7.

7
WELDING GUIDE
Weld-On Noses & Nose Rebuilds
 Welding Weld-On
Welding Weld-On Noses / XS / KMAX
Weld-On Noses
BE SURE TO READ ALL INSTRUCTIONS
PRIOR TO STARTING ANY WELDING!

Note: These are general guidelines and may not be all-inclusive due to the condition of the
adapter that the weld-on nose is being installed to. Sound welding techniques should always be
employed.

STEP 1 A
Establish a 10O cut line on the adapter (fig. 1.1) per dimensions Series
in mm
in the adjacent chart (fig. 1.2).
XS15 / K15 1.1 29

XS20 / K20 1.3 33

XS25 / K25 1.5 39

XS30 / K30 1.6 41

XS40 / K40 1.7 44

XS50 / K50 1.9 49

XS70 / K70 2.1 54

fig. 1.1 XS85 / K85 2.2 56

XS115 2.7 70

XS145 3.0 77

XS250 3.4 87

XS340 4.3 110

fig. 1.2

STEP 2
Remove unwanted nose by Air Carbon Arc Gouging (flame cutting can also be used, however the
heat input will be much greater).

STEP 3
Next prepare the surfaces on the adapter and weld-on nose. They should be free from paint, scale
and cutting/gouging slag. This can be achieved by grinding or sanding the surfaces clean.
The intention here is to provide a good surface for welding and to eliminate the opportunity for
welding defects.

638 Welding Guide | Weld-On Noses & Nose Rebuilds

 Welding
Welding Weld-On Noses / XS / KMAX Weld-On
CONTINUED
Continued
Weld-On Noses

STEP 4
Locate the weld-on nose on the adapter. To properly locate the weld-on nose on the adapter it
must be correctly positioned vertically (top-to-bottom) and horizontally (side-to-side). To locate
the weld-on nose vertically, the centerline of the weld-on nose should be at the same height and
angle as the other noses (fig. 4.1). To locate the weld-on nose horizontally, the centerline of the
weld-on nose should be positioned on the centerline of the existing adapter (fig. 4.2).

fig. 4.1

Proper Vertical (top-to-bottom)

location of the weld-on nose.

fig. 4.2

Proper Horizontal (side-to-side)

location of the weld-on nose.

STEP 5
With the nose properly located on the adapter, isolate preheat to both sides of the nose/adapter
joint and deposit tack weld on one side (fig. 5.1). Re-confirm proper placement of weld-on nose
and deposit tack weld on other side (fig. 5.1). Isolate preheat top and bottom of nose/adapter
joint and deposit tack weld on top side, then bottom (fig. 5.2).

Recommended Filler
Material: SMAW:
AWS A5.1, E7018
JIS Z3212, D5016

fig. 5.2
fig. 5.1

Weld-On Noses & Nose Rebuilds | Welding Guide 639

 WELDING WELD-ON
Welding Weld-On NOSES Welding
Noses / XS / KMAX Weld-On
Continued
CONTINUED
Weld-On Noses

STEP 6
If possible, position the bucket so that the nose is in a vertical position. This will allow welding to
be done in the horizontal position (fig. 6.1). If not, welding can be done in the vertical up position.

Establish a preheat of 300OF to 450OF (150OC to 230OC) to both the weld-on nose and adapter.
Be sure to maintain this throughout the welding process.

Stringer beads are recommended for higher strength and to minimize distortion.

Weave width for vertical up position welding not to exceed 1/2" (12mm).

Completely remove slag after each weld pass.

Cover nose/adapter with thermal blanket for slow cool down.

Weld Finishing:
Remove any unevenness of the weld beads by grinding to create a smooth transition from nose
to adapter.

fig. 6.1

640 Welding Guide | Weld-On Noses & Nose Rebuilds

 Mining
Mining Size Noses
Weld-On Noses

Mining Size Noses

(for machine classes over 200 tons)
BE SURE TO READ ALL INSTRUCTIONS
PRIOR TO STARTING ANY WELDING!

Note: These are general guidelines and may not be all inclusive due to the condition of the
adapter that the weld-on nose is being installed to. Sound welding techniques should always be
employed.

SPECIAL NOTES
Recommended Filler Material: AWS specification A5.2, class E71T-1 wire for the GMAW process
(preferred process). AWS specification A5.1, class E7018, stick electrode for the SMAW process
(not the desired process due to the number of stops and starts within the weldment). Stick
electrodes should be kept in a heated rod oven at 250°F (120°C) prior to use. See manufacturers
recommended procedures for storage and preservation of low hydrogen electrodes.

Recommended Weld Type: Stringer beads are recommended for higher strength and less
distortion. The use of weave or wash beads is NOT recommended and should not be used. Arc
strikes should be avoided or ground out.

STEP 1
Remove worn nose using the Air Carbon Arc Gouging process. Care must be taken to create
a “plane” for the proper nose angle, (up and down), as well as the correct distance, (front to
back), for the weld-on nose. The gouged surface should be ground to remove all carbon slag and
provide a clean and smooth surface for welding.
STEP 2
The weld-on nose and the base adapter should be preheated to 300OF to 350OF (150O C to
180OC). Use an infrared thermometer or temperature indicating crayons to measure temperature.
This temperature should be maintained throughout the welding process. A localized pre-heat can
be used for tack up purposes.
STEP3
Fit weld-on nose to required nose angle, (up and down), and front to back distance. Allow a 1/8”
root opening between the weld-on nose and the base adapter and tack in place (fig. 3.1). Starter/
Run-out Tabs should be used at the top and the bottom of the weld joint (fig. 3.2 - fig 3.3).

Weld-On Noses & Nose Rebuilds | Welding Guide 641

 Mining Size Noses Continued Mining

Weld-On Noses

fig. 3.1

fig. 3.2

fig. 3.3

642 Welding Guide | Weld-On Noses & Nose Rebuilds

 Mining
Mining Size Noses Continued
Weld-On Noses

STEP 4
Weld-out: Deposit a root pass on one side of the joint. Gouge opposite side of joint and grind
to insure 100% weld penetration. Deposit root pass on second side. Check nose for alignment.
Alternate weld layers from one side of the joint to the other, using the weld to maintain alignment
(fig. 4.1).

Note: Minor deviation from pictured sequence may be required to retain

proper placement of the nose. Continue sequence until weld joint is
completely filled.

fig. 4.1

Upon completion of the welding, the entire nose and surrounding

area should be wrapped in thermal blankets to slow the cooling rate.

STEP 5
Once the nose area has cooled, remove the starter/run-out tabs. Uneven weld surfaces and
gouged surfaces where the starter/run-out tabs were should be ground smooth .

Weld-On Noses & Nose Rebuilds | Welding Guide 643

 Rebuilding XS/Kmax Adapter Noses Rebuilding

Weld-On Noses

Hensley adapters with Kmax or XS noses have been developed to provide good weldability while
maintaining high toughness in the 363-444 Brinell hardness range. At these high hardness ranges
there is inherent danger of failure due to cracking associated with the heat affected zone of the
weld. Therefore, Hensley does not recommend rebuilding noses on adapters. However, for those
customers who still want to rebuild fit bearing areas, the following procedure is suggested.

In order to determine the extent of wear on the nose and to properly execute the repair, you will
need the HORIZONTAL (side to side) nose gauge, the VERTICAL (top to bottom) nose gauge,
and a ruler. Refer to gauge chart.

XS - KMAX GAUGE CHART

Adapter Nose Series Horizontal (side to side) Gauge # Vertical (top to bottom) Gauge #
Construction Size Construction Size Construction Size

XS Kmax XS Kmax XS Kmax

XS15 K15 XS15NTH K15NTH XS15NTV K15NTV
XS20 K20 XS20NTH K20NTH XS20NTV K20NTV
XS25 K25 XS25NTH K25NTH XS25NTV K25NTV
XS30 K30 XS30NTH K30NTH XS30NTV K30NTV
XS40 K40 XS40NTH K40NTH XS40NTV K40NTV
XS50 K50 XS50NTH K50NTH XS50NTV K50NTV
XS70 K70 XS70NTH K70NTH XS70NTV K70NTV
XS85 K85 XS85NTH K85NTH XS85NTV K85NTV
XS Mining Size Noses Mining Size Mining Size
XS115 XS115NTH XS115NTV
XS145 XS145NTH XS145NTV
XS250 XS250NTH XS250NTV
XS340 XS340NTH XS340NTV

Examples of Horizontal and Vertical templates.

STEP 1
Remove tooth. Refer to proper
'Owner's Guide' for removal
instructions.

STEP 2
Clean nose exterior and pin hole. All
surfaces must be clean and free of any
dirt, mud, fines, etc. This will insure
proper measurements and provide a
On a properly repaired good surface for welding.
nose, this notch will be
even with the top of
the pin hole.

644 Welding Guide | Weld-On Noses & Nose Rebuilds

 Rebuilding
Rebuilding XS/Kmax Adapter Noses Continued
Weld-On Noses

STEP 3
Place the Horizontal Template on the nose and measure the gap between the nose and gauge
in the areas indicated (fig. 3.1). Place the Vertical Template on the nose and measure the gap
between the nose and gauge in the areas indicated (fig. 3.2). If gap measured is greater than
what is listed in the Gap Chart (fig. 3.3), nose rebuilding should be considered.

fig. 3.1

XS - KMAX GAP CHART

Maximum Horizontal Maximum Vertical
Adapter Nose
(side to side) (top to bottom)
Series
Gap Distance Gap Distance
Construction Size
Construction Size Construction Size

XS Kmax in mm in mm
XS15 K15 0.06 1.6 0.06 1.6
XS20 K20 0.06 1.6 0.06 1.6
XS25 K25 0.06 1.6 0.06 1.6
XS30 K30 0.06 1.6 0.06 1.6
XS40 K40 0.06 1.6 0.06 1.6
XS50 K50 0.09 2.4 0.09 2.4
XS70 K70 0.09 2.4 0.09 2.4
XS85 K85 0.09 2.4 0.09 2.4
Mining Size Noses Mining Size Mining Size
XS115 0.09 2.4 0.09 2.4
XS145 0.09 2.4 0.09 2.4
XS250 0.09 2.4 0.09 2.4
XS340 0.09 2.4 0.09 2.4

fig. 3.2 fig. 3.3

Weld-On Noses & Nose Rebuilds | Welding Guide 645

 Rebuilding
Rebuilding XS/Kmax Adapter Noses Continued
Weld-On Noses

STEP 4
If it has been determined that the nose will be rebuilt, it must be preheaated prior to depositing
any weld. Preheat the nose to between 300 F to 400OF (150OC to 204OC). Temperature should be
measured with a temperature indicating crayon or an infrared thermometer.

Due to the shape of the nose, an all position stick electrode or wire is recommended using the
filler material listed in the chart below.

FILLER MATERIALS
Process AWS JIS Shielding Gas

E9018 JIS Z3212

SMAW N/A
AWS A5.5 D5816
E91T-1 JIS Z3313
FCAW 75%Ar / 25% CO2
AWS A5.29 YFL-A506R

To save time and reduce the possibility of weld induced defects, weld build up is applied only to
the critical “fit” areas of the nose (figs. 5.1, 5.2 & 6.1).

STEP 5
After preheat has been established, deposit stringer beads to a width of 3/4" (19mm) on the front
and the sides (figs. 5.1 & 5.2). Slightly over-deposit so that the weld extends just beyond the level
shown by the gauge. The crown of the weld bead may be flattened by hammering, while still hot.
Much care should be taken to ensure that the weld on the sides is Not deposited into the pin
hole. Any weld or weld spatter that is found in the pin hole, should be carefully removed with a
carbide burr or other suitable tool.

3/4"
(19mm)

3/4"
(19mm)

fig. 5.1
fig. 5.2

646 Welding Guide | Weld-On Noses & Nose Rebuilds

 Rebuilding
Rebuilding XS/Kmax Adapter Noses Continued
Weld-On Noses

STEP 6
Deposit stringer beads to a width of 3/4" (19mm) on the top and bottom of the nose (fig. 6.1).
Again, the high crown of the weld bead may be flattened by hammering, while still hot.

3/4"
(19mm)

fig. 6.1

STEP 7
Grind weld beads so that the Horizontal template fits over the nose and the notch in the
template lines up with the TOP of the pin hole (fig. 7.1). Top and bottom are ground to accept the
Vertical template (fig. 7.2). Minor adjustments in fit may be achieved by peening. Once the nose
has been ground/peened to accept both templates, check fit the nose with an actual tooth. Insert
tooth pin and turn to the locked position. The locking tag of the pin should turn freely. Refer to
'Owner's Manual' for tooth/pin installation and removal procedures.

fig. 7.1 fig. 7.2

Weld-On Noses & Nose Rebuilds | Welding Guide 647

 Rebuilding
Rebuilding XS/Kmax Adapter Noses Continued
Weld-On Noses

STEP 8
For additional stability between the nose and the tooth, weld dots may be added in the locations
pictured (fig. 8.1). Due to the location of the weld dots, their height cannot be gauged with a
template. Care should be taken so as not to over grind and render the dots useless or left too
high and cause the tooth not to seat properly. Fit check nose with tooth to ensure proper fit.

fig. 8.1

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