silver Eagle #1171 w/square polyurethane bushings #12170 & hex nut #15315

LIFT HANDLES: Two, power zone type

TILTSTOP: Mounted under tail frame (two 1" Plates)

TAILPLATE: 4 round LED lamps riveted & guard for license lamp

LEG: Replaceable rubber block mounted to shock housingNote: tongue weight not to exceed 65lbs w/ hooks on the handles

5TH WHEEL: Silver Eagle lever operated w/ shallow ramp & end cap plateRoadside release w/ hitch pin through adjusting rod

SUSPENSION: Polyurethane boot, #12172 mounted, transverse typeUse "Never Seize" on U-Bolts and fasteners

SPRINGS: 7-leaf, 2 stage, 38-1/2" center of eye to center of eye

SAFETY CHAINS: (2) 5/8" grade 70 chains, Zinc Dichromate finish, U-Bolt mounted w/ protector(2) 5 ton clevis hooks Zinc Dichromate finish

FRAME (cont.):

2007 Dolly Specification

UPS Spec - 2007(08-09-06) UPS/SEMCO CONFIDENTIAL 1 of 4

AXLE: Make-Meritor Model-TN4671 (5" dia.) Track - 71.5"Capacity - 20,000# Spring Centers - 38-1/2"Cambered, set for 1/16" toe-in (+/- 1/32") & 0 deg. Thrust AngleCamshaft enclosure tubes installed at factory.

S-CAMS: Q+ 28 spline length: 20.406"Part No.: 221058391 (Right) 2210T8392 (Left)

ABS sensor blocks

SLACK ADJUSTERS: Gunite #SA10813, 28 spline with 1/8" end play on s-cam, set @ 103 degrees"Never Seize" on Stainless Steel clevis pins and splines

BEARINGS & RACE: Make - General OPTION: Timken when available at extra costOuter bearing HM212011/HM212049Inner bearing HM218210/HM218248Note: Bearing and race to be from the same manufacturer.

SPINDLE NUT STEMCO Pro-Torq #447-4743

HUBS: Gunite: # 5712-3 Ductile Iron Hub and Cast Iron Drum Assembly W/ ABS Tone Ring

DRUMS: Outboard Mount Hub Piloted seat

STUDS: 10 each mounted on 11.25" bolt circle, Hub Piloted

HUB CAPS: Stemco #353-5099, Sentinel vent, with magnetic plug, painted black

HUB OIL: Synthetic - MOBILUBE SHC 75W90

OIL SEALS: Federal Mogul #380025A hub mounted type

BRAKE LINING: Q+ Abex - 3030-197 OEM & 6008-1(Meritor SOR-215) Size - 16.5x7x.75Q+ pull-back springs

CHAMBERS: MGM Type 30 Service Chambers

TIRES: Tires to be inflated to 100 p.s.i..TIRES: Goodyear G314 SIZE: 295/75R 22.5 LOAD RANGE G

RUNNING GEAR:WHEELS: Type - Disc Make - Accuride 29396PKBLK21 22.5x8.25

Steel with wt of 80#, primed and powder coated black, small powder coat decalOutboard mount, (10) hand hole Wheel Offset - 6.625"Exposed rim edge painted silver. Hub Piloted Dual: YesApply grease to Hub Piloted Wheel pads

VALVE STEMS: Meyers TR - 572-E12 with Meyers V2B inflate thru caps Alligator V2B 21-534(OPTION) Dill, Schrader, or Haltec valve stems

ABS SYSTEM: Bendix 2 sensor - 1 modulator, TABS-6 valve #5014112 service relay valve (S/E 16838)Bracket mounted includes odometer & PLC4TRUCKS

PRESS. PROTECT. VALVE: Sealco #110257 With steel stemRUNNING GEAR (cont.):SYNCRO VALVE: Bendix SV-4 # w/ #28435 breather on exhaust port

PUSH/PULL VALVE: Sealco #17620 - No pop-off pressure feature with steel stem


PILOT RELAY VALVE: Bendix R-12P #109424

EMERG. CONTROL VALVE: Sealco #110376

RESERVOIR: (1) Make: Hoosier with side drain for 1423 cu.in.

DRAIN VALVE: (1 ea.) Tramec #35000 with 1/8" cable plastic coated routed to roadside frame by front of tire

TUBING: Parker, Red for emergency, Blue for Service, Black for supply from reservoir

HOSES: 3/8" rubber w/ strain guards(1) 36" on service side to lead trailer(2) 96" (service & emergency) to towed trailer mounted on vertical surface offront crossmember below upper flange of drawbars

GLADHANDS:(1) fixed, mounted on drawbar, w/ full face polyurethane seal - painted red (incoming air)(1) on 36" whip hose, w/ polyurethane compression seal- painted blue (incoming air)(1) on 96" hose, w/ polyurethane compression seal - painted red (to towed trailer)(1) on 96" hose, w/ polyurethane compression seal - painted blue (to towed trailer)

Note: Only Teflon tape or Vibraseal will be used on all threaded connections in air system

FINISH:FRAME: Hot Dipped Galvanizing per ASTMA 123/A 123M-97a as separate pieces

prior to assembly

FRAME HUCK-BOLTS: Spot paint bolts

AXLE, AIR RESERVOIR, U-BOLTS & FIFTH WHEEL: Grit blasted, 8 stage zinc phosphate and cleaning

E-Coated PPG CF590-534 Black, Epoxy Primer - baked @375 deg. F.Topcoated, BASF R-M Uno-HD Light Acrylic Polyurethane, UPS grayColor to match Sherwin Williams GC-32669

LEAF SPRINGS: Primed & topcoated w/ BASF R-M Acrylic Polyurethane

ALUMINUM, BRASS, NYLON, RUBBER, CHAIN & HOOKS: Manufacturer's finish

FASTENERS: Zinc Plated

LIGHTING / ELECTRICAL :INTERVEHICLE CABLES: (1) Phillips 7 ft. straight cable - 8/10/12 Ga. Wiring

(1) Phillips 11 ft. straight cable - 8/10/12 Ga. Wiring

FRONT RECEPTACLES: (2) Phillips #16-726 plug-in type w/ split pins

HARNESS: Phillips QCS molded assembly with full 8/10/12 cable between receptacles w/lead to ABS valve , and rear sill. Connectors for Trucklite LED lamps built intoharness (no jumpers) with shrink tubing at each AMP connector

LIGHTING / ELECTRICAL (cont.):LAMPS: (4) Trucklite #44322R red 6 LED, 4" round, stop tail and turn(ICC/ATA REQUIRED LIGHTING) (1) Trucklite #30257Y Incandescent ABS light mounted in roadside drawbar

(1) Trucklite#15219 LED License Lamp w/ pigtail & AMP connector w/ #97032 gasket & #15729 bracket

Phillips Universal Cast #12-41010


WIRING PLUG ENDS: AMP at rear for LED lights

WIRING COLOR CODE: Black -2 tail lights,Brown License plate light, 2 tail lights.Green-right turn Yellow-left turn Red-stop White-groundBlue-auxiliary Constant power ABS function on blue

REFLECTORS: Mfg. standard as required by law

GROUND: Stainless steel ground strap between fifth wheel pedestal and rear frame(eye grounded to frame by stainless steel retaining cable)

Note: Dielectric lube is to be applied to all connections and to 7-way receptacle.7-way connectors use dielectric grease, LED lamp pins to be lightly coated

ACCESSORIES:MUD FLAP: Symplastics SPRAY GUARD 24" x 18"

Plain black-no logo

HANGER: Betts Direct Flex Hanger, 25" long - Galvanized. (Vertical mounting bracket is painted)Bracket huck bolted to bar. Locking nuts and fender washer on forward side of flap.

PUSH PULL GUARD Bolt-on Guard to prevent damage to Push/Pull valve and avoid hose hooking on knob.

DOCUMENT BOX: Aluminum Line #: 23891 Document Holder w/o ClipGrote pouch mounted in document boxAdditional, laminated copy of registration inserted in document box bodyInclude original of Federal Annual Inspection form in document box, keep a record copy.

DECALS: Furnish and install unit and car numbers 1-1/2 high on reflective decal onto each drawbar.Furnish and install Do Not Sandblast Decal to document boxHub Piloted Wheel System decals mounted on side of ballast hanger Fifth Wheel Operation decal mounted to top of curbside drawbarGladhand storage decal mounted to top of curbside drawbarHostling Valve decal mounted on center of valve plateAccuride Decal mounted inside document boxPerform Fed. Annual Inspection (Install document in document box)Install FAI Decal near VIN plate - UPS part number 3416634 - Vomella Graphics Date on FAI decal should be based on a date near time of delivery (Month and Year Only) - do not pre-dateFurnish and install 5" UPS logo on curbside drawbar

OTHER: No manufacturers identification decals or logosAluminum VIN plate mounted roadside drawbarAdditional Vehicle I.D. plate mounted in curbside tailframeInstall Mylar tape on backside of license plate - secure with Huck rivetsUnit serial number & car number engraved on the curbside drawbar in .50" min. heightNo Bendix ABS information decal

NOTE: FAI decals are to be supplied by Silver Eagle

POGO STICK/BASKET: Pogo stick to be installed on valve plate and expanded metal basket to be installed between frame - pogo stick Phillips #17-0201 Gold Chromate finish or equivalentPogo stick to include two 6" springs w/ 4 hole clamp


This warranty will be void in the case of:a) Any buyer modifications not expressly approved by Silver Eagle.b) Use of non-authorized replacement parts.c) Misuse or failure to maintain or service the product in accordance with Silver Eagle recommendations.

COMPONENT: Manufacturer: Manufacturers Warranty:Time Miles/Hours

Wheels Accuride 5 year unlimitedTires Goodyear 1 yr. prorated tread, 5 years on casingABS Bendix 36 mos. 350,000/10,800Pilot Relay Valve Bendix 12 mos. 100,000/3,600

Sealco 24 months - parts only n/aSuspension Silver Eagle 5 year Limited unlimitedSpring Boots ATRO 3 year - parts only n/aFifth Wheel Silver Eagle 5 year Limited unlimitedFrame Silver Eagle 5 year Limited unlimitedLunette Eye Silver Eagle 5 year Limited unlimitedEye Bushing ATRO 3 year - parts only n/aAxle Beam Meritor 5 Years - Parts only 500,000

Axle Components Meritor5 Years - Parts only (Q+ Cam Parts & Labor)

500,000 comp. (Q+ Cam 750k)

Slack Adjuster Gunite 5 year 500,000Wheel Ends Gunite Lifetime n/aBrake Chamber MGM 3 year unlimitedElectrical Harness Phillips 3 year unlimited

Seals Federal Mogul 3 years parts & labormax. of $125.00 per

unitHub Cap STEMCO 1 year n/aBearings General/HYATT 7 year Limited 1,000,000Lights Trucklite LED - Lifetime /Limited unlimited

Incandescent - 1 year n/aFlap Hangers Betts 1 Year - parts only n/aFlaps Symplastics 2 Year - parts only n/a

Component manufacturer's warranty prevails over Silver Eagle warranty

** Decals 1 year, Components - manufacturer's finish warranty

Agreed labor rate $50.00 per hour.revised August 21, 2006

Silver Eagle Manufacturing Company1,200 Model Year 2007 VA Dollies Built in 2006 - 2007

FIVE YEAR LIMITED WARRANTY

CAR Numbers: 898027 - 899226

THIS WARRANT IS IN LIEU OF ALL OTHER WARRANTIES OR OBLIGATIONS, EXPRESS OR IMPLIED. SILVER EAGLEEXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY OF FITNESS FOR A PARTICULARPURPOSE. IN NO EVENT WILL SILVER EAGLE BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES OF ANY KIND, SUSTAINED FROM ANY CAUSE RELATING TO THE PRODUCT OR ARISINGOUT OF ANY LEGAL THEORY, WHETHER CONTRACT, NEGLIGENCE OR STRICT TORT LIABILITY.

Silver Eagle™ Converter Dollies built for UPS (“Buyer”) carry a Five Year Limited warranty, from the date of shipment to theoriginal buyer, for periods as specifically outlined below. We warrant our product to be free from defects in materials andworkmanship, and to conform to their specifications.

Labor Only Addendum to standard Silver Eagle Warranty

Under the “workmanship” provisions of our warranty, labor that needs to be performed to bring the product to its specified originalcondition will be allowed within the first twelve months of use. This includes such conditions as improper adjustments and loosefasteners, fittings and connections. It does not include periodic maintenance (example: lubrication) nor repair due to normal wearand tear or abuse. Authorized weld repairs apply to the five year period.

Silver Eagle Mfg. Co. (“Silver Eagle”) will repair, replace, or reimburse repair costs, at its option, any products or components whichare found to be defective or nonconforming, providing the buyer gives written notification of proof of failure within the warrantyperiod. Buyer will return defective parts or components, if requested, prepaid to our manufacturing facility in Portland, Oregon. Wewill return, or send, replacement parts prepaid to any location in the continental United States.

Silver Eagle reserves the right to deny coverage on a component if its manufacturer will not, or cannot, provide warranty againstthe specific request.

Warranty (08-05-05) UPS/SEMCO CONFIDENTIAL 1 of 1


MAINTENANCE PROCEDURES

Drawbar Replacement Kit

Drawbar Eye Removal & Installation Fifth Wheel: Operation, Alignment & Jaw Wear Laser Axle Alignment ProTorq Wheel End Assembly Procedure Phillips Electrical

(503) 281-0727 - (800) 547-6792 5825 NE Skyport Way – Portland, OR 97218


PRO-TORQ WHEEL END ASSEMBLY PROCEDURE Insert keep tab with bent legs facing out. Engage the mating teeth. Keeper tab and arms to be fully seated into the undercut groove. Ø Repeat 3 times:

Ø Tighten nut to 200 lb-ft.

Rotate hub (1) one full turn Ø Back off 1/3 turn

Ø Repeat (3) three times:

Ø Tighten nut to 25 lb-ft.

Rotate hub (1) one full turn Ø Install Locking Ring



LASER AXLE ALIGNMENT Use CAUTION!

• Lasers Can Be Dangerous to Eyes! – Don’t Look Directly Into the Beam or Its Reflection. – Make Sure the Beam Is Not Directed Toward Another Person

or Work Area. – Turn off When Not in Use.

• Attach Magnetic Laser Levels to Hub • Aim at Target Scales • Reading Should be Within 1/8” • Adjust Axle Seat if Necessary • Set Gauge into 5th Wheel Throat • Attach Magnetic Laser Levels to Hub • Aim at Target Scales • Reading Should be Within 1/4”



DRAWBAR EYE REMOVAL AND INSTALLATION PROCEDURE 1. Set brakes on unit. 2. Remove safety wire on shank nut. 3. Remove shank nut and shank washer. 4. Use forklift for hostler to pull against drawbar

eye to remove it from the shock housing. 5. Lubricate the shank of the new drawbar eye with rubber lubricant or soapy

water and install the shock housing. To completely install, use one of the following methods: • Set the brakes on the trailer. Use a forklift or hostler to push against the

drawbar eye until it is seated on the shock absorber bushing. • Use a sledge hammer on the end of the drawbar eye until it is seated on the

shock absorber bushing.

6. After the drawbar eye is in place, clean the threads on the shank and coat the threads with Never-Seez, pipe compound or another similar product.

7. Install the shank washer and thread the shank nut onto the shank.

8. Tighten the shank nut until three to four threads remain exposed inside the nut. Eye should be somewhat difficult to turn with two to three foot long pry bar.

9. Install a Silver Eagle safety wire on the shank nut to prevent it from backing off. 10. Periodically check the tightness of the shank nut and adjust as necessary.



SILVER EAGLE FIFTH WHEEL OPERATION INSTRUCTIONS

Ø COUPLING Make sure jaw is locked open and trailer is at proper height. Back dolly slowly under trailer until jaw locks kingpin and handle moves into the fifth wheel.

Ø UNCOUPLING With vehicle at rest in a relaxed condition and landing gear down, (not being pushed together or pulled apart). Pull fifth wheel handle outward and upward to lock the fifth wheel open. Pull dolly slowly out from under the trailer.

ü NOTE If the handle will not pull outward when the vehicle is in a relaxed condition, use landing gear to raise trailer and unload the dolly fifth wheel.



SILVER EAGLE FIFTH WHEEL KEY PARTS

Jaw

Trip Block

LeverLever Adjuster

Jaw

Trip Block

LeverLever Adjuster




Pulling Release Handle -Jaw Moves Out, Trip Block Moves Into Throat.

Pulling Release Handle -Jaw Moves Out, Trip Block Moves Into Throat.




Jaw Shows Clearly When Fully Closed

Jaw Spring Closes 5th Wheel

Jaw Shows Clearly When Fully Closed

Jaw Spring Closes 5th Wheel




Move Adjusting Rod In or Out To Assure Lever Stays Up in Locked and Open Position.

Open LockMove Adjusting Rod In or Out To Assure Lever Stays Up in Locked and Open Position.

Open Lock



SILVER EAGLE FIFTH WHEEL CHECKED FROM FRONT



SILVER EAGLE FIFTH WHEEL TEST TOOL

• Push Tester Forward and scribe line • Pull Tester Rearward and Scribe line • Release Latch & Remove Tool • Measure Slack • Replace Jaw if slack is more than ¼”


PARTS LISTING

18810 VAST-20NU Frame Fifth Wheel Axle Assembly - PENDING Air System Electrical


APPENDIX

Welding & Hot-Dip Galvanizing Sealco Emergency Brake Pressure Protection Valve

No. 110257 Sealco Emergency Control Valve – No. 110376 Bendix Service Data: SD-03-1063

R-12P Pilot Relay Valve Bendix Service Data: SD-03-2201* (formerly SD-03-66)

In-Line Single Check Valves Bendix Service Data: SD-03-3611* (formerly SD-03-61)

Push-Pull Type Control Valves: PP-1 Bendix Service Data: SD-03-4020

SV-4 Synchro Valve Bendix Service Data: SD-13-4754

WS-20 Antilock Wheel Speed Sensor Bendix Service Data: SD-13-4834

MC-30 Trailer ABS Controller Assembly Bendix Technical Bulletin: TCH-013-007

EC-30T ECU Product Recall Campaign Troubleshooting Bendix MC-30

Trailer Antilock System Bendix TABS-6 SD-134767 Troubleshooting Bendix TABS-6 Trailer Antilock System Bendix Trailer Remote Diagnostic Unit (TRUD) Bendix Fuse Adapter Kit and ID Guide

WELDING

Welding & Hot-Dip Galvanizing

(503 281-0727 - 800) 547-67925825 NE Skyport Way - Portland, OR 97218

www.silvereagle.com

GALVANIZING

W E L D I N G

& H O T- D I P

6881 South Holly Circle, Suite 108Englewood, Colorado 80112Hotline 800-468-7732Fax [email protected]

© 2002 American Galvanizers Association. The material provided herein has been developed to provide accurate and authoritative information aboutafter-fabrication hot-dip galvanized steel. This material provides general information only and is not intended as a substitute for competent profes-sional examination and verification as to suitability and applicability. The information provided herein is not intended as a representation or warrantyon the part of the AGA. Anyone making use of this information assumes all liability arising from such use.

INTRODUCTION

As it becomes more common to specify hot-dip

galvanizing (the metallurgical combination of

zinc and steel) as the corrosion protection

system for structural steel fabrications, it is

essential to understand that considerations for

the galvanizing of welded black steel or for

welding on galvanized steel must be integrated

into the overall structural fabrication design.

Welding before and after galvanizing is com-

mon; the requirements are relatively simple for

a designer to implement, resulting in superior

corrosion protection.

HOT-DIP GALVANIZING FORCORROSION PREVENTION

The galvanizing process has existed for more than250 years and has been a mainstay of NorthAmerican industry since the 1890s. Galvanizing isused throughout various markets to provide steelwith unmatched protection from the ravages ofcorrosion. A wide range of steel products – fromreinforcing steel to playground equipment to pro-fessional sports stadiums to the artistic expressionof today’s sculptors – benefit from galvanizing’ssuperior corrosion prevention properties.

Galvanizing’s primary component is zinc. This vitalsubstance is silvery blue-gray in color and makes upan estimated 0.004% of the earth’s crust, rank-ing 25th in order of abundance. It is essential forthe growth and development of almost all life.Between 1.4 and 2.3 grams of zinc are found in theaverage adult, and the World Health Organizationhas recommended a daily intake of 15 milligrams.Numerous consumer products, including coldremedies, sunscreens, diaper creams, and nutri-tional supplements, contain beneficial amounts ofzinc, primarily in the form of zinc oxide.

Even though galvanized steel is blue-gray, it alsocan be “green.” The zinc and galvanizing industrieswork to promote sustainable development byenhancing zinc’s contribution to society and ensur-ing that its production and use are in harmony withthe natural environment and the needs of society,now and in the future.

Zinc, as it is used in galvanizing, is a healthy metal,completely recyclable. The energy used to smeltzinc is inversely related to the amount of zinc recy-cled. Galvanizing delivers incredible value in termsof protecting our infrastructure. Less steel is con-sumed and fewer raw materials are neededbecause galvanizing makes steel structures, bridges,roads, and buildings last longer. Over time, galva-nizing helps maintain steel fabrications’ structuralintegrity: galvanized structures are safer.

Additionally, because galvanized steel requires nomaintenance for decades, its use in public con-struction is an efficient use of our taxes. Selectinggalvanized steel for private projects makes a signifi-cant contribution to a company’s profitability.

WELDING BEFORE HOT-DIPGALVANIZING

To achieve a high-quality hot-dip galvanized coatingon welded areas of fabrications, two importantissues must be considered before galvanizing: chemical makeup of the weld metal and cleanlinessof the weld area.

Weld Metal ChemistryWhen there is a difference between the structuralsteel’s chemistry and the weld filler material’s chemistry, the galvanized coating on the weld can bethicker than the coating on the structural piece. Themajor difference between the weld metal and thestructural steel is the amount of silicon in the weldrod. Excessive silicon in the steel or weld filler material can accelerate the growth of the hot-dip galvanized coating. Because some weld electrodemetal contains nearly 1% silicon, the differencebetween the coating thickness on the weld metaland structural steel can be significant. Excessive sili-con in the weld material to be galvanized causes anaccelerated formation of the iron and zinc inter-

metallic layers that make up the hot-dip galvanizedcoating, greatly increasing coating weight (see Figure1). When the fabricated structure is immersed in thezinc bath long enough to achieve a coating thatmeets the minimum thickness of the galvanizing

Figure 1

3

standards (such as American Society of Testing andMaterials [ASTM] A 123/A 123M, StandardSpecification for Zinc (Hot-Dip Galvanized) Coatingson Iron and Steel Products), the coating on the high-silicon weld metal can be two- to five-times the thickness of the surrounding coating. This thickcoating on the weld detracts from the appearance of the fabricated structure and increases the possibility of the zinc coating’s becoming damagedin the weld area.

For typical welding processes, such as shielded metalarc welding (SMAW), submerged arc welding (SAW)and flux-cored arc welding (FCAW), there are weldrod materials that will not cause excessively thickcoatings. Figure 2 indicates the material and chemistry for several welding rods that yield goodcoating appearance and thickness.

Weld Cleanliness When welded structures are hot-dip galvanized, theweld area’s cleanliness significantly affects the quality and appearance of the galvanized coatingaround the weld (see Figure 3). If a coated electrodeis used during welding, all welding flux must beremoved prior to galvanizing or the zinc coating willnot adhere to the weld area (see Figure 4). Becauseweld flux and slag are insoluble in the chemicalcleaning solutions used in the galvanizing process,they must be removed by other methods. Slag andflux must be removed by wire brush, flame-cleaning,chipping with a pick, grinding or abrasive blast-clean-ing.

Design Considerations

On assemblies with contacting surfaces having a gapof less than 3/32” (2.5 mm), a full seal-weld must be used on all edges, depending on the size of theoverlapped area. Zinc’s viscosity prevents it fromentering any space smaller than 3/32” (2.5 mm), resulting in ungalvanized surfaces (see Figure 5).Ungalvanized surfaces in tight spaces will corrodeand bleed iron oxide onto the surrounding galvanized surfaces, making for an unsightly appearance.

Cleaning solutions have lower viscosities, allowingthem to enter these small gaps. Cleaning solutionsalts can be retained in these tight areas. Humidityencountered weeks or months later may wet these

Figure 4

4

Welding Process Weld Rod Material Silicon Content

__________________________________________________SMAW Jetweld 2 (E6027) 0.25%

Fleetwood 35 LS (E6011) 0.10%Fleetwood 7 (E6012) 0.30%

_________________________________________________SAW L60-860 (F6A2-EL12) 0.22%

L61-80 (F7A2-EM12K) 0.35%__________________________________________________FCAW NR-203NiC+ (E71T8-K2) 0.04%

NR-311 (E70T-7) 0.07%

Figure 2

Figure 3

salts and cause iron-oxide weeping. A second designconsideration is to use equal or nearly equal thick-ness of assembly pieces, with symmetrical welds.

During galvanizing, the assembly is heated to themolten zinc bath temperature – more than 815 F(435 C) – and then cools to ambient temperature.When welded pieces of dissimilar thickness are galvanized, one of the pieces will often have a highstress induced in the fabrication process and/or bythe galvanizing temperature changes. If the stress ishigh enough, distortion of the assembly or, inextreme cases, a fracture of the weld or of thestressed piece in the assembly can occur.Galvanizingwelded fabrications is a common method of protect-ing a structure from corrosion. A high-quality hot-dipgalvanized coating, even over welded areas, isachieved by properly selecting a weld metal, thoroughly cleaning the weld area, and using gooddesign practices.

WELDING AFTER HOT-DIPGALVANIZINGAll commonly practiced welding and cutting techniques can be used on galvanized steel (seeAmerican Welding Society’s [AWS] specification D-19.0, Welding Zinc Coated Steel). Welding on

galvanized steel is usually necessary if the final struc-ture is too large to be dipped in a galvanizing bath orfor structures that must be welded in the field.

Preparation of Weld Area AWS D-19.0, Welding Zinc Coated Steel, calls forwelds to be made on steel that is free of zinc in thearea to be welded. Thus, for galvanized structuralcomponents of a fabrication, the zinc coating shouldbe removed at least one to four inches (2.5-10 cm)from either side of the intended weld zone and onboth sides of the workpiece. Grinding back the zinccoating is the preferred and most common method;burning the zinc away or pushing back the moltenzinc from the weld area also are effective.

Weld Metal Chemistry

Because the galvanizing has already taken place,selection of weld material is less critical. Most of thematerials used for touchup of the weld area willadhere and cover the weld and any damaged areaaround the weld (see “Touch-up of Weld Area”).

Welding MethodsFour methods of manual/semi-automatic welding aredetailed below. More flexible than resistance or laserwelding, which usually are in-line processes on galvanized sheet, all four manual/semi-automaticmethods benefit from the removal of zinc from theareas to be welded, but it is not an absolute requirement.

Figure 6 - Diagrammatic Illustration of CO2 Welding

Figure 5

1. Gas Metal Arc – Particularly suited to welding ofthinner materials, gas metal arc welding, (GMAW)also known as CO2, is a convenient and versatile semi-automatic welding process (see Figure 6 on theprevious page). The presence of the zinc coating hasno effect on weld mechanical properties, although itmay produce some appearance changes due to weldspatter. Arc stability is excellent and generally unaf-fected by the galvanized coating. There may be areduction in welding speed because the galvanizedcoating must be burned off ahead of the weld. Theuse of a 100% CO2 weld shield gas is acceptable forgalvanized steel. There are no advantages to usingmore expensive shielding gas combinations.Penetration of the weld in zinc-coated steels is lessthan for uncoated steels. Therefore, slightly widergaps must be provided for butt-welds.

The major difference between welding zinc-coatedsteel and welding uncoated steel using the GMAWprocess is the need for higher heat input to removethe zinc from the weld pool and lower weldingspeeds to burn off as much of the zinc coating at theweld area as possible.

Typical welding conditions for CO2 welding of butt-joints on batch galvanized steel are available inAWS D19.0, Tables 5.5 through 5.12.

2. Shielded Metal Arc – This most common of themanual processes uses flux-covered electrodes. Theconditions necessary for SMAW are similar to thoseused on uncoated steel. However, the speed of thewelding may be slower because the angle of the electrode is reduced to about 30º and a whippingmotion of the electrode back and forth is required tomove the molten zinc pool away from the weld (seeFigure 7).

The major difference between welding zinc-coatedsteel and welding uncoated steel using the SMAWprocess is that the root opening must be increasedto give full weld penetration. The amount of spatterformed when SMAW is used is slightly higher thanfor welding on uncoated steel.

Typical SMAW conditions for the root pass in butt-welds on batch galvanized steel are available in AWSD19.0, Tables 6.2 through 6.5.

SMAW is recommended for galvanized steels of 1/2”(33 mm) thickness or greater galvanized steel pieces.In general, SMAW can use the same procedures forgalvanized steel as for uncoated steel, although thefollowing should be noted:

• The electrode should be applied slower than normal, with a whipping action that moves the electrode forward along the seam in the directionof the weld and then back into the molten zinc pool.

• Weaving and multiple weld beads should be avoided, as should excessive heat injection into the joint. Excess heat may damage the adjacentzinc coating.

• A short arc length is recommended for all positions to give better control of the weld pooland to prevent either intermittent excessive penetration or undercutting.

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Figure 7 - Diagrammatic Illustration of Shielded Metal-Arc Welding

• Slightly wider gaps are required in butt-joints inorder to have complete penetration.

• Grinding off edges prior to welding give the bestquality weld joint. It also reduces fuming from thegalvanized coating. Welding procedures will thenbe the same as for uncoated steel.

Electrodes similar to those used for arc weldinguncoated steel may be used. The major differencewhen SMAW on galvanized steel compared touncoated steel is the need for higher heat input toremove the zinc from the weld pool and lower weld-ing speed to burn off as much of the zinc from theleading edge of the pool. This may result in greaterfluidity of the slag and increased splatter.

3. Oxyacetylene – Preparation for oxyacetylenefusion welding is similar to that for welding uncoatedsteel. Because low travel speed is necessary to bringthe joint edges to the fusion temperature, the extraheat causes the zinc coating to be affected over amuch greater area than other welding processes.Best results are obtained when the filler rod ismoved back and forth, producing a ripple weld.

4. Friction – Friction welding is generally used formaking butt-welds in which one component of circular cross-section is rotated relative to and in contact with another component to produce heat at the interface. Once sufficient heat is generated,the relative rotation of the parts is stopped and pressure is increased to complete the weld. Frictionwelding is often used for attaching shear connectorsto steel beams for the anchoring of concrete in concrete/steel structures. Flat-ended studs, whetheruncoated or galvanized, cannot be welded to galvanized plate because the zinc coating’s alloy layers appear to act as a low friction-bearing surfaceand insufficient heat is developed for welding. Thismay be circumvented by using pointed studs with apoint having a 120º angle. Conditions for weldingpointed studs are available in AWS D19.0.

TOUCH-UP OF WELD AREAAny welding process on galvanized surfaces destroysthe zinc coating on and around the weld area.Restoration of the area should be performed in accordance with ASTM A 780, Standard Practice forRepair of Damaged and Uncoated Areas of Hot-DipGalvanized Coatings, which specifies the use ofpaints containing zinc dust, zinc-based solders or sprayed zinc. All touchup and repair methods are capable of building a protective layer to thethickness required by ASTM A 780.

The restored area of the zinc coating will have noaffect on the overall lifetime of the part. Repair materials and their coating thickness have been chosen to give comparable lifetimes to the coatingminimums required by ASTM A 123/A 123M,Standard Specification for Zinc (Hot-Dip Galvanized)Coatings on Iron and Steel Products. There may besome visual differences between the original hot-dipgalvanized coating and the restored area, but, overtime, the natural weathering of the galvanized coating and the repair material yield a similarappearance.

QUALITY OF WELDED JOINTSIt is recommended in AWS D19.0 to remove all zincfrom the weld area prior to welding because burningthrough the zinc slows the welding process, generates zinc fumes (see “Safety & Health,” on thenext page) and creates an unsightly burn area aroundthe weld.

However, as studies performed by the InternationalLead Zinc Research Organization (ILZRO) haveshown, the tensile, bend and impact properties ofwelds on galvanized steel are equivalent to the properties of welds on uncoated steel.

Fracture ToughnessTests establish that the fracture toughness propertiesof welds are unaffected by the presence of galvanized coatings.

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Fatigue Strength

The fatigue strength of arc welds on galvanized steel is equivalent to welds on uncoated steel made byCO2 welding as shown in Figure 8.

Porosity

The extent of weld porosity is a function of heatinput and the solidification rate of the weld metal.Not always possible to eliminate, porosity affects thefatigue strength and cracking tendencies of welds.

When welds are subject to fatigue loading, welds ongalvanized steel should be made oversized to reducethe influence of any weld metal porosity. When eval-uating the effect of porosity on the fatigue strengthof a fillet weld, it is necessary to consider both thefunction of the joint and the weld size. When a filletweld on galvanized steel is large enough relativetoplate thickness to fail by fatigue from the toe ofthe weld in the same manner as in uncoated steel,the presence of porosity in the weld does not reducethe fatigue strength of the joint. Where the dimen-sions of the weld are just large enough to causefatigue failure from the toe in a sound weld, a weld containing porosity at the root may fail preferentiallythrough the throat of the weld.

Intergranular cracking of fillet welds containingporosity, sometimes referred to as zinc penetratorcracking, does not significantly affect the strength ofnon-critical joints. For more critical stress applica-tions, it is advisable to carry out procedural tests onmaterials and samples.

SAFETY & HEALTH

All welding processes produce fumes and gases to agreater or lesser extent. Manufacturers and weldersmust identify the hazards associated with weldingcoated and uncoated steel and workers must betrained to maintain work practices withinOccupational Safety and Health Administration(OSHA) regulations. In general, welding on steel withthe zinc coating ground back away from the weldarea will produce lead and zinc oxide emissionsbelow OSHA permissible exposure limits (PELs) forzinc and lead. When welding directly on galvanizedsteel is unavoidable, PELs may be exceeded andevery precaution, including high-velocity circulatingfans with filters, air respirators and fume-extractionsystems suggested by AWS, should be employed.

Fumes from welding galvanized steel can containzinc, iron and lead. Fume composition typicallydepends on the composition of materials used, aswell as the heat applied by the particular weldingprocess. In any event, good ventilation minimizesthe amount of exposure to fumes. Prior to weldingon any metal, consult ANSI/ASC Z-49.1, Safety InWelding, Cutting and Allied Processes, which contains information on the protection of personneland the general area, ventilation and fire prevention.

SUMMARYWith proper preparation of the weld area, selection of a suitable welding material and process, and careful touch-up of the weld area, welding on galvanized steel provides an excellent product foruse in myriad applications, from bridges, towers, andgrating to handrail, trusses and guardrail.

Figure 8 - SN Curves Showing Fatigue Tests on Cruciform Joints

Documents

Silver Eagle Model 2006 VAST-20NU - 1200 Galvanized ... 18810 Parts Book.pdf · Vehicle Make: Silver Eagle Model Year: 2007 Date: 9-Aug-06 Updated: K. Fulp & G. Gaussoin QUANTITY: