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BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

BASIC WELDING REPAIR EXAMPLES


930E ELECTRIC DRIVE MINING TRUCK

This 930E Welding Repair Example book is not intended to be a substitute for direct factory
support and guidance. Please consult your local Komatsu service support contact with any
questions regarding correct repair processes for a given situation. Technical Service Request
(TSR) or Machine Down Request (MDR) should be utilized for specific support questions.

This material is proprietary to Komatsu America Corp and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America Corp. This is
not an officially numbered Komatsu publication. This report has been authored specifically for
SMS Equipment Inc. to help communicate repair processes on 930E machines. If duplicate copies
are required please contact Komatsu Mining Service.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to
install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that customers contact their distributor for information on
the latest revision.

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BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

TABLE 1: KOMATSU REFERENCE DOCUMENTS FOR WELDING REPAIRS

Document Type Source Location Document Name Reference Number

Welding Reference Komatsu Extranet: Welding II SEBF15002


Shop Manuals Home>Service>CSS>CSS
Miscellaneous Welding I SEBF14001

Parts and Service Komatsu Extranet: Field Welding for AA00046C


News Home>Service>CSS>CSS Assembly or Repair
Lookup>Parts & Service
News

Operation and Service Komatsu Extranet: Operation and Service Specific to the
Manual Home>Service>CSS>CSS Manual machine serial number
Net

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BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

Table of Contents

1 CRACK LOCATION MAP ON 930E FRAME ................................................................................................. 4


FRONT RH SIDE VIEW ................................................................................................................................ 4
TOP & RH SIDE VIEW ................................................................................................................................. 5
BOTTOM & LH SIDE VIEW ......................................................................................................................... 6
REAR AND FRONT HORSE COLLAR VIEW .................................................................................................. 7
LH & RH SIDE HORSE COLLAR VIEW.......................................................................................................... 8
REAR RH SIDE VIEW................................................................................................................................... 9
REAR LH SIDE VIEW.................................................................................................................................. 10
BOTTOM VIEW......................................................................................................................................... 11
INDEX ...................................................................................................................................................... 12
2. Parts & Service News Resource ............................................................................................................... 13
AA01042A: 930E FRAME CRACK REPAIR PROCEDURE ........................................................................... 13
AA07013: RIGHT HAND PLATFORM CRACKING ...................................................................................... 13
AA13034: CENTER DECK SUPPORT CRACKING ....................................................................................... 14
AA07106C: ENGINE SUB-FRAME WELD IMPROVEMENT........................................................................ 14
AA02169: WELD JOINT CRACKING AT REAR ENGINE MOUNTS.............................................................. 15
AA04045: ENGINE SUB-FRAME BRACKETS CRACKING ........................................................................... 15
AA04109A: ENGINE SUBFRAME CRACKS ................................................................................................ 15
AA10038: AXLE CRACK REPAIR PROCEDURE .......................................................................................... 16
AA01141A: INSPECTION AND REPAIR OF AXLE BOX............................................................................... 16
AA03059: REAR AXLE WELD CRACKS AT SUSPENSION MOUNTS & REINFORCEMENT PLATE ............... 17
AA14042: AXLE HOUSING ACCESS HATCH WELD REINFORCEMENT .................................................... ..17
AA05055A: INSPECTION AND REPAIR OF REAR AXLE BOX (HATCH AREA) ............................................. 17
AA05056: INSPECTION AND REPAIR OF AXLE BOX ................................................................................. 18
3 General Welding Examples on EDT Frame .............................................................................................. 19
Horse Collar Weld Joint Repair Example ................................................................................................. 19
Casting to Frame Structure Joint Example .............................................................................................. 24
Body Pivot Crack Example ....................................................................................................................... 25
Frame Repair Access Windows Examples ............................................................................................... 26
Frame Rail Crack Example ....................................................................................................................... 27
Drive Tube Casting Example .................................................................................................................... 32
Horse Collar Casting Example .................................................................................................................. 35
Upper/Lower Horse Collar Crack Example .............................................................................................. 37

3
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

Crack Location Map on 930E Frame

AA

4
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

E
F
AP

AB

AD
AC

5
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

AQ

H AI
AF
I

AG
AH

6
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

J
K

7
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

N
AM

AJ

AK

8
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

AL
Q

9
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

AO

AR

10
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

AE

AN

11
BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK

Location PSN number / Weld Repair Procedure Page Location PSN number / Weld Repair Procedure Page
A Frame Rail repair guide 27 AA Frame Rail repair guide 27
B ***AA04065 & Drive Tube Casting repair guide 32 AB Frame Rail repair guide 27
C Frame Rail repair guide 27 AC Frame Rail repair guide 27
D Frame Rail repair guide 27 AD Frame Rail repair guide 27
E AA14041 & ***AA04065 --- AE Horse Collar casting repair guide 35
F AA14041 --- AF Casting to Frame Structure Joint repair guide 24
G Horse Collar Casting repair guide 35 AG Frame Rail repair guide 27
H AA14041 --- AH Frame Rail repair guide 27
I AA14041 & ***AA04065 --- AI Casting to Frame Structure Joint repair guide 24
J **AA02209C & Frame Rail repair guide 27 AJ Casting to Frame Structure Joint repair guide 24
K **AA02209C & Frame Rail repair guide 27 AK Casting to Frame Structure Joint repair guide 24
L Frame Rail repair guide 27 AL Horse Collar casting repair guide 35
M Horse Collar Casting repair guide 35 AM Horse Collar casting repair guide 35
N Horse Collar Casting repair guide 35 AN Drive tube casting repair guide 32
O Top/bottom HC repair guide 37 AO Horse Collar casting repair guide 35
P Frame Rail repair guide 35 AP Casting to Frame Structure Joint repair guide 24
Q Frame Rail repair guide 35 AQ Drive Tube Casting repair guide 32
R *AA01121 --- AR Frame Rail repair guide 27
S Top/bottom HC repair guide 37
T Frame Rail repair guide 27
U Frame Rail repair guide 27 NOTE: * For 930E-1 trucks
V Horse Collar casting repair guide 35
W Horse Collar Weld Joint repair guide 19 ** For 930E-1 and 930E-2 trucks
X Horse Collar Weld Joint repair guide 19
*** For 930E-1, 930E-2 and 930E-3 trucks
Y Horse Collar Casting repair guide 35
Z Horse Collar Casting repair guide 35

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BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

2 Parts & Service News Resource


The following table outlines published material available on the Komatsu Extranet that specifically
addresses repairs or improvements that involve welding on the 930E. Use this table to locate the
appropriate PSN number for a given situation and access full details by signing into the Extranet.

TABLE 2: REFERENCE PSN DOCUMENTS

PSN Number & Description Reference Image

AA01042A: 930E FRAME CRACK


REPAIR PROCEDURE
($
$$

($$$
$$

ONLY -1 & -2 TRUCKS

AA07013: RIGHT HAND


PLATFORM CRACKING

930E-2: A30012, A30098, A30100,


A30121-A30293, A30295-A30303;

930E-2SE: A30183;

930E-3: A30294, A30304-A30461;

930E-3SE: A30171, A303I 8,


A30319, A30322, A30366, A30367,
A30370,
A30371 , A30373, A30382, A30389

ONLY -1, -2 & -3 TRUCKS

13
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

TABLE 2: REFERENCE PSN DOCUMENTS

PSN Number & Description Reference Image

AA13034: CENTER DECK


SUPPORT CRACKING

930E-2SE: A30183;
930E-3: A30294, A30304-A30461;
930E-3SE: A30171-A30389;
930E-4: A30462-A31641;
930E-4AT: A30504 & Up;
930E-4SE: A30587-A31640

AA07106C: ENGINE SUB-FRAME


WELD IMPROVEMENT

930E-3: A30329-A30461;

930E-3SE: A30318, A30319,


A30322, A30366, A30367, A30370,
A30371,
A30373, A30382, A30389;

930E-4: A30462 - A30632;

930E-4SE: A30587 - A30588

ONLY -3 & -4 TRUCKS

14
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

TABLE 2: REFERENCE PSN DOCUMENTS

PSN Number & Description Reference Image

AA02169: WELD JOINT


CRACKING AT REAR ENGINE
MOUNTS

AFE48-A & Up, A30019, A30026


thru A30120

ONLY -1 TRUCKS

AA04045: ENGINE SUB-FRAME


BRACKETS CRACKING

830E: 31320-32825, A30544 thru


A30726;

930E: 32604-32816, A30019,


A30026-A30120;

930E-2: A30012, A30098, A30100,


A30121 thru A30303;

930E-3: A30304 - A30313

AA04109A: ENGINE SUBFRAME


CRACKS

930E: 32604-32816, A30019,


A30026-A30120;

930E-2: A30012, A30098, A30100,


A30121-A30293, A30295-A30303;

930E-3: A30294, A30304-A30328

ONLY -1, -2 & -3 TRUCKS

15
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

TABLE 2: REFERENCE PSN DOCUMENTS

PSN Number & Description Reference Image

AA10038: AXLE CRACK REPAIR


PROCEDURE

860E-1K: A30001 & Up;


930E-4: A30462 & Up;
960E-1: A30001 & Up;

AA01141A: INSPECTION AND


REPAIR OF AXLE BOX

930E: AFE48 & Up

A30019

A30026 & Up

ONLY -1 TRUCKS

AA05055A: INSPECTION AND


REPAIR OF REAR AXLE BOX
(HATCH AREA)

930E: 32604-32816, A30019,


A30026-A30120;
930E-2: A30012, A30098, A30100,
A30121-A30293, A30295-A30303;
930E-2SE: A30183;
930E-3: A30294, A30304 & Up;
930E-3SE: A30171, A30318,
A30319 & A30322 and Up;

16
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

TABLE 2: REFERENCE PSN DOCUMENTS

PSN Number & Description Reference Image

AA03059: REAR AXLE WELD


CRACKS AT SUSPENSION
MOUNTS & REINFORCEMENT
PLATE

930E: 32604 - 32816, A30019,


A30026 and up;

930E-2: A30012, A30098, A30100,


A30121 and up

ONLY -1 & -2 TRUCKS

AA14042: AXLE HOUSING


ACCESS HATCH WELD
REINFORCEMENT

930E: 32604-32816, A30019,


A30026-A30120;
930E-2: A30012, A30098, A30100,
A30121-A30293, A30295-A30303;
930E-2SE: A30183;
930E-3: A30294, A30304 - A30461;
930E-3SE: A30171 - A30389;
930E-4: A30462 & Up;
930E-4AT: A30504 & Up;
930E-4SE: A30587 & Up

17
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

TABLE 2: REFERENCE PSN DOCUMENTS

PSN Number & Description Reference Image

AA05056: INSPECTION AND


REPAIR OF AXLE BOX

930E: 32604-32816, A30019,


A30026-A30120;

930E-2: A30012, A30098, A30100,


A30121-A30293, A30295-A30303;

930E-2SE: A30183;

930E-3: A30294, A30304 & Up;

930E-3SE: A30171, A30318,


A30319 & A30322 and Up;

18
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

3 General Welding Examples on EDT Frame


Horse Collar Weld Joint Repair
Same process for upper and lower joint sections

UPPER LOOP JOINT

LOWER LOOP JOINT


19
Upper loop shown transparent 
to provide view of casting 
structure below surface.

20
Komatsu America corp.
Peoria Operations
Horse Collar Upper Loop Weld Joint Repair Guide

TSI : Part #: 930E-4 Frame Date:


Part Description: Truck FrameA30860
Material Code: LW205-21 Material Type: Casting
Defect Description:
Crack on LH/RH Upper Horse Collar Weld Joint

Repair requested by: H. Dawal Dept. Quality


Preheat Temp.: 400°F-Maintain through welding Postheat Temp.: NA
Postheat Time: Interpass Temp. (Max): 550° F
Filler Metal Classification : SMAW E8018-C1 or E8018-C3

Procedure Description:
1 Grind or air arc to remove defects.
(Preheat to 400°F if air arc gouging.) Grind entire groove
after air arcing to
remove carbon
2 Use Dye Check or Magnetic Partical
to insure defect removal. deposits.

3 Shape to suitable Weld Groove (Fig. 1) Insure bottom of


groove does not have
sharp cornersbut 1/2” r
4 Use above specified preheat, of 400° F. smooth radius
Maintain throughout welding.

5 Use filler metals specified above. Fig. 1

6 Use stringer bead technique. Do Not puddle weld.


Remove slag and wirebrush each pass.

7 Let Slow Cool using insulating blanket.

8 Use Dye Check or Magnetic Partical


to insure no cracks or defects.
Document inspections and send to Komatsu-Peoria

Distribution:

Prepared by:

21
Komatsu America corp.
Peoria Operations
Horse Collar Lower Loop Weld Joint Repair Guide
MDN Part #: 930E Frame (A30939) Date:
Part Description: Horse Collar Sub-structure
Material Code: LW5725/LW205-21 Material Type: Plate/Casting
Defect Description:
Crack in lower loop to KL/KR Casting in Horse Collar.

Repair requested by: Ben Stear Dept. Quality NA


Preheat Temp.: 225°F-Maintain through welding Postheat Temp.: NA
Postheat Time: NA Interpass Temp. (Max): 500° F

Filler Metal Classification : GMAC LW102-15 ER70SP or ER80S-D2


FCAW E70T-5, E71T-8, or E71T8-NI1
SMAW E7018-1, E8018-C1, or E8018-C1

Shielding Gas 85%Ar - 15% CO2 - 35cfh minimum at nozzle.


Note::
Follow the guidelines that are outlined in Parts Service News, Field Wleiding for Assembly or Repair (AA00046C),
Welding Manual I (SEBF14001), and Welding Manual II (SEBF15002). It is improtant that these instructions are read,
fully understood, and followed.

Procedure Description:
1 Remove all paint, oil, grease, and other coatings in repair area.

2 Air carbon arc gouge or grind crack on inside as shown in Fig 1.


(Dye Check to insure end of crack is found and removed.)

3 Restore weld joint to original single vee groove at 45 Degrees(sect B-B).


(Make sure crack is 100% removed prior to repair)
(Grind as needed to remove carbon arc slag)

4 Install run-off tabs on inside (weld starts must begin on run-off tabs)

5 Use above preheat + filler metals to weld inside joint.

6 Remove slag and wire brush between each weld pass. Figure 1
7 Cut off run-off tabs.

8 Air carbon arc gouge or grind crack on rear surface.


(Grind as needed to remove air arc slag)

9 Restore weld joint to section B-B as shown in Fig 1, install run-off tabs.

10 Weld final joint on rear surface using above filler metals and preheat.

11 After repairs are complete the corner between the two repaired welds cannot be a hard 900 transition.
(Please smooth corner angle to match casting above and below the repair)

12 Dye Check all repairs after slowly cooling.

13 Figure 2 (Page 2) details weld joint and run-off tabs

Distribution: B. Stear

Prepared by:

22
Figure 2

Section   B‐B Original Joint
45°
45°
6mm 6mm

Air Carbon Arc/Grind out

Section   A‐A

Weld Layers Run‐off Tab

23
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

Casting to Frame Structure Joint Repair

Special Note::
This process is only valid in a weld
seem due to the built in or
additional backing that was added.
If the crack is located in the side
sheet anywhere other than a weld
seem another procedure must be
used.

24
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

Body Pivot Crack Example

25
BASIC WELDING REPAIR EXAMPLES

930E ELECTRIC DRIVE MINING TRUCK

Frame Repair Access Windows Examples


In some situations an access window is required to allow 100% crack repair.
Please contact the local Komatsu representative for any situation that could potentially require an
access repair window. KAC will provide assistance with repair process methods and specialized
instructions for the situation.

KOMATSU WILL PROVIDE ALL REQUIRED DETAILS: Access hole dimensions, location & tolerances;
backer dimensions; cover plate dimensions; human restrictions (if applicable) & full repair process.

EXAMPLE FROM 830E: Window Requirement Repair

HUMAN ELEMENT CONSIDERATIONS

26
Komatsu America corp.
Peoria Operations Frame Rail General Repair Guide

TSI : 930 Frame Rail General Weld Repair Part #: 930E-4 Frame Date: 08/01/14
Part Description: Truck Frame
Material Code: Material Type: Steel Plate
Defect Description:
For cracks located on the frame rail

Repair requested by: Dept. Quality


Preheat Temp.: 400°F-Maintain through welding Post heat Temp.:
Post heat Time: 20 minutes Interpass Temp. (Max): 550° F
Filler Metal Classification : SMAW E8018-C1 or E8018-C3
GMAW ER80S-D2
Procedure Description:
1 Grind or air arc to remove defects.
(Preheat to 400°F if air arc gouging.) Grind entire groove
Refer to Figures page for material thickness after air arcing to
remove carbon
2 Use Dye Check or Magnetic Particle deposits.
to insure defect removal.
Insure bottom of
3 Shape to suitable Weld Groove (Fig. 1) groove does not have
4 Use above specified preheat, of 400° F.
sharp cornersbut 1/2” r
Maintain throughout welding.
smooth radius

5 Use filler metals specified above. Fig. 1

6 Use stringer bead technique. Do Not puddle weld. (Vertical down or Down hand are not allowed)
Remove slag and wire brush each pass.

7 Let Slow Cool using insulating blanket.

8 Use Dye Check or Magnetic Particle


to insure no cracks or defects.
Document inspections and send to Komatsu-Peoria

9 Grind welded area to match the surrounding parent material, make sure there are no pockets, dents, gouges, undercut
or other defects in the welded material that could cause a stress riser.

10 If a defect in the rail starts, ends or crosses a existing frame weld then that defective area should be excavated
to remove the defect and repaired. Then a section of the frame weld where the defect crossed must be removed
and replaced to original configuration, see Figure 5 for an example

Distribution:

Prepared by:

27
Defect across the
plate face

This general procedure refers to defects in material


on the Frame rails, examples shown here.

For a defect that exceeds the material thickness , a 6mm root opening must be
added and backing material must be placed under the root opening to for the
necessary repair joint configuration
Defect within the
welded joint

Figure 3

28
Figure 2 represents a crack that crosses an existing backer and
requires additional backers to allow a 6mm root opening to be
created. in this example the defect over the backing material but did
not crack the backing material itself, however since the defect
extends through the entire material thickness backing material must
be added under these sections befiore the weld repair can be made

A36 backing material added to joint where the defect passes


through the entire material thickness

29
For a defect within a welded joint excavate the
defect as per process, these joints however
have backing material added to them as shown
below. If the defect continues through the
original backing material this backing material
will also need to be removed and replaced with
new backing material to complete the weld
joint

Cut away of a welded frame joint, notice


there is already backing material in this
joint. If the defect passes through the
backing material then this backing
material must be replaced, see Figure 2
for an example

30
Figure 4

Figure 5
assuming the there is a defect in a section of the frame rail represented here by the green line.

1) The first step would be to excavate the defect completely, repair and buff to return the joint and rail section to its original
shape.

2) Step 2: a section of the rail frame weld that the original defect crosses must be excavated, 2 inches to either side, here
represented by the dashed line. To ensure the defect is completely removed and to return the joint to original weld design.
- Figure 4 details the joint configuration for step 2

31
Komatsu America corp.
Peoria Operations Drive Tube Casting General Repair Guide

Drive Tube General Weld Repair Reference Guide Part #: 930 Drive Tube
Part Description: 930E Drive/Torque Tube
Material Code: Cast Material Type: Casted Steel
Defect Description:
To repair cracks next to welds as shown in Fig 1.

Repair requested by:


Preheat Temp.: 450F Post heat Temp.: 450F
Post heat Time: 20Min. Max.Weld Interpass.: 500F
Filler Metal Classification:

Procedure Description:
1 Remove all paint, grease, and oil from the crack / repair location and surrounding area where necessary

2 Grind Crack to form a Single-V-groove as shown in View C-C of figure 2


(If carbon arc gouging to remove crack, preheat first.)

3 Preheat Joint to 450 F and maintain throughout welding..

4 Weld excavated area using above electrodes and using vertical up progression. (Vertical down is not allowed)
if the crack is in a welded area the excavated area must be filled to return the joint to original joint design and then
then welded joint material can be replaced to match the surrounding weld joint.

5 Use Stringer beads, chip and wire brush each pass.

6 Grind repair flush(note grind marks should be perpendicular to weld length and repair should match
contour of original surrounding surfaces

7 Post heat as shown above to 450F for 20Min.

8 Let cool and use Dye Penetrant, or Magnetic Particle to check for cracks.

Distribution:

Prepared by:

32
Defect in Weld Material
45 degrees Min.
reinforcement should be no less than
1/16"
also when the repair is complete there
should be no undercut, gouges dents or
cracks that might cause a stress riser in
or around the welds

Weld Repair 1 inch past


original crack and Grind
Smooth After Welding in
This Direction

general weld
excavation joint
design

Figure 1

33
Defect outside Weld Material reinforcement
should be no less than
1/16"
also when the repair is complete there
should be no undercut, gouges dents or
cracks that might cause a stress riser in or
around the welds

45 degrees Min.

Weld repair joint design will remain


the same as well as the method for
replacing the weld. However after
welding and allowing the material to
cool all additional reinforcement
must be ground to match the
surrounding parent material

Weld profile after grinding to


match parent material

Figure 3

34
Komatsu America corp.
Peoria Operations Horse Collar Casting Repair Guide

TSI : Horse Collar Casting General RepairPart #: 930E-4 Frame Date: 08/01/14
Part Description: Truck Frame
Material Code: LW205-21 Material Type: Casting
Defect Description:
Crack on LH and RH Horse Collar Casting

Repair requested by: Dept. Quality


Preheat Temp.: 400°F-Maintain through welding Post heat Temp.: 400°F
Post heat Time: 20 minutes Interpass Temp. (Max): 550° F
Filler Metal Classification : SMAW E8018-C1 or E8018-C3
GMAW ER80S-D2
Procedure Description:
1 Grind or air arc to remove defects.
(Preheat to 400°F if air arc gouging.) Grind entire groove
after air arcing to
remove carbon
2 Use Dye Check or Magnetic Particle
to insure defect removal.
deposits.

3 Shape to suitable Weld Groove (Fig. 1) Insure bottom of


groove does not have
sharp corners
but 1/2” r
4 Use above specified preheat, of 400° F. smooth radius
Maintain throughout welding.

5 Use filler metals specified above. Fig. 1

6 Use stringer bead technique. Do Not puddle weld.


Remove slag and wire brush each pass.

7 Let Slow Cool using insulating blanket.

8 Use Dye Check or Magnetic Particle


to insure no cracks or defects.
Document inspections and send to Komatsu-Peoria

9 Post Heat as noted above

10 Grind welded area to match the surrounding parent material, make sure there are no pockets, dents, gouges, undercut
or other defects in the welded material that could cause a stress riser.

Distribution:

Prepared by:

35
This general procedure refers to defects in material on the
Frame center section, shown here. More specifically to the
areas of the casting noted here

36
Komatsu America corp.
Peoria Operations Upper and Lower Horse Collar
Structure Repair Guide
TSI : Horse Collar General Repair Part #: 930E-4 Frame Date: 08/01/14
Part Description: Truck Frame
Material Code: Material Type: Casting
Defect Description:
Crack on Upper and Lower Horse Collar

Repair requested by: Dept. Quality


Preheat Temp.: 400°F-Maintain through welding Post heat Temp.:
Post heat Time: 20 minutes Interpass Temp. (Max): 550° F
Filler Metal Classification : SMAW E8018-C1 or E8018-C3
GMAW ER80S-D2
Procedure Description:
1 Grind or air arc to remove defects.
(Preheat to 400°F if air arc gouging.) Grind entire groove
Refer to Figures page for material thickness after air arcing to
remove carbon
2 Use Dye Check or Magnetic Particle deposits.
to insure defect removal.
Insure bottom of
3 Shape to suitable Weld Groove (Fig. 1) groove does not have
sharp corners
but 1/2” r
4 Use above specified preheat, of 400° F.
smooth radius
Maintain throughout welding.

5 Use filler metals specified above. Fig. 1

6 Use stringer bead technique. Do Not puddle weld.


Remove slag and wire brush each pass.

7 Let Slow Cool using insulating blanket.

8 Use Dye Check or Magnetic Particle


to insure no cracks or defects.
Document inspections and send to Komatsu-Peoria

9 Post Heat as noted above

10 Grind welded area to match the surrounding parent material, make sure there are no pockets, dents, gouges, undercut
or other defects in the welded material that could cause a stress riser.

Distribution:

Prepared by:

37
This general procedure refers to defects in material on the
Frame center section, shown here. More specifically to the
areas of the casting noted here

if a defect exceeds the material thickness then backing


material must be added to and a 6mm root opening must
be added

38
Notice the differences in plate
thickness , top and bottom plates
are 25mm but the side plates are
32mm thick

all plates shown


here are 32mm

39

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