930 Frame Weld Reference Example Book
930 Frame Weld Reference Example Book
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
Operation and Service Komatsu Extranet: Operation and Service Specific to the
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BASIC WELDING REPAIR EXAMPLES
Table of Contents
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BASIC WELDING REPAIR EXAMPLES
930E ELECTRIC DRIVE MINING TRUCK
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
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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-2SE: A30183;
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BASIC WELDING REPAIR EXAMPLES
930E-2SE: A30183;
930E-3: A30294, A30304-A30461;
930E-3SE: A30171-A30389;
930E-4: A30462-A31641;
930E-4AT: A30504 & Up;
930E-4SE: A30587-A31640
930E-3: A30329-A30461;
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BASIC WELDING REPAIR EXAMPLES
ONLY -1 TRUCKS
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BASIC WELDING REPAIR EXAMPLES
A30019
A30026 & Up
ONLY -1 TRUCKS
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BASIC WELDING REPAIR EXAMPLES
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BASIC WELDING REPAIR EXAMPLES
930E-2SE: A30183;
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BASIC WELDING REPAIR EXAMPLES
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Komatsu America corp.
Peoria Operations
Horse Collar Upper Loop Weld Joint Repair Guide
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.
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.
Procedure Description:
1 Remove all paint, oil, grease, and other coatings in repair area.
4 Install run-off tabs on inside (weld starts must begin on run-off tabs)
6 Remove slag and wire brush between each weld pass. Figure 1
7 Cut off run-off tabs.
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)
Distribution: B. Stear
Prepared by:
22
Figure 2
Section B‐B Original Joint
45°
45°
6mm 6mm
Section A‐A
Weld Layers Run‐off Tab
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BASIC WELDING REPAIR EXAMPLES
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.
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BASIC WELDING REPAIR EXAMPLES
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BASIC WELDING REPAIR EXAMPLES
KOMATSU WILL PROVIDE ALL REQUIRED DETAILS: Access hole dimensions, location & tolerances;
backer dimensions; cover plate dimensions; human restrictions (if applicable) & full repair process.
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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
6 Use stringer bead technique. Do Not puddle weld. (Vertical down or Down hand are not allowed)
Remove slag and wire brush each pass.
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
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
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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
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
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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.
Procedure Description:
1 Remove all paint, grease, and oil from the crack / repair location and surrounding area where necessary
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.
6 Grind repair flush(note grind marks should be perpendicular to weld length and repair should match
contour of original surrounding surfaces
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
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.
Figure 3
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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
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
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
38
Notice the differences in plate
thickness , top and bottom plates
are 25mm but the side plates are
32mm thick
39