J -Bolt Edge System

for LHD Trams

Hensley presents the J -Bolt Edge System for LHD (load-haul-dump) tram loaders.
This patented system offers maximum bucket lip protection plus several advantages over
conventional weld-on shrouds.
The Hensley J -Bolt Edge System is designed
as a bolt-on system for quick and easy assembly
(some initial welding required)
Constructed of harder alloy than weld-on cast alloy
shrouds for longer wear life
The low profile/sharp contour design gives better
penetration reducing cycle times and overall wear
on tires and machine
Complete shroud changes in minutes rather than days
The Hensley J -Bolt Edge

System gives you increased wear life, greater productivity and
faster change-outs. Tram bucket life can be increased even further by also using Hensley
vertical wear shrouds (VS450 recommended). So switch-out your old weld-on shrouds for
the Hensley J -Bolt Edge System today.
LHD Lip Shrouds
A B
Edge
System
No.
Dimensions
inches (mm)
LS1000 61.250 (1556) 56.250 (1429)
LS1200 73.250 (1861) 66.250 (1683)
LS1400 85.250 (2165) 76.250 (1937)
LS1500 91.250 (2318) 82.75 (2102)
LS1800 109.250 (2775) 97.75 (2483)
LS1900 115.250 (2928) 102.75 (2610)
SHROUD
PART NO.
DIMENSIONS: INCHES (MM)
A B C D E F
WEIGHT
LBS./
KGS.
WELD
BASE
J -BOLT
LIP
THICKNESS
1" LS1000J L 18.375 10.000 16.000 5.000 2.375 1.125 60.0 / LSWB3 SFA34J 2
LS1000J R (467) (254) (406) (127) (60) (29) 27.2
1" LS1200J L 18.531 12.000 15.750 5.000 2.375 1.125 68.0 / LSWB3 SFA34J 2
LS1200J R (471) (305) (400) (127) (60) (29) 30.9
1" LS1400J L 18.875 14.000 15.500 5.000 2.375 1.125 80.0 / LSWB3 SFA34J 2
LS1400J R (479) (356) (394) (127) (60) (29) 36.3
1.5" LS1500J L 26.063 15.000 22.437 6.500 3.500 1.687 175.0 / LSWB1 SFA1J 3
LS1500J R (662) (381) (570) (165) (89) (43) 79.4
1.5" LS1800J L 26.437 18.000 22.125 6.500 3.500 1.687 200.0 / LSWB1 SFA1J 3
LS1800J R (671) (457) (562) (165) (89) (43) 90.8
1.5" LS1900J L 26.563 19.000 22.000 6.500 3.500 1.687 210.0 / LSWB1 SFA1J 3
LS1900J R (675) (483) (559) (165) (89) (43) 95.3
typical center shroud
left hand shown
right hand opposite
typical lip layout
System Widths
typical lip layout w/corner lip shrouds
A B
Edge
System
No.
Dimensions
inches (mm)
LS1400 88.250 (2165) 76.250 (1937)
LS1800 112.250 (2775) 97.75 (2483)
LS1900 118.250 (2928) 102.75 (2610)
typical corner shroud
left hand shown
right hand opposite
SHROUD
PART NO.
DIMENSIONS: INCHES (MM)
A B C D E F
WEIGHT
LBS./
KGS.
WELD
BASE
J -BOLT
LIP
THICKNESS
1" LS1400J LC 18.875 15.500 18.875 5.000 2.375 1.125 99.0/ LSWB3 SFA34J 2
LS1400J RC (479) (394) (479) (127) (60) (29) 44.9
1.5" LS1800J LC 26.250 19.500 25.750 6.500 3.500 1.690 235.0/ LSWB1 SFA1J 3
LS1800J RC (667) (495) (654) (165) (89) (43) 106.7
1.5" LS1900J LC 26.500 20.500 26.500 6.500 3.500 1.690 245.0/ LSWB1 SFA1J 3
LS1900J RC (673) (521) (673) (165) (89) (43) 111.2
LHD Corner Lip Shrouds
Weld Bases
J -Bolt Assemblies
LSWB3
3.2 lbs./1.4 kgs.
(for LS1000, LS1200
and LS1400)
LSWB1
8.5 lbs./3.9 kgs.
(for LS1500, LS1800
and LS1900)
J -BOLT EDGE SYSTEM FOR LHD SCOOP TRAMS
ASSEMBLY AND WELDING INSTRUCTIONS
IMPORTANT NOTE:
READ ALL INSTRUCTIONS COMPLETELY BEFORE STARTING ASSEMBLY
FOR A NEW INSTALLATION START AT STEP 1.B
FOR A REPLACEMENT INSTALLATION START AT STEP 1.A
Position shrouds on lip in proper position (fig. 1.1) maintaing a gap of .25" (6 mm) between
shrouds (fig. 1.2). Make sure that the shroud front surface X contacts lip front surface Y (fig. 1.3).
NOTE: This contact must be maintained throughout assembly process to insure proper location
of weld base.
STEP 1.B
Grind the top surface of the lip material that will be affected by weld. Insure all carbon slag or other
impurites from the removal of the old base are ground out. The use of non-destructive testing at
this point will help determine if there are any cracks present in the base material. Repair base material
as needed. Now proceed to step 1.B
STEP 1.A
Position the weld base 2.25" (57.15 mm.) from end of shroud as shown (fig. 3.1).
STEP 3
WELD BASE
fig. 2.1
Slide weld base from the rear into the receiving slots of the shroud (fig. 2.1).
STEP 2
fig. 3.1
2.25"
(57.15 mm)
fig. 1.2
fig. 1.1
fig. 1.3
J -BOLT EDGE SYSTEM FOR LHD SCOOP TRAMS
ASSEMBLY AND WELDING INSTRUCTIONS-continued
Utilizing the chart (fig. 4.1) preheat the lip/weld base to the appropriate temperature.
The preheat temperature will be determined by the type and thickness of the lip material
plus the thickness of the weld base. Tack weld the weld base at the rear along weld prep surface
A making sure that the weld base is still 2.25" (57.15 mm) from the end of the shroud (fig. 4.2)
STEP 4
fig. 4.2
weld prep
surface A
2.25" (57.15 mm)
Remove the shroud (fig. 5.1) and prepare to weld-out the base by re-establishing the preheat
temperature that was established by the chart (fig 4.1) in STEP 4. Maintain this temperature
throughout the welding process.
STEP 5
fig. 5.1
SPECIAL NOTES
Recommended filler material: AWS specification A5.1, class E7018, stick electrode.
Stick electrodes should be kept in a heated rod oven
at 250
O
/120
O
C prior to use.
NOTE: See manufacturers recommended procedures for storage and preservation of
low hydrogen electrodes.
Recommended weld types: 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 down.
Weld-out for the base should begin with the slot weld. A 1/2" (13mm) fillet weld should
be deposited in this area (fig. 6.1).
STEP 6
LIP
THICKNESS
PLUS
WELD BASE
THICKNESS
PREHEAT AND INTERPASS TEMPERATURES
ASTM A514 ASTM A572-50 AR 400 HARDOX 400
1" + LSWB3 175
O
F/79
O
C 150
O
F/65
O
C 250
O
F/120
O
C 250
O
F/120
O
F
1.5" + LSWB1 275
O
F/134
O
C 225
O
F/106
O
F 350
O
F/175
O
C 350
O
F/175
O
C
*For lip materials not listed, consult AWS or equivalent specs for preheat and interpass temps. For AWS weldability
classification, the weld bases (LSWB3, LSWB1) have a maximum carbon equivalency of 0.65.
LIP MATERIALS*
fig. 4.1
J -BOLT EDGE SYSTEM
ASSEMBLY AND WELDING INSTRUCTIONS-continued
Apply weld to the base perimeter next. Utilizing groove welds, fill the 1/2"(13mm) weld groove on the
base completely (fig. 7.1 & fig. 7.2). Care must be taken at this point not to add too much weld. If
joint is over welded, the weld material can interfere with the lip shroud. The idea is to add as much
weld as possible to the base without causing interference with the lip shroud (fig. 7.3 & fig. 7.4)
When the welding process has been completed, allow a slow cool down period to ambient tempera-
ture. A cool down rate of no greater than 35
O
F/2
O
C per hour is recommended.
STEP 7
fig. 7.2
fig. 7.3
fig. 7.1
fig. 7.4
Before repositioning the shroud on the lip, insert the J -bolt into the shroud through the
top hole (fig. 8.1). Rotate the bolt 90
o
so that the threaded end is facing the rear of the
shroud (figs. 8.2 - 8.3).
STEP 8
area of detail for
figures 8.1 - 8.3
fig. 8.1 fig. 8.2 fig. 8.3
Reposition the shroud on the lip by sliding it onto the weld base as far as it will go, once again,
making sure surface Xcontacts surface Y(fig. 9.1).
STEP 9
fig.9.1
J -BOLT EDGE SYSTEM
ASSEMBLY AND WELDING INSTRUCTIONS-continued
Attach the washers, the spring and the nuts in the order indicated (fig. 10.1),
then torque to specifications below. (fig. 10.2). Finish assembly by installing
cap with lock washer and cap bolt.
[NOTE: the locking nut cannot be hand-threaded onto the J -bolt]
STEP 10
J -BOLT
ASSEMBLY
MAX TORQUE
ft-lbs Nm
SFA34J 2 175 237 175 237 NA NA NA NA
SFA1J 3 200 271 200 271 NA NA NA NA
ft-lbs Nm
MAX TORQUE
LOCKING NUT BARREL NUT
ft-lbs Nm
MAX TORQUE
COUPLING NUT
ft-lbs Nm
MAX TORQUE
GRADE 8 NUT
fig. 10.1
Washers
Spring
Cap
Locking
nut
Barrel
nut
Lock
washer
Cap bolt
NOTE: Above assembly is show for illustrative purposes only.
Not all assemblies utlilize all parts shown.
Your Authorized Hensley Dealer
Safety First: Hensley recommends that you use a soft-faced hammer and ANSI-approved (Z87.1) eye protection while using our products
Hensley Industries, Inc.
2108 J oe Field Road
Dallas, Texas 75229, USA
Customer Service
Tel. (888) 406-6262
Fax. (888) 241-3274
www.hensleyind.com
NOTES
Copyright 2004 Hensley Industries, Inc.
This publication is protected under the copyright laws of the United States. Unauthorized duplication or distribution is prohibited.