Académique Documents
Professionnel Documents
Culture Documents
Printed
07-88(01,02)02002
The
affected
following
pages are
marks.
indicated
by the
use of the
Action
Indication
Mark
I( )I
Add
Page to be replaced
Page to be deleted
required
Replace
Discard
Mark
Revision
number
Page
lark
Page
Revision
number
k lark
Page
PAGES
Revision
number
lark
Page
Revision
number
lark
Page
00-l
30
69
108
11-6
00-Z
31
70
109
11-7
00-Z-l
32
71
110
11-8
00-3
33
72
111
1 l-9
34
73
112
11-10
35
74
113
11-11
(COVER
(01))
01-l
CONTENTS
36
75
114
11-12
CONTENTS
37
76
115
11-13
CONTENTS
38
77
116
11-14
CONTENTS
39
78
117
.ll-15
00&2
/
revised or
made additions.
LIST OF REVISED
40
79
118
11-16
41
80
119
11-17
42
81
120
11-18
43
82
121
1 l-19
44
83
122
1 l-20
45
84
123
11-21
46
85
124
11-22
47
86
125
11-23
48
87
126
11-24
10
49
88
127
11-25
11
50
89
128
11-26
12
51
90
129
11-27
13
52
91
130
11-29
14
53
92
131
11-31
15
54
93
132
16
55
94
133
12-l
17
56
95
134
12-2
18
57
96
135
12-3
19
58
97
136
12-4
20
59
98
137
12-5
21
60
99
138
12-6
22
61
100
139
12-7
23
62
101
140
12-8
24
63
102
25
64
103
11-l
12-l 0
26
65
104
11-2
12-l 1
27
66
105
11-3
12-12
28
67
106
11-4
12-l 3
29
68
107
11-5
12-l 4
Revision
number
12-9
WELDING
Mark
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Page
12-15
12-16
12-17
12-18
12-19
12-20
12-21
12-22
12-23
12-24
12-25
12-26
12-27
12-28
12-29
12-30
12-31
12-32
12-33
12-34
12-35
12-36
12-37
12-38
12-39
12-40
12-41
12-42
12-43
12-44
12-45
12-46
12-47
12-48
12-49
12-50
12-51
12-52
12-53
12-54
12-55
12-56
12-57
12-58
12-59
13-1
13-2
13-3
13-4
13-5
13-6
13-7
WELDING
Revision
number
Revision
Jark
Page
13-8
13-9
@
0
20-l
20-2
20-3
20-4
20-5
20-6
20-7
iO-8
20-9
20-10
20-11
20-12
20-13
20-14
0
0
@
@
@
@
@
@
0
0
0
@
@
@
20-15
20-16
20-17
20-18
20-19
20-20
20-21
20-22
20-23
20-24
20-25
20-26
20-27
20-28
20-29
20-30
20-31
20-32
20-33
20-34
20-35
20-36
20-37
20-38
20-39
20-40
20-41
20-42
20-43
2044
20-45
2046
20-47
20-48
20-49
20-50
@
@
@
@
0
0
0
0
@
@
0
@
@
@
0
0
@
@
@
@
@
@
@
@
0
0
0
0
@
@
@
@
@
@
0
0
number
Aark
Page
20-51
20-52
20-53
20-54
20-55
20-56
20-57
20-58
20-59
20-60
20-61
20-62
20-63
20-64
20-65
20-66
20-67
Revision
number
dark
Page
30-13
30-14
30-15
Revision
number
Mark
Page
Revision
number
0
0
0
20-68
20-69
20-70
20-71
20-72
20-73
20-74
20-75
20-76
20-77
20-78
20-79
20-80
20-81
20-82
20-83
20-84
20-85
20-86
20-87
20-88
20-89
20-90
30-I
30-2
30-3
304
30-5
30-6
30-7
30-8
30-9
30-10
30-11
30-12
oo;-1
CONTENTS
(Sections marked *
GENERAL
are in preparation.)
INSTRUCTIONS
01 GENERAL INSTRUCTIONS
No. of page
Ol-
ll-
12 HARD-FACING
12-
13-
APPLIED
. ..
. _. _.
.. . .
. .. .
INSTRUCTIONS
OF WEAR PARTS
13 REPAIR OF RADIATOR
20 REPAIR OF BULLDOZERS
Mainframe
BY WELDING .......
.......................................................
Trackframe
Blade
....................................
......................................................
............................................................
Bucket
20-
20-16
...........................................................
20-70
20-83
BY WELDING
............................
Mainframe
.......................................................
Dumpbody
.......................................................
40 REPAIR OF HYDRAULIC
Revolvingframe
Trackframe
EXCAVATORS
30-
30-
BY WELDING
*
*
...................................................
......................................................
...........................................................
Boom ............................................................
Arm
Bucket
..............................................................
BY WELDING
..........................
*
*
.......................................................
...........................................................
Boom .............................................................
Bucket
60 REPAIR OF MOTOR
Mainframe
Blade
GRADERS BY WELDING
.........................
Hitchframe
*
*
.......................................................
............................................................
SCRAPER BY WELDING
.......................................................
70 REPAIR OF MOTOR
-sr
Bowl .............................................................
80 REPAIR OF SOIL COMPACTOR
BY WELDING .........................
*
*
Foot .............................................................
LIST OF SERVICE NEWS NO. RELATED TO WELDING
ts The list of Service News No. related to welding
the Service News until the Applied Instruction
Manual is completed.
WELDING
20-
20-
is attached. Refer to
Section of the Shop
00-3
2
01 GENERAL INSTRUCTIONS
techniques .....
................
..................
Selecting welding methods
Preparations for welding .....................
Welding techniques .........................
..........
Weld defects and countermeasures
General description
of welding
Features
methods
of welding
How to distinguish
materials
areas
symbols
.................
................
55
62
welding
...............................
Preventing accidents ........................
................
Cost of welding consumables
70
and cutters.
of troubles
and countermeasures
of welding
92
rods by countries
104
.................................
table
............................
Names of standards
Aguidetoweldingterms
99
by
.................................
temperature
Conversion
87
......................
of metal materials
andalloys
84
structures
List of standards
countries
WELDING
in welded
List of standards
Melting
17
44
and
Examples
9
10
in various countries
109
......
. . . . . . ..___....._.._
114
115
01-l
cc
CONTENTS
1.
GENERAL
l-l
1
DESCRIPTION
OF WELDING
TECHNIQUES
........
1
1
2.
FEATURES
OF WELDING
2-1
Gaswelding
2-2
Arcwelding..
....
METHODS
1
1
1
1
2
3
, ...........
, ......
4
4
............................................
..........................................
5
5
.........................
..................................
..............................
6
7
3.
4.
5.
SELECTING
WELDING
METHODS
1
1
.............................................
2 Hint on safety in operation ..................................
.........................................
1) Introduction
Preface..
..........................
PREPARATIONS
...........................
FOR WELDING
..........................................
..................................
4 - 2 Standard edge preparation
...............................
4 - 3 Types of steels and weldability
1) Rolled steel for general structures ...........................
2) Rolled steel for welded structures ...........................
: .............
3) Cold rolled steel .........................
4) Carbon steel for machine structural use. .......................
5) Carbon steel forgings for general use ..........................
6) Carbon steel tubes for general structural purposes .................
7) Carbon steel tubes for machine structural purposes ................
8) High tension rolled steel plates for welded structures (SHT) ..........
4 - 4 Drying welding rods ......................................
4 - 5 Cleaning weld zones ......................................
10
4- 1 Typesof
10
WELDING
17
5-l
joints
11
12
12
12
13
13
13
14
14
15
16
16
TECHNIQUES
, . . . . . . . . . . , . . . . . . . . . , . . . . . . ., . . . .
.....................
1) Classification of welding rods ..............................
2) Types and features of covered welding rods .....................
. Types and features of covered welding rods for mild steel ..........
. Types of covered welding rods for mild steel ..................
. Types of covered welding rods for high tensile steel ..............
..................
17
18
19
20
20
21
.......................
................................
22
23
5-2
5-3
...........................
........................................
Welding positions
Methods of deposition .....................................
25
5-4
17
26
27
1) Forehand welding
2) Backhand welding
3) Symmetric
welding
4) Skip welding
5) Prestrain welding
6) Restrain welding
9) Multi-layer
welding
5-5
5-6
Welding conditions
.......................................
29
1) Arc voltage
..........................................
29
2) Arc current
..........................................
.........................................
30
Deposition
rate
31
...........
2) Welding conditions for fillet welded joints in horizontal position .......
Welding conditions for pipes .................................
5-7
Back run and backing .....................................
5-8
Tack welding ...........................................
5-9
1) Just after tack welding. ..................................
2) Butt tack welding ......................................
3) Examples of tack welding jigs ..............................
5-10 Regular welding .........................................
1) Welding conditions for V-shape butt joints in flat position
1) Examples of treatment
of starting/ending
5-11
40
41
.........................................
41
2) Carbon electrodes
42
42
WELD DEFECiS
AND COUNTERMEASURES
6 . 1 Welding strains. .........................................
welding
4) Prestrain welding
43
.................
Cracks
3) Skip welding
5) Restrain welding
6) Peening
...............................................
1) Bead cracks
46
46
46
46
47
zones .............................
48
.........................................
4) Cold cracking. ........................................
5) Unusual cracking ......................................
6) Countermeasures against cracking ...........................
6 . 4 Internal defects .........................................
3) Hot cracking
1) Countermeasures
46
47
..........................................
2) Cracking in heat-affected
44
44
2) Backhand welding
48
49
52
52
53
...................
HOW TO DISTINGUISH
MATERIALS
AND HOW TO
CHECK WELDED AREAS ..................................
7 . 1 Simple methods of distinguishing materials .......................
1) Spark test ...........................................
2) Spectroanalysis
.......................................
7-2
37
37
3) Gouging torches
1) Symmetric
7.
36
40
......................................
.......................................
4) How to gouge ........................................
6-3
36
40
.........................................
4) How to braze .........................................
5-12 Arc air gouging. .........................................
36
39
2) Flux ...............................................
6.
35
39
..................................
3) Brazed joints
1)Powersource
33
38
Brazing ...............................................
1) Brazing and its features
32
positions
...............................
31
Howtocheckweldedareas..
................................
........................................
...................................
Magnaflux inspection
Detecting supersonic flaws ................................
Penetration inspection (Color check) .........................
Magnetic-analysis inspection ...............................
54
55
55
56
59
60
1) Visual checks.
60
2)
60
3)
4)
5)
60
60
61
8.
HOW TO READ
WELDING
SYMBOLS..
........................................
.....................
8-2
8
9.
63
.................................
Howtoenterweldsymbols
64
Structure
...................................
3) Cutting method .......................................
Pressure regulator ........................................
1) Types of pressure regulators ...............................
2) Structure of pressure regulators .............................
welders
77
79
...........................
9-6
79
79
79
80
80
...................................
......................................
Assembly of equipment ....................................
....................................
Removal of equipment
............................................
Safety rules
80
................................
...........................
1) Accidents caused by electrical shocks .........................
........................
2) Ailments caused by harmful radiation.
3) Ailments caused by the smoke produced in welding ...............
84
2) Collecting devices
10. PREVENTING
11.
81
82
83
ACCIDENTS
4) Countermeasures
IO-2
84
84
84
85
85
...............................
1) Cautions in work operation
2) Cautions when handling tanks ..............................
86
86
86
.......................
CONSUMABLES
.......................................
11-2 Expenditures on welding ...................................
1) Consumption of weld metal ...............................
2) Consumption of covered arc welding rods ......................
COST OF WELDING
87
1 l-l
87
Cost of preparation
12.
73
76
......................................
2) How to handle torches. ..................................
3) How to handle regulators .................................
Other tools for welding and cutting ............................
10-l
73
76
1) General cautions.
9-9
72
75
9-7
9-8
71
72
74
9-5
70
74
..........................
9-4
70
74
.............................
type)
62
62
8 . 1 Welding symbols.
88
88
............
..........................
EXAMPLES OF TROUBLES
AND COUNTERMEASURES
IN WELDED STRUCTURES
................................
12-1 Box type welded structures .................................
12-2 Butt welding of box type welded structures .......................
........................
12-3
12-4
Connection
12-5
Connection
...................
.................
89
90
91
92
93
93
94
95
96
12-7
12-8
patches.
...........................
12-6
........
because of
......................................
12-9 Box type welded structure with bosses ...........................
difference
13.
14.
15.
16.
98
98
of rigidity
LIST OF STANDARDS
OF WELDING
RODS
BY COUNTRIES ..........................................
13-I
Classification
96
97
99
1) Classification
2) Classification
3) Classification
4) Classification
.....................
.....
100
100
....................
101
......................
.....................
102
103
LIST OF STANDARDS
OF METAL MATERIALS
BY COUNTRIES ..........................................
1) Rolled steel for general structures ...........................
2) Rolled steel for welded structures ...........................
3) Cold rolled steel .......................................
4) Carbon steel for machine structural use. .......................
5) Carbon steel forgings for general use ..........................
6) Carbon steel tubes for general structural purposes .................
7) Carbon steel tubes for machine structural purposes ................
8) High tension rolled steel plates for welded structures (SHT) ..........
107
MELTING
TEMPERATURE
OF VARIOUS
BASE
METALS AND ALLOYS .. : ................................
108
CONVERSION
109
16-1
Strength
TABLE .....................................
..............................................
1.6-2 Temperature
16-3
Pressure
16-4
Length..
16-5
Weight
17.
NAMES
18.
A GUIDE
105
105
106
106
111
.............................................
112
...............................................
113
IN VARIOUS
TERMS
104
105
110
..............................................
TO WELDING
104
109
...........................................
OF STANDARDS
104
COUNTRIES
...........................
..........
114
115
1.
l-1
OF WELDING
DESCRIPTION
GENERAL
PREFACE
Welding
tries,
is a technique
used widely
and it is common
in many indus-
knowledge
that welding
used in the
manufacture
struction machinery.
the structure
and maintenance
Unauthorized
cutting machines.
(5)
of con-
of construction
machinery
portant
greatly
affect
(6)
sling-
of the machinery.
(4)
is
role
TECHNIQUES
service department.
This
manual
will
3) Safety in welding
Standard).
by AWS/ASTM.
For
and standards of
refer to Section 13,
by JIS (Japa-
of Metal Materials by
(3)
Never
(4)
(5)
Countries.
use damaged
holders or cabtyre
Use a noncombustible
cables.
1 -2
I)
HINTS
ON SAFETY
(1) Always
IN OPERATION
remove
hammer.
Use only
them.
means
protecting
yourself
and others
(3)
(making the
(4)
strictly
observe
the
and be-
standard
work
slinging
work,
and
hoisting
(1)
position
without
ignition
your
lighter.
(Clse
place
working
screens
with
(1)
(2)
Always
to be welded
are grounded
securely.
Always
make
sure electrode
holders
are well
insulated.
(4)
Always
insulated.
of an
for abnormalities.
a grinder,
(3)
bring
with
working
When
a crane, never
(6)
good
reason.
(3)
When
and the
work
over with
material
work
accidents and
Never
(5)
transportation,
When turning
and
the specified
turned over.
change as
The workers
operations.
of the workpieces
operations
cause workers
properly
a sledge
using
from
injury.
they
when
Introduction
Safety
gloves
Then
-l-
(5)
(6)
flame.
Always wear
dry shoes.
(7)
When working
ventilation.
(2)
Before
cutting
inflammable
a container
which
contained
an
before cutting.
Remember
temperatures
When working
has contained
on a container
an inflammable
substance,
sure there
is an opening
to
allow
any
If
When
After
cutting
materials
with
gas, protect
the
have a different
remove bear-
thermal
expan-
being heated
cident.
-2-
l-3
TYPES
OF WELDING
METHODS
a covered
service department
machinery
electrode
are often
field.
Arc weld-
is widely
used in the
to repair structures
and provide
reinforcement.
Spot welding
Seam welding
Lap welding
-E
Projection welding
Resistance welding
Flash welding
Gas pressure weldingf
Upset welding
Butt welding
-E
Pressure welding
Percussion welding
Friction welding
Forge welding
Brazing
-
Soldering
covered electrode
Soft soldering
Submerged arc welding
Welding methods
Consumable electrode
Non-consumable electrode-
bpz--HV,
L
Tig welding
Thermit welding
Fusion welding
Electroslag welding
Electrogas welding
Pressure welding:
Joining
metals
by
heating
them
Brazing:
Fusion welding:
-3-
2.
FEATURES
OF WELDING
METHODS
2 - 1 GAS WELDING
*
with
a high temperature
(welding rod).
Generally,
flame
pro-
Welding rod
metal
is shown at right.
pro-
Core of flame
duced by gas welding is much lower than by arc welding and the concentration
not
efficient,
However,
it
is not
nowadays.
because of
sensitivity
metals
to heat,
that
formed
in places where
carrying
electric
the
equipment
simple
Weld metal
welding
metals.
Basemetal
sheet metals
Another
available
Solidified
weld metal
crack
is not
devices.
Gas welding
Disadvantages
Advantages
1)
2)
2)
3)
3)
The mechanical
easily.
4)
Equipment
5)
cost is low.
4)
5)
6)
metals,
7)
ed in some cases.
and especially
metals
with
a low fusion
point.
-4-
2- 2
-
ARC WELDING
In arc welding,
When steel
the temperature
can exceed
6,OOOC.
The temperature
oxygen
the
and
nitrogen
from
air
and becomes
various methods
Transformer (AC)
Base metal
Grounding cable
Rectifier (AC)
Generator (AC)
used method,
the flux
covering the
Electrode
that
is, the
decomposed
flux
covers the
Welding direction-
melted metals.
The flux not only improves the chemical and mechanical properties
its workability.
method
has the
following
advantages:
oxidize
Impurities
phur
(4)
(5)
Elements
and sul-
in the melted
metals.
metals.
6. Reinforcement
C. Penetration
rapidly.
D. Weld metal
improving
economical
AC
the
electrodes,
welders
and thus
are more
widely
the
more
used at
present.
-5-
E. Heat-affected
A. Slag
of weld
zone
it from
contacting
the
metals.
arc welding
because the
instead
machines
Submerged
are
of
using covered
automated
or
electrodes,
semiautomated.
advantages
(1)
and penetration
relatively
are extremely
high, and
in a
single pass.
(3)
Therefore,
differences
minimized
and reliability
welders,
skills
are
improves.
mate-
Submerged
arc welding
is mainly
structures,
carriages
in
build
of construction
up welding
machinery,
for
and
underin wear
thick
materials con-
-6-
Contact tip
co,
- O2 arc welding
Fed continuously from steel
while welding.
Before it was confirmed
were
used.
However,
inert
gas shielded
arc
Bare steel wire containing
deoxidizing elements (DSI)
and carbon
steel and
low alloy
steels are
gas shielded
welding
is roughly
(DC),
divided
-Mixture
into
gas of
three methods.
containing
deoxidizing
etc.)
elements
(manga-
wire.
(2)
Grounding:
\
Grounding power source
(DC), 0
polarity
\
Deposited
metal
\
Melted
metal
\
Base
metal
A mixture
shield
gas, and
relatively
large quantity
steel
wire
containing
of deoxidizing
elements
and continuously)
manga-
ways.
-
-7-
Arcosarc wire
is supplied
continously
in the
the
described
submerged
machine
arc
welding
is automated
before,
or semiautomated
the
and is easy
to use.
Welding
highly
thick plates.
welding
used for
and produces a
welding.
The advantages common
(1)
Weld
metals
can
be
obtained
which
contain
(2)
Since
cheap CO2
gas (sometimes
with
a little
oxygen)
welding
high.
-8-
I
co
I
=3
6
4
Ship
=I=
I
Bridge
3m
a
7
Train
Machine
Lap joint
velding
cost of
cost of
equipment
Automobile
Building
Pressure
container
Butt joint
Thick,
25 or more
Medium,
3.2 to 25
4.
PREPARATIONS
priately
best welding
rial to be welded,
4 - 1 TYPES
*
FOR WELDING
of the mate-
of the materials
and the
OF JOINTS
Corner joint
Lap joint
Butt joint
Edge joint
Double-strapped joint
joint
Butt welding
Singlestrapped
Corner welding
Fillet welding
Plug welding
line is
The
welding
ed intermittent
made continuously
on a weld
intermittent
welding.
Intermittent
Parallel welding
welding
-lO-
Staggered intermittent
fillet welding
4 -2
STANDARD
* To facilitate
EDGE
arc welding,
PREPARATION
*
it is necessary to prepare
Common
edge preparation
materials.
Thickness
(mm)
Shape of edge
(KES)
Shape of edge
Remarks
Thickness
(mm)
- Without backing
Less than
2.3
strip
* Without back
- Without backing
strio
chipping
19to60
strip
Less than
4.5
-I
L-a
30
+H
N
- Welding on
-
singleside
Used for welding
thin plates
19
6to25
- With backing
strip
- Welding on
single side
19to69
* Welding on both
sides
- Used for welding
very thick plates
12to60
* Without backing
strip
- Back run may
be made.
- Without
to 60
backing
strip
12to
69
- With back
chipping
- Without backing
6to
16
strip
so-
P
-
* Without backing
strip
- With back
chipping
- Used for welding
thick plates
6to25
05
di3
sides
for welding
thick plates
* Without backing
strip
- With back
chipping
- Weiding on both
- Used
- With backing
Remarks
- With backing
6to
16
strip
- Welding on
single side
l-2
11 -
4-3
TYPES
ABILITY
The
steel
OF
most
machinery
can
STEELS
commonly
be classified
AND
used
in
into
WELD-
construction
steel plate
the weldability.
(mild
from
steel sheet used for cabins etc., and steel pipe used for
Carbon equivalent
booms, etc.
(Ceq) =
C + 1/6Mn + l/24%
factor in
the following
formula:
In addition
(Ceq) is an important
It is obtained
+ 1/40Ni
and low alloy steel are used for gears and wear resis-
In the
tant parts.
Table
below,
indicates
weldability,
good weldability
TvPe
Svmbol
(JIS)
Tensile
strength
(kg/mm21
Yield
point
A441-79)
Chemical composition
Elongation
(kg/mm*)
A283-78,
Mn
(%)
Tvpe 1
ss34
34 to 41
>20
>26
Type 2
sS41
41 to 52
>24
521
Tvpe 3
ss50
50 to 62
>28
>19
Type 4
ss55
>55
X0
>I7
,_
Weldability
usage
I I
c=l
cco.05
General structure
<0.30
Type
Symbol
(JIS)
<0.04
<I.60
A242,
A63579)
Chemical composition
Tensile
strength
(kg/mm*)
Yield
point
(kg/mm*
Elongation
(%)
Impact
value
kgm)
Mn
Si
-IS
uYeld
C=l
ability
Usage
>0.4c
0.41
0.42
A
SM50YA
Type3
SM50Y 8
>19
SM536
Tvoe 4
53to
65
SM53C
Type5
SM5P
I
58 to 73
>46
>20
-12-
General
structure
A619,
A6201
Chemical composiiion
Mechanical properties
Symbol
(JIS)
Tvw
Tensile
G$:$
SPCC
Tvpe 2
SPCD
Tvpe
Elongation
(%)
&38)
co.12
0.50
K 0.040
9 0.045
>40
<O.lO
0.45
ZG0.035
< 0.035
>42
<O.OB
0.40
4 0.030
< 0.030
(228)
Mll
Ceq
Weldability
Usage
Weld
ability
Usage
0.15
228
Tvpe 3
SPCE
Tensile
trength
(%
:g/mm*
Elongation
Yield
point
(kg/mm*
Hai,A,xq
-, ,.Mb)
(%I
SlOC
> 32
L? 21
zz 33
s15c
2 38
2 24
2 30
111 to 167 ;p
s2oc
2 41
2 25
228
ll6to
S25C
245
>27
Z 27
123to1830~28
s3oc
248
I?29
2 25
s35c
2 52
> 31
223
149 to 207 $2
S4OC
255
2 33
>22
156to217
S45c
258
>20
262
zz?37
218
35
A576-79)
Chemical composition
Mechanical properties
Svmbol
(JIS)
MI-I
Si
Ceq
l----i
0.24
0.29
.22 to
O$O$
0.030
Structure, wear
resistant parts,
gears, etc.
I<
;.
.I
0.45 to
s5oc
0.64
l-i
0.53
>66
s55c
>40
0.69
>I5
Symbol
(JIS)
Tvw
Yield
point
(kg/
mm*)
Tensile
strength
rAz$,
Mn
C
?:Lhv
S F34
34to42
217
5 31
Tvw 2
SF40
4Oto50
220
229
Tvpe 3
S F45
45to55
223
;r 27
Tvpe 4
S F50
5Oto60
2 25
> 25
SF55
155to651
SF 60
6Oto70
~28
5 30
- Weldability
Ceq
2 26
j 2 24 /
1 223 / z 18 l
2 20
Si
Usage
Crosswise
lo.25 / 0 j
IO.481
A1051
Elongation (%)
Tvw 1
A666-78,
Chemical composition
Mechanical properties
Type 6
-r--l
174 j$;
s48c
Tvoe 5
0.13
0.53
15
-13-
I
x
Tensile
strength
(kg/mm*
%?
Type 1
STK30
Yield
point
(kg/mm
2 30
Elongation
Mn
Si
-_
STK41
z 41
2 24
zz 23
ZG0.25
Type 3
STK51
2 51
2 36
215
I 0 .30 0i3gfo
I 0.35
Type 4
STKBO
z? 50
Z 32
CO.18
CO.55
SO.05
Twe 2
Cw
(%I
230
A252-90)
Chemical composition
Mechanical properties
Type
A500-80,
23
zZl.50
0
~0.04
I 0.04
0.40
0.35
-TMn
Neld-
Ceg
ity
0.23
0
0.31
Type 13
STKM13B
I? 45
31
25
0.41
co.25
LO.35
A
0.46
0.63
X
0.73
0.45
-14-
Boom and
other parts
A519-80)
Chemical composition
Usage
0.25
0.30
Mechanical properties
SO.05
Weldability
usage
(Tensile strength:
50 kg/mm2
to 80 kg/mm2
class)
Chemical composition
Mechanical properties
- Weld.
Type
Class
50kdmm2
Tensile
strength
(kg/mm
5.
tO
63
class
60kglmm
class
treated
ing)
60 to 72
Yield
point
(kg/mm2
(%)
80k /mm
clan cil ot conthing
Ni)
55kdmm2
55 to 67
Ceq
0.36
0.44
>46
>20
<0.18
<1.60
<0.16
<1.50 <0.3
<0.18
>36
>I 6
60kglmm
class
60 tO 72
>46
8Okglmm
class
80 to g5
>70
Y1.20
-
>70
>15
<1.50
<0.20
<1.50
0.60
0.50
;tructure
0.57
1.60
<O.lO
<I.20
0.63
<0.60
<1.60<0.70
0.47
,80t
OD8to0.1OtolDOto
0.15
0.50
2.00
-15-
I.30
<0.5c
<0.15
-CO.55
<0.18
-<0.55
class
<1.50
>I6
8Oto95
MO
<0.16<0.40
class
ability
Cu
Cr
>15
70kdmm27.Jtose >63
classlC0n
mining Nib
Mn
Si
Ni
>36
80kglmd
Non-heat
treated
(Rolled
steel or
annealed
steel)
Elongation
Nb+V=Max.O.lZ
AQ: <0.08,
Nb + Add: V
0.50
Zranes,
3ooms,
?tC.
4-4
-
DRYING
WELDING
RODS
and there
Therefore,
is likely
to be an
dry.
in the flux,
must be dried at
Redrying
temperature
(C)
Standard
Type of rod
llmenite type
JIS D4301
Lime-titantia type
JIS D4303
Cellulose type
JIS D4311
AWS E6011
JIS D4313
AWS E6013
Drying time
(minutes)
70 to 100
30to60
JIS D4316
Low hydrogen type
300 to 350
JIS D5016
Flux for submergedarc
welding
4 -5
-
CLEANING
There
is a tendency
However,
150 to 300
WELD
ZONES
by rust, paint,
must
always be clean.
Cloth,
wire
brushes, a grinder,
-16-
5.
WELDING
5-1
TYPES
OF WELDING
HOW TO SELECT THEM
Along
with
machine
TECHNIQUES
welding
component
of welding
the greatest
RODS
influence
AND
of welding
methods.
major
on the mechanical
properties
and be able to
of
welding
rods should
never
be based
On the other
Classification
Various
of welding rods
welding
.For manual
welding
welding methods.
r Bare welding
rods
divided
into
two
groups,
depending
whether
on
or auto-
Welding rods.
For manual-Covered
rods
welding
. Covered welding
rods
and sometimes
from
contacting
welding
flame,
argon, COZ,
nitrogen,
the melted
metals.
Some covered
zone with
covering
covered
materials.
ing welding
welding
rods protect
the
is made from
the
-17-
welding
Fuses, arc
For automatic -welding
rods,
and others
welding
Exposed core
only
small
phosphorous
rials
are
amount
to prevent cracks.
made
organic matters,
from
oxides,
fluorides,
of carbon,
sulphur,
and
silicates,
They are
covering
welding
according
low
nonferrous
alloy
steel,
alloys.
hard
facing,
cast iron,
and
above:
llmenite type
Lime-titania
type
oxide type
oxide type
Iron powder-low
hydrogen type
Iron powder-iron
oxide type
D 43
Special type
Each type
features.
of welding
As an example,
rod for
or D4340)
18-
rods for
D4301
llumenite
44to48
Elongation (%I
y
High titaniurn oxide
High
cellulose
_ime-titania
I
Pi
c
44to49
II
Low
high titani-
hydrogen
powder-low powder-iron
44 to 50
48 to 55
48 to 54
48 to 55
I 50 to
58
/ 44to48
37 to 42
39 to 46
42 to 50
37 to 41
22 to 28
17to22
28 to 35
25 to 30
2 25
55 to 75
5 40
240
.;k
B
5
m
2
5
_c
8to
12
Endurance limit
(kg/mm 1
Brinnel hardness
130 to 160
9to
18
I -
I -
150to170
14Oto160
1
7.80 to
7.85
Specific gravity
Welding
current (A)
Arc
voltage (V)
Dia. of core
wire: 4 mm
120 to 180
Dia. of core
wire: 5 mm
170 to 250
7.80 to
7.85
7.80 to
7.85
II
I
27
Slightly
strong
II
I
Slightly
calm
Strong
I
I
Must be
kept short
Calm
I
180 to 240
230 to 290
-I
22 to 26
l-
23to27
Condition of arc
7.80 to
7.85
200 to 280
25
Dia. of core
wire: 5 mm
130to160
/
160 to 220
Dia. of core
wire: 4 mm
7to11
Must be
Calm
Spray
kept short
Shallow
Medium
Dense.
Covers
completely
Al
Co:&
completely
A lot.
Covers
completely
Attractive
Attractive
Attractive
Attractive
Condition of fillet
Plain or
slightly
concave
Convex
Plain or
slightly
convex
Internal structure
Excellent
Penetration
Condition of slag
Appearance of beads
Deep
Medium
Deep
Shallow
Medium
/
t
c
Impurities
Spatters
Few
Few
-19-
Plain
Excellent
Excellent
I
-t
Slightly deep
Few
Few
Types
of covered
welding
rods for
mild
steel (JIS
2321 I-1978).
Types of
welding rods
(JIS)
Type of covering
material
Welding position
Tensile
strength
(kg/mm2
Yield
point
(kg/mm*
Elongation
(%I
Impact
value
(kgm)
D4301
llumenite
F, V. 0. H
AC or DC (*I
43
35
22
4.8
D4303
Lime-titania
F. V. D. H
AC or DC (r)
43
35
22
2.8
D4311
High cellulose
F. V, 0, H
AC or DC (+b
--.
43
35
22
2.8
D4313
F, V, D. H
AC or DC (-1
43
35
17
Low hydrogen
4.8
D4316
F. V, 0, H
AC or DC (+I
43
35
25
D4324
F, H
AC or DC (?I
43
35
17
D4326
Low hydrogen
F, H
AC or DC (+I
43
35
25
4.8
D4327
Iron powder-iron
oxide
F, H
AC or DC (-) in
horizontal fillet
welding. AC or DC in
flat welding.
43
35
25
2.8
Type of welding
current
V: Vertical
0: Overhead
H: Horizontal
(A)
F: Fiat
(B)
AC: AC current
DC (2): Both polarities of DC current
DC (+): DC electrode positive
Types of covered welding rods for high tensile steel (JIS 23212-1976)
I--I
Type of
welding rods
(JIS)
~~~~~
Type of covering
material
Welding position
1-
Tensile
strength
(kg/mm*
Yield
point
(kg/mm
Elongation
Impact
(%)
value
(kgm)
D5001
llumenite
F V. 0, H
ACor
DC (t)
50
40
20
4.8
D5003
Lime-titania
F. V. 0. H
AC or DC (+I
50
40
20
4.8
50
40
23
4.8
53
42
20
4.8
D5816
58
50
18
4.8
D5026
50
40
23
4.8
53
42
20
4.8
58
50
18
4.8
D5016
D5316
D5326
Low hydrogen
Iron powder-low
hydrogen
F. V. 0. H
F, H
AC or DC (+I
AC or DC (+I
D5826
- 20 -
roughly
Types
as solid
wires.
welding.
A 5.18 -1979)
~~
Type 2
YCW2
50
40
22
2.8
Type 3
YCW3
50
40
20
2.8
Y CW4A
43
35
22
2.8
YCW4B
50
40
20
2.8
Type4
The
combined
deoxidizer,
The
table
The powdered
alloys,
below
and
FIUX
substances consist of
slag forming
materials.
of commonly
used wires.
Type of wire
Features
Contains 0.10% or less aluminum, and 0.30% or less of either titanium or zirconium, or a combination of them
YCWl
and zirconium are not specified, but amount of manganess and silicon, which
are deoxidizing agents, are specified. The former elements are usually intentionally omitted.
Mainly used for short circuit arc welding on thin sheet metals with a small welding current, or in vertical or
overhead position welding.
YCW3
Contains 0.10% to 0.50% aluminum, and 0.30% or less of either titanium or ziroconium, or a combination of
them not exceeding 0.30%.
Since it contains a lot of aluminum in addition to the manganese and silicon deoxidizing agents, blow holes do
not occur easily even if rust or mill scale is present, and smooth beads can be obtained.
When this type of wire is used in horizontal fillet welding, plain beads can be obtained. However, ductility and
toughness of multi-layer welded metals decrease slightly.
-21-
(JIS 23201-1976/AWS
A5.2-1969)
types of welding
carbon
of
are easy to
In
- 22 -
is fairly
difficult
for
inexperienced
persons to
based on the
theory
and experience
of
repair shops.
Steelfor structures
Materials (JIS)
. __
-::.:
*::.
-::.:
,*:.*.
. . . . . . .~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~
~.~.~.~.~.~.~.~.~.~.~.~.~.~..~.~.-.~
. . . . . . . . . . . . . . . . . . .
Note
When joints
use C.
D4316
I D4326 I
metal
is not especially
of the
required,
use
(~50161
below 50 kg/mm
welding rods.
Figure
in
) following
rials indicate
(calculated
component).
- 23 -
percentage
with
upper
equivalent
of each chemical
caststeel
Material (JIS)
SC46
g;
SC
55W
SCSi
SCSi
Mn5 Mn2BH
6%
SCMn
34H
SCMn
CrMo3
s43c
s53c
SCM
3H
Steel pipe
ST
35K
STKM
13A
. . . . . . . . . . . . . . . . . . . *. . . -. . .- . -. . .- . -. . .- . -. . -. . .- . .- . .. . .- . .- . .- . .- . .- . _
. . ._. -. . .-. .- . .-. .- . .-. -. . .-. -. . .-. -. . -. . .- . -. . -. - _
..
ss41
SM41 B
SMi41
(0.52)
::.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:
~.~.~.~.~.~.~.~.~.~.~.~..~.~.~.~.~.~.~.~.~.~.~.~.~.~..~.~..~.~.~.~.~
~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~
._._._._.*.
. . . . . . . . . . . ._._. . . . . .*.*. . . . . . . . . . . .
. . . . . .*.-.~.~.~. . * *:.
- * *::. . * -:.*.*.-.*.~::
*
. . . . . . . . . . . ::. . A(,&2). . . . . . . . ::.9 . . . . . . . . . . . . . . . . .:.I . . . . . . . .
........................... ... ................ .. .
.
~.~.~.~.~.~.~.~.~.~.-.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~
.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.-.~.~.~.~.~.~.~.~.~.~.
.
SML45
5 I SHTGOH
(0.45)
F:+:.:.:.:.:.:,$
:::::::.
:::::::.
SHT80A
(0.5,)
:i:g:i:;:;:;:,
SHT808
(0.44)
.
_
1
z
t;
d
Note
SHTl 10A
(0.5,)
sc55w
(0.62)
SC63W
(0.56)
SCSiMn5
(0.71)
SCSiMn2BH
(0.82)
SCMn34H
(0.80)
SCMnCrMo3
(0.87)
.
_
.
_
_-_*_
s.s.s.
*::::.
. .
~:::::::,
~:::::::,
:.:::::::<
_ _._*_*_*_*_..
of large
of
use welding
strength
below
of
50
kg/mm
has a
in order
to
* Figure in (
composition).
- 24 -
5-2
Covered
welding
welding
methods
welders
for
in Komatsus
arc welding
are divided
and DC.
into
two
with
types
The following
service
covered
shops.
The
welding
rods
by the current
used, AC
welders.
Motorgenerator
Rotary type
type
DC arc welder
Thermal flow tvPe
-c
Static type
i
Arc welder
Removable core tVPe
Removable coil type
AC arc welder
Saturable reactor tvpa
Tap changer type
were widely
replaced
used.
them
of welders,
However,
as the coverd
DC arc
Items
arc welding
rods
present,
DC
arc
welders
purposes
such as welding
outdoors
with
AC
welders
The main
pared
are
are used
for
special
are inexpensive
features
in
AC arc welder
Stability of arc
Excellent
A little low
Strengthening of
polarity
Possible
Impossible
Magnetic blow
Occurs
Hardlv occurs
No load voltage
A little low
High
Breakdowns
Occur often in
rotary type
Seldom occur
in the table
used
DC arc welder
AC arc welders
and easy to
of AC and DC welders
at right.
workshops,
Generally,
and
(engine
maintain.
are com-
AC welders
driven)
DC
25 -
5 -3
*
WELDING
Various
welding
POSITIONS
positions are possible, as shown in
tion,
vertical
flat position,
position,
horizontal
Flat position
Vertical
position
$0
Ctd
i\ZO
posi-
the materials to
m
Vertical
- Horizontal position
below.
Vertical
Horizontal
Welding in horizontal
26 -
fillet welding
position
Overhead position
5-4
METHODS
OF DEPOSITION
shrinking,
addition,
the
heat
affected
zone
may
become
methods
of deposition
welding,
welding,
layer
welding,
welding,
symmetric
To prevent strain,
restrictive
welding,
heat
methods
include
buildup
welding,
pre-
induction
Multicascade
1) Forehand welding
Forehand
welding
used method.
is the simplest
this method,
there
is likely
welding,
to be a lot of shrinkage
symmetric
welding,
or skip welding
can be used.
2) Backhand welding
In backhand
Forehand welding
Progressof weld
Backhand weld
Symmetric
of beads is oppo-
(buckling
distortion)
which
occurs on thin
steel sheets.
3) Symmetric
welding
In this welding
method,
welding
is performed
depositing
the proper
from
length of beads, as
X-grooved
or H-grooved joints,
alternately.
For
a long fillet
welding
sym-
112211)1~)\)))))))(((((((((((~
-
Progressof weld
--
weld
on both
alternately
sides,
on the right
4) Skip welding
In
this method,
welding
is performed
Skip welding
by skipping
- 27 -
5) Prestrain welding
In this method,
is predicted.
*
the deformation
The prestrain
Prestrain welding
caused by welding
6) Restrain welding
In this method,
by
force
The
figure
Restrictive welding
to prevent
deformation
of t;ie materials.
of restrictive
is clamped
by
jigs.
is transferred
conductivity
to
in the welding
to a substance with
prevent
deformation
Base metals
good
Jig
caused
by heat.
The
heat
such as copper,
Copper
as shown in the
figure at right.
caused by
heat.
9) Multi-layer
When performing
built
up
* Build-up welding
welding
multi-layer
by build-up
sequence or forward
welding,
welding.
block
Water
However,
cascade
sequence is often
used
-I@-
* Cascade sequence
- 28 -
5 - 5 WELDING
*
To
prevent
defects
always work
tors
in welding,
it is important
affecting
voltage,
CONDITIONS
welding
arc current,
conditions
to
The fac-
include
the
arc
and
welding position.
I) Arc voltage
The
arc voltage
is usually
proportional
to the arc
length.
If the arc is too long, the arc will become unstable
and the troubles
mentioned
occur.
Generally,
arc voltage
covered welding
is 20 to 30V
when
welding
rods of 3 to 6 mm diameter
with
in the
flat position.
When welding in the overhead and vertical positions,
the arc length should be a little shorter and the arc
voltage should be lowered 2 to 5V.
To stabilize arc
1.
2.
3.
4.
5.
6.
Oxygen and nitrogen from the air get mixed into the
beads, and the weld metal becomes brittle.
if too
1.
2.
3.
4.
easily.
Cautions
Set the
to
grounding
be welded
sparking
as possible.
may occur
(Be careful
in the hydraulic
terminal
because
cylinders.)
to be welded.
29 -
2) Arc current
The arc current must be adjusted in the proper range
according to the welding position, type and thickness
of the base metal, etc.
Generally,
welding
in the flat
vertical
position,
position.
When welding
in the
the current
should be 20 to 30%
overhead position,
tend-
1.
2.
Penetration is insufficient.
3.
4.
5.
6.
a large current
to the
is necessary to increase
of the weld-
- 30 -
5- 6
*
DEPOSITION
Although
RATE
the deposition
edge preparation,
deposition
welding current,
current
is determined
to the deposition
by the ratio of
rate.
Therefore,
almost
in proportion
rate can
to the welding
current.
The table below shows an example
of conditions
for
conditions
for
V-shape
position
loot yp$ing
(s)
Welding
Current (A)
Number of beads
3.2
110 * IO
4.0
160 + IO
2-B
3.2
110~10
4.0
160 2 IO
2.
4.0
160 ? 10
lto4.B
4.0
160+10
5.0
210?
10
4.0
16Ok
10
6.0
270 _+IO
Dia;ood~~l$g
1.0
1.0
1.5
Note:
12.0
1.5
22.0
2.0
1.B
2.3
I,
2-B
3to7
means that the first welding and the back run are
(for example,
4.0 mm,
of welding
rod diameters
5.0 mm,
performed
with
welding
rods of 4 mm diameter,
-31
fourth
layer with
2) Welding condition
for fillet
tal position
t
tnY4!&7
.&
Method of depositing beads
Root opening k
(mm)
Dia. of welding
rod (mm)
4.0
170 * 10
4.0
170 f 10
5.0
220 f 10
6.4
290+10
16.0
5.0
220 + 10
1 to 3
19.0
5.0
220 f 10
1 to 6
4.0
170 f 10
1 *B
9.0
1
5.0
220 * 10
2 to 7
4.0
170 + 10
1 *B
5.0
220 * 10
Thi;:;
(t)
4.5
Welding
current (A)
Number of beads
6.0
9.0
12.0
/5
3-
/I
1
12.0
4.0
16.0
1
5.0
- 32 -
2to
10
5-7
WELDING
CONDITIONS
FOR
PIPES
,e,,$;(a)
-hree places around rim.
f pressure is to be applied,
ivoid places where the
naximum tensile or
ompressive load is
Ipolied.
10
5
27.2
I---
34
3
2.6@
42.7
15
43.6
60.5
26
LH!s
a
70
4
3.2@
76.3
25
89.1
Fig. 1
(1)
stress when
the welded
material
is in use.
(Fig. 2)
Startinq position
rressure
Tack welding
Direction of weld
\
Stress will be maximum.at
these position when in use.
Fig, 2
- 33 -
(2)
Must be (crater
(Fig. 3 and 4)
Note:
(1)
not be sufficient,
and will
For strengh,
it is ideal to deposit
oil
leakage.
narrow
workability
(2)
&
0
but the
in the direction
Fig. 3
concentrated
Crater
penetrated,
stress is applied
Therefore,
it
and
stress is
there.
In addition, the
(4)
First
never
in which the
If the
- 34 -
Fig. 4
layer
5 -8
BACK
When
butt
RUN
AND
welding
may be performed
weld
defects
inclusion
BACKING
thin
without
back chipping.
such as insufficient
However,
penetration,
slag
Therefore,
is often
second
and subsequent
required
The
back
Back chipping
layers.
especially
if the joint
is
needs to be strong.
Flatten with a grinder
gouging.
For boxes or pipes, whose back side cannot be chip
ped off, backing is efficient.
The
backing
strip should
6 mm or less thick
the strip, the better
welding,
Strips
The narrower
so close to the
In addition,
current
for
first
layer
to
penetrate
deeply.
35 -
Backing strips
5-9
.
TACK
WELDING
Tack welding
is an auxiliary
welding
performed
be-
G!i%
4i3
point
insufficient
and a crater.
penetration,
Therefore,
tack welding
must be
4!9
such
welding
which
later
impossible
must
will
to
not
performed
be welded
avoid
on the
permanently.
places
If it is
tack welded
To
prevent
methods
are used.
1) Just after tack welding (while the slag is dark red):
Gap: 0 - 0.5 mm
I f
be kept strong.
2) Butt tack welding:
t Root
36 -
height
welding.
examples
assembly and
are shown
below.
5-10
*
REGULAR
WELDING
In regular welding,
of materials,
position
in order to obtain
The following
and
of the work.
to be incomplete,
welding
(2)
If
at the
your
end
or corner
welding
of
material.
or ending
(4)
Examples
ones
of
good starting
(insufficient
points
penetration),
and bad
and
good
method
of the
concentration
of stress.
37 -
1) Examples of treatment
of starting/ending
T-
Explanatory
drawing
Weld zone
Weld zone
End at 20 to 30 mm from
corner.
Round corners of
reinforcement plate to
30 to 50R.
Design reinforcement
plate so that beads do not
cross each other.
lzl
R
- 38 -
5-l 1 BRAZING
The principle of brazing is as follows.
is a method
of joining
metals known
since
becomes liquid.
long ago, and is still used in many electrical, mechanical, and chemical fields.
metal
feature
of brazing
is that
property
The
Its main
important
flux
being melted.
Metals of different
can be joined.
The
The
work
can be automated
is used.
brazing
struction
machine work.
04
JIS Symbol
example,
the
Operation
temoerature ranae C
11
A5.8-76)
A5.8-76)
Chemical components
f%)
Ag
cu
Zn
Cd
BAg-1
44 to46
14 to16
14 toI8
23 to 25
0.15 or less
BAg-2
34 to36
25 to 27
19 to23
17to19
0.15 or less
39 -
for
In this
by reheating.
JIS
Symbol
is almost
to join hydraulic
combination,
and rationalized.
method
Brasssolder
Silver solder
machinery
Table 1
Type
it is
Therefore,
thereby
Wetting
the deposited
base metals
a melting point
of the
4) How to braze
2) Flux
Flux
is a material
flowing
which
properties
of the filler
81
metal.
and
It must have
present.
They
used to melt
There
(flame)
induction
the flow
of the filler
the filler
brazing,
metal.
Among
them,
torch
brazing
are most
parts in construction
the filler
in practical use at
widely
machinery.
used to make
In torch
a torch.
brazing,
This is the
metal.
oldest method,
the force
of the filler
metal
from
is described below.
Not deteriorate
composition
turer,
Although
the
(2) Completely
the following
the corresponding
Borax-boric
oxidization
of with flux.
base metals.
(3)
Brass solder
When brazing with the torch, pay special attention to the place of application
Silver solder
the flux may mix with the filler metal and create
3) Brazed joints
Typical
voids.
Do not use borax type flux for cleaning since it
used.
Joints
liquidus
In construction
of the joints
machinery
at the corners
(4)
line
for
+lOOC
brazing.
range
A range at
or so should be chosen.
because of vibration
They
torch
inforcement
cient
care.
of these portions
If an enclosed container
is brazed from
(5)
are especially
The
mostly
in brazing with a
is carried
out
manually.
important
of
brazing
with
a torch
depends
If heating the
(liq-
until
as heating,
preheating
brazing is finished
is the
most
is defined
important
work.
Heating
(until
prevents radiation
the
base metals
and improves
the flow
metal),
metal.
In
After treatment
The
brazed
joints
Air vent
be
removed
completely
chemical method.
(a) Bad
need to
be cleaned.
The
(b) Good
- 40 -
by
a mechanical
or
5-12
.
ARC AIR
GOUGING
metal
with
the
heat
produced
by an arc
metal with
an air flow
injected
The
vantages
and
disadvantages
compared
adwith
Disadvantages
A lot of powder and dust is produced.
current
and electrodes
were used.
chipping
boring,
This method
with
sections
for back
range of
application
development
stainless steel.
However,
with
its
the
1) Power source
As one of the features
As a
When using an AC current, an AC arc welder is usually used as the power source, in which case a special
electrode
containing
an arc stabilizing
be used or a capacitor
secondary
agent must
must be connected
to stabilize
to the
the arc.
-41
2) Carbon electrodes
Carbon
electrodes
graphite,
formed
with
carbon,
are
and
made
from
a binder.
a mixture
This
copper.
Its properties
of
mixture
is
and plated
1.
0.0013 *
0.0002
1.85 *
0.02
60+5
O-=
or less
7 f 2
700 f
100
rectangular,
etc.
Electrodes
with
Bead
circular
are
base metal,
circular
on the
Electrodes
for AC
current
agent is mixed
into
in workability
The
base meta
of carbon
and
11
12
16
13
dimensions
carbon electrodes
Table 2
Hollow circular
Circular
a standard
gouging current
of the
Diamater
(mm)
3.5
4.0
5%
6.5
ZZ::
9.5
11
Standard
(c%ire9nt
9 A)
250
305
305
305
305
510
510
510
80to120
100 to 200
100 to 200
200 to 300
200 to 300
25Oto350
350 to450
400 to500
150to250
150 to 250
250to350
350 to 450
400 to 500
3) Gouging torches
1. Support metal
13.
Head
2.
Body
14.
Cable connector
Cable
3.
Spring
15.
4.
Spring stand
16.
Rubber hose
5.
Valve
17.
Terminal connector
water
spray type
torch
it is
6.
Packing
18.
Punch band
gouging.
7.
O-ring
19.
Cover of terminal
It is said that
this torch
8.
Valve cap
20.
70%.
9.
21.
Bolt
10.
Cover of body
22.
11.
Support lever
23.
Swivel joiner
electrode
12.
Handle
24.
Box nut
Another
type
is the automatic
feeder motor.
- 42 -
4) How to gouge
The
brazing
welding
DC
with
current,
method
covered
welding
connect
the
the
rods.
When using a
cables with
electrode
the positive
electrode,
and hold
with
the
torch
projecting
is used.
otherwise
least 5 kg/cm2,
be blown
off
sufficiently,
will decline.
In addition,
metal cannot
efficiency
will be deep.
Torch head
Generally,
In addition,
3 m with
groove.
four
AC
minutes.
current
described
current
The workability
is worse
before.
than
The
the sectional
of gouging with
an
gouged with
a DC current,
as
with
work
However,
efficiency
of an AC
current
shape of a groove
will
usually
become a
a DC current.
an AC
DC
current,
because the
intermittent
Diameter
Copper
plating
Gouging speed
tmm/min.)
5.0
305
Plated
100 to 200
900 to 1200
3to4
7to9
6.5
305
Plated
200 to 350
900 to 1200
4to5
9toll
305
Plated
250 to 400
700 to 1000
5to6
lOto
8.0
to 700
9.9
305
Plated
300 to450
400
6to7
11 to13
11 .o
305
Plated
400 to 550
300 to 400
8 to9
13to15
13.0
305
Plated
450 to 600
200 to 300
9 to10
15tol7
- 43 -
arc
6.
WELD
DEFECTS
AND
COUNTERMEASURES
it is necessary to be famil-
iar with the kinds and causes of weld defects and the
countermeasures
against them.
depends on the materials used (base metals and welding materials), the plan (design and performance),
and
these three
conditions,
Weld
factors
weld
defects
are adapted
defects will
often
occur
to the welding
because there
are many
defects
are roughly
divided
6 - 1 WELDING
When
metals
rapidly,
STRAINS
are welded,
the weld
base metals.
zone is heated
thermal
different
expansion
and contraction
places at different
deformations
Transverse contraction
Longitudinal
contraction
Angular distortion
(of fillet welded joint)
by the surrounding
times.
occurs in
The
resulting
i
I
I
I
I
I
Joints are deformed
figure at right.
The
most common
tortion
deformation
in contraction
the upper
occurs;
contraction
If this deformation
the
contract
lengthwise,
longitudinal
occurs.
is restrained by an outside force,
stress corresponding
to
the outside
force
will
crack.
Since it is usually difficult
mation
and
the
residual
to
are used,
and try
to minimize
minimize
and thick
t----,
l!!i!i3
cEYIL
Progress of weld
c -_
*
deformation
Rotative distortion
44 -
---7
/--
Angular distortion
(of butt welded joint)
Various
mize
methods
the
and procedures
strain.
Some
common
below.
1) Symmetric
Welding
welding
is performed
sides of
2) Backhand welding
Welding by depositing the weld metal in the opposite
direction to the progress of the weld.
3) Skip welding
Welding
is performed
sections.
00000
----4) Prestrain welding
The
welding
strain
and applied
before
welding.
Prestrain welding
Restrictive welding
5) Restrain welding
The base metals are held by force to prevent strain.
6) Peening
The welded metals are hit with a peening hammer to
reduce the residual stress and strain.
All of the above methods are used widely
can be performed
since they
- 45 -
6- 2
*
DEFECTIVE
Defective
OF BEADS
appearance
of
the
cause cracking
concentration
The
SHAPES
welded
because of
structures
insufficient
strength
or
of stress.
main defects
Overlap
diameter
of welding rods, or
the throat
depth
may
2) Overlaps
If the welding speed is too low, the melted metals will
overlap.
Overlaps
can be prevented
proper welding
of manipulating
by using the
and method
3) Undercuts
Undercuts are dents made on the border between the
base metal and weld metal.
welding
is too
J-l
must be prevented
concentration
of stress.
To prevent undercuts,
into the
in the vertical
position, and
welding
when welding
4) Defective treatment
fillet
welds.
Undercut
Defective treatment
of craters
abruptly,
be
the weld-
dents.
46 -
of crater
6 -3
CRACKS
Therefore,
nated
the quality
recently,
and
of steel products
welding
rods
selected carefully
has been
have
cracks
(preheating,
been
There
and welding
Cracking in heat-affected
Base metal
cracks
zones
Solidification
Hot cracks
c
Types of cracks
Contraction
cracks (Ductility
Time of cracking
Peculiarities
Lameller tear
1) Bead cracks
Beads may be cracked transversely, longitudinally,
Longitudinal
cracks
or
of the weld
of
bead,
longitudinal
Cracks
of
* Transverse cracks
occur
cooled rapidly
in the
the
craters are
craters
when
because of
bad treatment.
47 -
cracks.
are
Generally,
elimi-
materials
Crater cracks
reducing cracks)
Root cracks
figures at right.
Root cracks
Root cracks occur from the roots of a weld, and
are caused by
the
stress concentrated
on the
roots.
The stress is concentrated
which
works
as a notch.
which
occurs in
constraction
rapid
cooling,
and the
caused by cooling.
Toe cracks
Toe cracks
Toe cracks occur at the toes of a weld.
cracks
often
occur
These
have
Underbead cracks
Underbead
cracks occur
in heat-affected
zones
occur
Underbead cracks
alloy steel.
They are dangerous because they cannot be seen
the hydrogen
caused by cooling.
Heat-affected
3) Hot cracking
Hot weld cracks occur when the stress generated in
the weld zone is large and the ability
to resist deformation
of the material
will be reduced if
grain
boundaries
solidified.
when
the
melted
metals are
aries by
the contraction
forces which
occur
in multi-layer
welding.
In this
the
beads.
occur in
metals which
alloys with
contain
elements
that
can
- 48 -
zone
4) Cold cracking
Whereas
hot
cracking
occurs
occurs after
Since
cooled.
during
the
The ability
cooling
it occurs
cient.
welding,
it
may
+ 1/4Mo
stress
be mixed
The
in the deposited
matter
and
in the
water
of crystallization
materials,
in the moisture
covering
materials,
in the water
in the
which
absorbed in the
gen.
melted
on the surfaces of
reduced abruptly,
diffused
into
When
the
solubility
crystal
deposited
This
blow
is
(This
low alloy
is further
cooled,
(atomic)
hydrogen
is
equivalent
is low, whereas
The hardened
the
structure
is also affected
by the cool-
must be
(or
postheating)
is an effective
way
to
delay cooling.
Preheating
inclu-
weld
called non-diffusible
hydrogen.
As the temperature
and solubility
can
not only
prevent
hardening
of the
hydrogen
Molecular
machinery
weldability.
free
contains
ing speed.
metal
of iron.
+ l/!Xr
0.
In other words,
hydrogen.)
of hydrogen
is set free.
lattice
equivalents
the
called diffusible
the solubility
+ 1/40Ni
to
the carbon
carbon
+ 1/14V
used in construction
expression.
if there is a lot of
Hydrogen,
is also
hydrogen
of each element
from
ing speed.
In other words, the preheating action prevents crack-
hydrogen
is collected
decreases, a lot of
ing by restraining
Finally,
residual
time.
hydrogen
enough to follow
crack.
hardened
the
because it
structure
has been
pressure, it will
in weld
heated
ing, the
the defor-
The properties
to
equivalent
carbon
pressure will
rise.
after weld-
If this pressure
the material
will crack.
is
and cooled
Since structures
to follow
made of thick
material
are bound
are related
speed.
internal
not
zones
the deformation.
the
from
it is used widely
abruptly,
Therefore,
cracking.
mation
hydrogen
49 -
From
points
to prevent cracking:
Prevent
hydrogen
from
getting
into
the weld
zone.
Remove
matter
which
contains
hydrogen
metal
during
welding
rods contain
relatively
little
hydrogen.
Diffusible hydrogen
(cc/100 9)
Welding method
21.9
Arc welding with low hydrogen type covered welding rods (4 mm@)
3.15
Arc welding with high cellulose type covered welding rods (4 mm@)
25 to30
0.67
1 to1.2
0.5 to 1.2
for
preventing
cracks
and postheating
depends
on the
An example
of these conditions
for arc
is low
the thickness
or diameter
is also law if
of the material
is small,
is convenient
if used together
with
the
- 50 -
Remarks
25
2.5
0.2
Note:
0.4
based
on their properties.
Examples:
Condition
SHTGO,
etc.
SHT80A.
SC55W.
SC63W,
of preheating/postheating
Type of cover
Preheating
temperature C
z
Postheating
temperature
C
Peening
Not required
Not required
590 to 680
Not required
II
II
50 to 200
III
Remarks:
The
parts
200 or more
above conditions
that
conditions
0.5
0.6
0.7
Carbon equivalent %
0.3
refer to
under
lower
past.
-51
0.8
0.9
Welding conditions
5) Unusual cracking
In addition
purities with
contain
current,
voltage,
welding
speed, etc).
prevented by welding
making multilayer
from
lameller
tears which
thickness
occur at a right
of copper
class, and
beads.
angle to the
like layers or
If
intermittent
beads crack,
deposit
the beads
continuously.
stairs.
Select
(skip
the
proper
welding,
order
to deposit
backhand
welding,
the beads
symmetric
welding, etc).
6) Countermeasures
The
against cracking
countermeasures
against
explained
Connect
of a bead when
When welding
starting
a weld
from
a bead.
Preheating
Control
with thermal
choke, etc.
Set the
preheating
temperature
a little
Carefully
higher
5OC) to com-
However,
do not set
too high.
control
the interlayer
temperature
so
Welding materials
When welding materials that crack easily, use low
hydrogen
type welding
CO2
rust,
oil,
etc.
from
the
edges to
be
welded.
- 52 -
speed.
6 -4
INTERNAL
DEFECTS
penetration
Blow holes
Pits
Non-metallic
Slag inclusion
right.
impurities
at the upper
Slag inclusion
low.
If a thick
welding
because of
insufficient
penetration.
If slag
Slag inclusion
penetration
lower right.
the
method
correct
of
welding
current,
manipulating
the appropriate
the welding
blow
included
in the moisture
of welding
rods, rust
starting
low
hydrogen
type
welding
rods at the
The
at the beginning
of welding.
by generating
Therefore,
a lot of shield
This is realized by
inputting
reworking
generating
coating
penetration
of welding
made
Insufficient
It can be
diameter
metal.
agents, (blow
rod), or rewelding
hole preventing
using gas
agent, tip
(back-
hand welding).
- 53 -
Insufficient penetration
1) Countermeasures
against blow holes and pits (manual welding and CO2 gas shielded welding)
Countermeasures
Remove thick red rust. Rust contains water, which impairs CO, gas
shielded welding.
Paint containing heavy metals such as lead, zinc, etc. must be removed
by all means. If it cannot be removed, paint must be selected by
testing in advance.
Dry the welding rods. They should be dried just before making one
layer filler welds.
Make a wind shield. Wind speed must be less than 2 m/set for CO, gas
shielded welding.
Check circuits.
Use backhand welding, extra pad method, tip reworking rod. Use a
hot start welder. Use antiblow hole agent or tip coating rod.
* :
** :
No mark:
Only blow holes may be produced.
- 54 -
7.
HOW TO DISTINGUISH
MATERIALS
CHECK WELDED AREAS
7-l
SIMPLE METHODS
ING MATERIALS
AND
HOW
TO.
OF DISTINGUISH-
and widely
used method
of dis-
the
steel
If
products
can
be distin-
guished perfectly.
Method
Tvpe
The percentage of carbon and presence of special elements in a test specimen are
judged from the shape, color, and number of sparks made by a rotating grinder.
The powder of a test specimen is spread in an electric furnace or the flame of a gas
burner. Judgement is based on the shape and color of sparks generated disruption
sounds, and ignition point. This method can also be applied to nonferrous metals.
Burying test
Pellet test
Some powder of the test specimen ground by a grinder is oxidized and melted, and
made into pellets. Judgement is based on the color and shape of the pellets.
Thermal electromotive
force method
Standard bar and test specimen are formed into a thermocouple. Test specimen is
judge from the electromotive force generated by this thermocouple.
Materials can be
tested without being destroyed.
Spectroanalysis
This method is divided into the acid corrosion method and spot reaction method.
A reagent is dropped onto the test specimen. Judgement is made from the resulting
color and deposit.
The amount of carbon in steel products is estimated from the maximum hardness
obtained by water quenching.
Microscopic test
10
Fracture test
The amount of carbon and the presence of special elements are judged from the
roughness and color of fractures.
11
Magnet test
12
Magnetism test
13
Triboelectric
If two kinds of metals are rubbed together, a little current flows. If two metals of
the same kind are rubbed together, no current flows. The test specimen is judged
from this current.
14
Cyclograph test
15
The kind of metal is judged from its specific gravity. The percentage composition
of an alloy made from two metals whose specific gravities are very different is
estimated by measuring the specific gravity of the alloy.
16
metal sorter
55 -
1) Spark test
As shown in the table on page 55, there is both a
grinder spark test and a powder spark test. The grinder spark test will be described here.
This test can be used to judge the type of steel, the
differences
between
whether
etc.
to l/3
HP, 3500
to 5000
rpm,
The stand-
and
conditions
constant.
use a portable
darkroom.
Make sparks horizontally
will
be approximately
visually.
Divide the streamline
carefully.
From the base of the streamline,
C and Ni can be estimated.
the amount of
of the
detected.
From
the
streamline,
- 56 -
How to judge
The quality
of steel products
can be judged by
form
and number
of flowers,
with
and by the
Angleof streamlines
----
test.
(i) Effect of carbon
Carbon has the most distinctive influence on
the sparks made by the grinder.
caused by carbon
The splits
test.
The relation
bon
of the
0.2
0.4
0.6
0.8
Amount
I.0
1.2
1.4
of carbon
(%)
table below.
The judgement
ber,
size,
and
brightness
of
the
to
judge
and
involve
certain
Foz&
K=0.153/0)
elements,
correction
ThreAth
two branches each
t- Color
Orange
Dark
E!
Length
Long
*
Star-shaped splits
+
Several splits with
two branches each
(C=10.3%)
4
Several splits with
three branches each
(C=o.4%)
Kz0.5%)(Mn)
Streamline
Brightness
(C=o.l%)
Se*
(c=o.2%)
0%
Three splits
must be made
--+
some
degree of error.
In addition,
+
Two s lits
(c=o.&%)
Thorns
(C<O.O5%)
difficult
flowers.
hicknes
Q:ty
Thick
Few
Flowers
Pollen
Oty
Resistance
against
hands
None
I--
0.05
FeW
0.1
0.2
0.3
---I
0.4
0.5
Reddish
yellow
Soft
I\
Yellow
Bright
Long
Thick
\I
\I
\I
Dark
Short
Thin
Many
j Maw
Dark
Short
Thin
Many
Many
Present
I
Hard
- 57 -
ele-
ments
points
for
identifying
special ele-
differences
in the amount
in various kinds of
for structural
(WI
of Si
steel, 0.1%
Foxtail
(W)
Small drip
(WI
*Z
resistant
in amounts
steel makes
of up to
no distinct
1% in structural
difference
in the
spark.
+
White ball
(Si)
(09
_------.--___..
However,
___
Broken
streamline
(WI
Corrugated
Spearhead
(MO)
streamline
(WI
It is difficult
If structural
thin streamlines,
and pol-
influence
to detect a difference
between
this difference
can be detected by
len.
However,
Cr
the
steel,
fewer
streamlines
in number,
In high
are shorter
and
streamlines.
Thinner
MO can be detected
heads. However,
form
amount
of
In
differences
Cr can be detected
as
streamlines
indicate
less Ni.
if there
is a lot of carbon.
Therefore
lines
the decarburized
by grinding
will
be corrugated
layer.
and broken.
appear, which
If
are similar to
Type of effect
I Added
I
element
1
Mn
Streamline
Color
IYellowish
Short
Thick
Thin,
corrugsted.
andbroken
Si
Restraint
of carbon
splits
Dark red
Brightness
Thickness
Length
Short
Thick
Pale color
Dark
Ni
Thin
MO
Red
Long
Al
- 58 -
occur.
material
and classify
(Carbon:
it as structural
steel
hardening
high
steel (Carbon:
strength
steel
0.25%
(Carbon:
or less) or
more
than
0.25%).
(ii) Determine
the
amount
of other
elements,
2) Spectoanalysis
If the presence and amount of elements in the steel
cannot be estimated by the spark test, perform spectroanalysis.
Spectroanalysis
is especially
convenient
for
deter-
it is not so easy to
the amount.
percentages
can be estimated
at the following
made by Adam
Element
Cr
Measurableamount
0.5%*19/o-2%
Ni
MO
W
50/o-10%
- 20%
10%-15%
1%-3%-
0.1%-0.5%-10/o-2%
0.5%-1%-2%
-5%-10%
-18%
5%-IO%-15%
co
V
0.1%-l%
59 -
20%
7-2
HOW TO CHECK
WELDED
AREAS
3) Supersonic inspection
being destroyed.
inspection,
and
includes
the
following
methods:
by the inter-
nal defects.
The
1. Visual inspection
existence
detected
2. Radiant-ray
3. Magnaflux
inspection
4. Supersonic inspection
time
inspection
6. Magnetic-analysis
location
inspection
5. Penetration
and
test.
This method
equipment
Another
than the
merit of this
inspection
most important
to an
it is difficult
1) Visual check
kind of inspection.
all external
of
welded
magnetic
force
are
passed through
The penetrating
the
welded
detected
Usually,
and
magnetic
magnifies
powder
small
the
The penetrating
by visual inspection.
cent material.
magnetic
powder
is usually
iron powder
or a
or
black
to
contrast
with
the
magnaflux
detection
method,
material
to be checked.
liquid
is mixed into
in
cracks, the
The defects
liquids
because they
can be detected.
60 -
are inflam-
completely
the
With
remove
material.
the powder
the penetrating
surface to be
checked.
face. In the wet method,
liquid is
liquid remain-
welded
Then a developer
is used. Since it
defects,
to penetrate
area, allowed
defects.
which is used
inspection
5) Magnetic-analysis
The
inspection
in
thickness
material
quality,
of surface layer
electromagnetic
induction
Flaws, dis-
dimensions,
flows.
Materials
which AC
this method.
and
inspected with
pictures
below
show examples
0
@
inexpensive
an electromotive
0
of the materials,
change in magnetic
the
frequency,
and flaws.
directly,
flux
over time,
cannot
in other words
of materials
There is no
and permeability
Cnm
,_...e
be measured
of the materials.
The inspection device analyzes the change of impedance of the coil (complex
quantity)
mation
and dimensions.
on flaws, quality,
to obtain inforVarious
-61-
in-
features:
Portable
Relatively
of common
8.
HOW
TO READ WELDING
SYMBOLS
selves.
This
section
describes
the
welding
symbols
which
8 - 1 WELDING
SYMBOLS
Basic
Remarks
symbol
Page
64
II
For Double V-Groove welding, this symbol is entered symmetrically
on both sides of the reference line.
64
For Double Bevel-Groove welding, this symbol is entered symmetrically on both sides of the reference line. The vertical lines of
symbols must always be on the left side.
64.65
IJ
65
66
66
If
66
11
v
Bevel weld,
Double Bevel-Groove weld
Fillet weld
66,67
67
Bead
68
68
Build-up weld
L
Classification
Contour of weld
zone
Finish method
of weld zone
Flush
Convex
Concave
Chipping
Grinding
Machining
Field weld
Weld all around
Field weld all around
1 mentary 1
Remarks
68
C
G
62 -
68
B- 2
HOW TO ENTER
Except
WELD
the welding
SYMBOLS
and build-up
welding,
Reference line
welding
symbols
should by entered
Reference line
F=r
line
Arrow
on refer-
indicate
the portions
to be
horizontal.
Tails
connected.
The
reference
(See
figures at right).
Draw the leader lines straight at 60 to the reference
The
welding
symbols
entered
leader lines.
However,
if it is
Double
reference
flare or flare-bevel
welding,
should
be
surfaces for
and dimensions
welded:
place the
symbols
under the
and dimensions
reference
should
be entered
They
should contact
the
reference lines.
The
supplementary
symbols
for field
welding,
all
at intersecting
Number
0f rpotor projection
welds
may be emered under reference line)
Welding methods and other points should be entered at the tails of the reference lines.
itch Of intermiftent,
or ~rojecf,on weld
spat,
Length of intermittent
weld, or if necessary.
leng~rh of weld inot entered for renraint welds,
63 -
8- 3
*
EXAMPLE
Examples
OF ENTRIES
symbols are
* shown below.
are groove welding
gymbol
II II
Actual shape
rtion to be welded
V-groove weld
ortion to be welded
Drawing
Arrow side or
?ear side
Arrow side or
near side
Ijpposite side of
srrow or far side
Opposite side of
arrow or far side
qoot opening:
2mm
Backing strip is
used.
Thickness:
12 mm,
groove angle:
45.
root opening:
46 mm,
finish method:
machinin!
Root opening:
Zmm
Actual shape
mustbe
Drawing
This oortion to
be machined.
Bevelgroove
welding
Root opening:
Dmm
ortion to be welded
I
Symbol
Angle of symbol to be
90.
Actual shape
rtion to be welded
Arrow side or
near side
Drawing
Both sides
Firoove depth: 10
mm,at arrow side,
9 mm at opoosite
side of arrow,
Groove angle: 60
at arrow side, 90
at opposite side
of arrow, root
opening: 3 mm
1 1;;f;a;;;yboI
Thickness: 19 mm,
groove depth:
16 mm,
groove angle:
60,
root opening:
2mm
Both sides
(groove welding
Egy-
Opposite side of
arrow or far side
T-joint.
Backing strip is used.
Groove angle:
45.
root opening:
6.4 mm
a
-
0,
3
90
64 -
Actual shape
Drawing
Double bevel-groove
weld
Portion to be welded
S;;K
Both sides
Arrow side or
near side
Opposite side of
arrow or far side
opening:
Svmbcl
Y
Actual shape
Portion to be welded
A-~A-~~~~deOr
Drawing
Actual shape
Groove depth: 28
mm, groove angle:
36
, root radius:
,30mm,root
T-joint.
Groove depth: 10
mm, groove angle:
45. root opening:
2mm
Ugroove welding
Symbol
Y
Portion to be welded
Drawing
Actual shape
J-groove weld
B/^
f\
2 mm
Double Jgroove
welding
Svmbol
K
Portion to be welded
Both sides
3mm
- 65 -
Drawing
Actual shape
Opposite side of
arrow or far side
&
Double U-groove
(H-groove) welding
Symbol
x
Portion to be welded
Actual shape
Fillet weld
(continuous)
Symbol
fortion to be welded
Drawing
Actual shape
Arrow side or
near side
Both sides
Groove depth:
Opposite side of
arrow or far side
root radius:
Both sides
Leg length: 6 mm
2ortion to be welded
Arrow side or
near side
Opposite side of
arrow or far side
Both sides
Flare bevel or
Double flare bevel
Length of weld:
566 mm
s;z-
Portion to be welded
1f
IC
and
astraight
line
and
(I
:z z3tz!zl:~2~::
half circle
for both sides flare iXvd<rwM
WBIC1.
ILeg length
Actual shape
of both
rides: 6 mm
Drawing
ILeg lengths
of both
rides are not same.
Opposite side or
farside
&
, q
A,:
Both sides
66 -
Portion to be welded
ortion to be welded
Actual shape
Actual shape
Drawing
Drawing
Arrow side or
near side
n
Arrow side or
near side
i
>
Section A - A
L-P
L-P
Opposite side
of arrow or
far side
Opposite side
of arrow or
far side
L&
Section A -A
Arrow side or
near side
L-P
Both sides
Chain intermittent
fillet welding.
Length or weld:
50 mm,
Pitch: 150 mm
L-P
J&
Section A - A
?
>
t
5
i
Opposite side
of arrow or
far side
rz
50-150
Section A - A
P
z
1
I
r:
;
f
2
:
5
ii
- 67 -
Hole dia.:
22 mm,
pitch: 100 m,
groove angle:
60
depth of weld:
60mm
Section A - A
50
Section A - A
100
Width: 22 m,
length: 60 mm,
pitch: 150 mm,
groove angle:
O,
depth of weld:
6mm
Bead
II
I
Actual shaoe
II
Finish method of
weld zone
Drawi no
Arrow side or
near side
Portion to be welded
I
1::-I
Chipping
Grinding1
Machining
Actual shape
Grinding finish
Machining finish
Drawing
Opposite side of
arrow or far side
~~__
?
Building up
Portion to be welded
Thickness of built
up metal: 6 mm,
width: 50 mm,
length: 100 mm
Flush
Contour of portion
to be welded.
Actual shape
Portion to be welded
Portion to be welded
Drawing
Surface of butt
weld zone or fillet
weld zone is flush.
J!E
Surface of butt
weld zone or fillet
weld zone is convex.
Surface of fillet
weld zone is
concave.
E-
Continuous all
around field fillet
weld
- 68 -
0
Actual shape
Drawing
Combination of
symbols
Portion to be
welded
Combination of
bevel-groove
weld and bead
deposition
Actual shape
Drawing
-v-l2
Combination of
Double bevelgroove weld and
fillet weld
h7
Combination of
bevel-groove
weld and fillet
weld
L!F
Combination of
Jgroove weld,
fillet weld, and
bead deposition
69 -
9.
HOW TO HANDLE
AND CUTTERS
9- 1
BASIC
The
FACTORS
equipment
welding
for
oxyacetylene
the welding
(OXYACETYLENE)
OF OXYACETYLENE
can control
GAS
flame
WELDERS
WELDERS
Gas regulators
pre-
cisely.
The
equipment
cetylene
welding
required
for
oxya-
an
acetylene tank
or acetylene generator
(plus a safety
tank
sources
of
gas
Pressureregulator
Torch and mixer
t
Oxygen
I
Fuel gas
and
effectively.
The oxyacetylene
of the flame
70 -
9 -2
*
STRUCTURE
AND
USE OF WELDING
TORCHES
Low pressure type
(Injector type)
Valves are
35
Oxygen
and acetylene
27
are mixed to
nozzles with
different
gas mixing
chambers
1. Torch head
2.
Body
3.
Holding pipe
4. Gas pipe
5.
Internal pipe
6.
Valve
8.
Hoseconnector
9.
Nozzle tip
7.
Needle valve
Torch head
2. Valve
3.
Armor pipe
5.
Internal pipe
6. Adjustment valve
Hose connector
8.
Nozzle body
9.
Holding pipe
Nozzle tip
In
according
injector
below
0.07
type
with
kg/cm
uses acetylene
higher.
uses acetylene
with
kg/cm*
The medium
or
and
with
medium
pressure type
a medium
or high pressure
torch
works effectively
pressure acetylene,
but cannot
or a high
be used with
a low
the
torch
acetylene
into
the injector
of
the
itself
nozzle.
injector
type,
oxygen
sucks
and
acetylene
constant
the
operation.
-71
acetylene
oxygen
and
acetylene.
The
torch,
ing to manufacture.
pressure type
a pressure
pressure type
a pressure of 0.07
The injector
medium
mixing nozzle.
the
acetylene
injector
Therefore,
completely,
on the handle.
nozzle.
acetylene within
When
oxygen
injector
passes through
nozzle,
completely
- Acetylene
gas beyond
itself.
kg/cm2
pressure can
the injector
Acetylene
,,-,
0.0 7 kg/cd
5 kg/cd
I
Mixed gas
the
center
hole
in
some manufacturers
the
manufacturer
inlet
and
sent to
the
nozzle
through
the
recommends
the
pressure
of
oxygen
and acetylene
volume
to 1.3 kg/m2.
Mixer
Oxygen
\
Acet ylene
so
Torch head
72 -
Nozzle
An
flame;
$I^.+.^
and
l:l,
a neutral flame is ob
excess of oxygen
yields
excess of acetylene
Reducing
flanw~->
Flame core
Acetylene
fuser
an oxidizing
yields
a reducing
NeutralflameZ&----D
Highest temperature
first become
dizing flame.
either
an
of oxygen
oxidizing
4) Welding methods
Gas welding methods are divided into forehand welding and backhand welding.
right to left.
methods
the
tip
in Fig. 2.
of the welding
Progressof weld
///
left to right.
In any
Backhand welding
strain by
thick
melted
metal
however, the
plates thicker
than
3 mm.
When welding
URANAMI
in Fig. 4(b).
E-type
(b)
the
fluctuate
hole
is blocked
and make
or stained,
heating difficult.
the flame
of the nozzle,
will
If too much
Therefore,
it will be
clean the
nozzle often,
- 73 -
-3
STRUCTURE
AND
USE OF CUTTING
TORCH
become oxidized,
and
melt.
When the oxgen is blown off, a groove will appear.
Gas cutting
utilizes
has become
more
been improved.
this phenomenon.
automated
This method
Gas cutting
as the equipment
has
stage of welding.
the
cutting
direction
can be changed
freely
a concentric
gas mixer
pressure type
the
low
gas cutter
pressure
propane
type)
has become
flame
in the !ow
has an injector
welding
more
similar
torch.
commonly
to
Recently,
Oxygen
used as the
fuel.
The
switch
to
change
in the
injector
nozzle
propane
structure,
the
any basic
diameter
of the
to supply
more
pressure type
torch,
oxygen
welding
torch.
The cutting
cutting
mixture
nozzle,
is blown
out from
and acetylene
74 -
Acetylene
Replaceable nozzles
In addition
by replacing
almost
general
torches
the cutting
nozzles.
oxygen
Although
to the welding
use,
for
each
and cutting
manufacturer
torches for
produces
many
thin
and economically
cut with
To
rusty dirty,
flame
or
or painted
plate, use a
oxygen,
of
After
heating
open wide
igniting
the
oxygen
for acetylene,
torch,
until
open
a neutral
and then
the
ignite.
valve for
flame
pre-
is obtained.
starting point.
When the starting point becomes a shiny red, gradually open the valve for high pressure cutting
After
confirming
bottom
line.
Table 7.3-l
Thickness
(mm)
Diameter
nozzle
(mm)
Pressureof
oxygen
0.5to1.0
1 .o to 2.1
510to760
0.5to 1.6
0.17t00.26
0.8 toI.
l.ltoI.4
4IOto660
I.0 to 2.6
0.19t00.31
(kg/cm
Cuttingspeed
(mmlmin.1
Gasconsumption (m'/h)
Oxygen
Acetylene
0.8 toI.
1.2to 2.1
380to610
I.3 to 3.3
0.19to0.34
I2
1.oto1.5
1.4to2.2
305to560
1.9 to 3.6
0.28t00.37
I9
1.2to1.5
1.7to 2.5
306to510
3.3 to 4.1
0.34t00.43
25
1.2to1.5
2.0to 2.8
230to
3.7 to 4.5
0.37t00.45
46
38
I .5 to2.0
2.1 to3.2
150to305
4.2 to 6.4
0.43t00.57
50
1.7 tog.0
1.6to 3.5
150 to330
5.2 to 6.5
0.45t00.57
75
1.7to20
2.3to 3.9
100to255
5.9 to 8.2
0.45t00.65
2.1t02.2
3.0t04.0
100to210
0.57t00.74
100
125
2.1 to2.2
3.9t04.9
90toI60
7.9 to12.3
0.57t00.82
150
2.5
4.5t05.5
60toI40
11.3toI6.1
0.71 too.90
200
2.5 to2.8
4.0t05.4
65 toll0
14.3to17.7
0.85toI.10
250
2.5 to2.8
4.6t06.8
50 to 80
17.3 to21.2
1.02t01.30
300
2.8 to3.1
4.1 to6.0
35 to 65
20.4 to26.2
1.19to1.55
- 75 -
oxygen.
9 -4
PRESSURE
REGULATOR
150 atm.
the oxygen
reduced
In
tanks,
Therefore,
ing.
only
the
welding
is usually
charged
French type
pressure regulator
(for acetylene)
French type
pressure regulator
(for oxygen)
in
the
to a value
addition,
while
of oxygen
pressure
proper
of
for
pressure
must
even though
oxygen
must
the welding
be kept
the pressure
be
method.
constant
in the tank
decreases.
This operation
is performed
by an oxygen
regulator
An acetylene
regulator
valve).
The so-called
regulators
French
type regulator
The pictures
regulator,
type
are most
All
at right
show
a French
of them
type
The German
type
acetylene
regulator,
and
regulator.
are equipped
the
a French
oxygen
with
Therefore,
type pressure
used.
and German
commonly
two
pressure
gauges
gauge indicating
the pressure
in the
be welded
or
cut
the thickness
instead
of
of plates which
the
pressure
of
oxygen.
76 -
2) Structure
of pressure regulators
regulator
sectional
drawing
of a pressure regulator
is
High pressure
Low
pressure
shown at right.
Diaphragm
by
the
adjustment
It
spring.
moves valve C
for hose
While
the
pressure adjustment
screw is turned
spring, diaphragm
to
A will
D flows into
as shown by the
arrows.
Then,
spring
B shortens
Consequently,
slightly.
pressure
chamber
words,
the
closes valve
pressure
becomes
and
lower,
in
low
the
dia-
the adjustment
spring tires to
these two
screw is turned
if the pressure
to press spring B, a
can be obtained,
and
Therefore,
diaphragm
A, valve C, and
pressure regulator,
will determine
parts in the
of these parts
- 77 -
A.
Diaphragm
E.
B.
Spring
F.
C.
Valve
G.
D.
spring on
large volume
of oxygen.
tank valve
D. Sat nut
C. Safety valve
- 78 -
9- 5
HOW TO HANDLE
OXYACETYLENE
WELDERS
Troubles of this kind often occur in high pressure
1) General cautions
opened
weld-
often.
repair
instruction
by a shop authorized
which
in the
value.
repaired
it to the normal
Always
keep
the
connection
regulator airtight.
pressure adjust-
by the manufacturer.
loosening the
without
ment screw.
of the tank
and
welding.
it may scratch the seats of the nipples at the inlets of the regulators, and prevent the regulators
and tank
from
after tightening
Work with
tip.
Although
which
roughly.
a cleaning
recommended
confirm
drill
of the proper
by the
torch
the regulator.
to repair
the tank.
be closed completely,
clean
may
and
the seat or
size,
much,
the seat.
too
close
and clean
them
If gas leaks
the seat of the tank valve, the nipple and the seat
airtight,
break easily,
becoming
If
several
justment
valve body.
confirm
If
the
regulator
creeps, repair
it immediately.
relatively
to make the
repair.
soft material,
regulator
screw counterclockwise
using that
sure adjustment
79 -
9-6
OTHER
TOOLS
FOR WELDING
AND
CUTTING
are specially
strength
made.
to withstand
flexibility
equipment
the internal
pressure, enough
of the torch, and
green,
and equipped
with
welding
be airtight.
or
The
with
These hoses are the passages for gases, and are connected to the equipment
by using couplings.
purposes,
otherwise
and acetylene
a serious accident
for
may
occur.
2) Collecting devices
In places where many oxygen tanks are used or in
the oxygen
connected
devices.
type collecting
connected
each
There
other
by
means
of collecting
a great volume
an acetylene
available,
the
of acetylene
generator
acetylene
of
the
tanks
is required
proper
can
and
size is not
be connected.
80 -
9- 7
ASSEMBLY
OF EQUIPMENT
* Sequence of assembly
Install
the acetylene
regulator
Connect
to the acetylene
the
tank.
torch
valve.
Install the oxygen regulator to the oxygen tank.
Adjust the nozzle.
Connect
Adjust
the
working
pressure
of
and torch.
oxygen
and
acetylene.
handle.
pressure,
torch
gauges, torch,
directions
and manufacturer,
of the manufacturer.
to the tanks
always follow
the
pressure, then
pressure of
and acetylene
supplying devices.
with a lighter.
Adjust the flame until it is neutral.
Adjust the oxygen valve to make a neutral flame.
Study
connector.
Never stand in front of the valves when opening
them.
How to install pressure regulators.
Install
tank,
the acetylene
then
install
regulator
the oxygen
to the acetylene
regulator
to the
oxygen tank.
Install the hoses to the regulators.
Install
regulator,
regu-
lator.
Open the tank valves.
Loosen the screws of the regulators, then slowly
open
before
the
tank
loosening
valves.
regulators.
-81
the devices.
9-8
*
REMOVAL
When
removing
OF EQUIPMENT
the
devices,
follow
the procedure
described below.
@
the
adjustment
and
screw of the
immediately
close
oxygen
the
oxygen
valve of torch.
@
pipe
while
torch is closed.
the acetylene
valve of the
close the
A flash-back
oxygen
will
if the flame
not flow
into the
write Empty
on the cap
82 -
9-9
.
SAFETY
Starting
RULES
work
dangerous
without
both
Understand
first
confirming
to the woker
safety
is
one turn.
While
using
the
opening/closing
- Oxygen
that
Always write out the word Oxygen.
tank,
wrench
leave the
on the
tank
valve
valve stem
so
if an
accident occurs.
near combustible
materials,
itself
does
but
promotes
not
burn,
materilas
combustion.
contact
a different
kind
Do not
tank.
valve, regulator,
hose,
etc.
When
returning
tightly
an empty
tank,
out.
hands or gloves.
outdoors,
Do not use the oxygen
regulator,
place
it far from
fire,
manufacturer.
atmospheric
pressure.
ing work.
Do not mix a different
tank.
When
closed tightly.
Do
directly
without
the
Acetylene
Always
Acetylene.
Do
in
is completely
home
and
different
in furnaces,
is more
dangerous.
Always
keep the
tank
upright
in use and in
storage.
Do not bring the tank near fire or hot substances.
Before
using
acetylene,
reduce
its
pressure
- 83 -
for oxygen
and acetylene
is con-
the instal-
regulator.
the piping
10.
PREVENTING
10-l PREVENTING
1)
ACCIDENTS
ACCIDENTS
IN WELDING
WORK
2)
caused by harmfull
radiation
In arc welding,
man body.
ated.
In addition
Strong
it tired.
20 to 40V
during welding.
electricity
Although
in the home,
down
this is lower
it can still
the temperature
contains ultraviolet
than
light stimulates
Ultraviolet
tissue, so if they
enter
be very
Strong
infrared
and corea.
ration, etc.
of eyesight.
0
@
Radiation
gets shocked,
do not touch
Immediately
administer
Therefore,
turn
artificial
him
with
sunlight.
If he has lost
respiration
until
to a shield glass.
welding is stopped.)
a screen or shield
in diagonally,
Use a preventive
Ailments
84 -
3)
Ailments
Almost
of weld
-Progress
Fumes are
component
of fumes is iron
The main
Other
oxide.
com-
An example
of the components
Base metal
of fumes is
Chemical composition
materials
of fumes
zinc or cadmium,
zinc or
metals containing
a lot of
fume
fever
languor,
ing.
will
fume
cause recurring
welding
produced,
fume
However,
IO,
Al,O,
CaO
MRO N&O
KLI
25.20
10.
0
3.70 3 82
0 25 0.32
I
m
Fe,O,
17.50
12.25
13.60
SO,
MnO
IO,
l0.l
0.97
Al,03
CaO Me0
N&O
KzO
be
steel plates.
will
MnO
30.
of
If low hydrogen
50,
Metal
metal
fever.
symptoms
These symptoms
type
Fez03
relatively
ordinary
harmless low
(2) Pneumoconiosis
Pneumoconiosis
caused by fumes.
insoluble
diseases
the lungs.
Although
in
4)
Gas poisoning
When
arc welding
carbon
fluorine,
though
they
monoxide,
nitrogen
and other
the
amount
of
When
welding
in a poorly
for
gas, there
is danger
of
long a
caused by the
Install a fume
measures.
restoring device.
Ventilate
the
with fans.
ventilated
ailments
Al-
against
rods,
ozone,
can be poisonous
time.
oxides,
Countermeasures
a shortage
of
(2)
When
working
in
(such as in a tank),
mask, or horse mask.
oxygen.
- 85 -
a poorly
ventilated
use a dustproof
place
mask, gas
10-2
PREVENTING
ACCIDENTS
CAUSED
BY GAS
or cutting
limit (combustible
In
addition,
materials
The
are explosions.
has a relatively
wide explosion
2)
there
are
often
other
moving or transporting
combustible
the
not project
from
the sides.
ropes.
Wear proper clothes,
including
goggles, gloves,
Always
ing the
Use a detector
welding equipment,
cutting
pressure
regulators,
Confirm
that
there
adapter
of
the
valve of
the
bombs with
you
main
oxygen
tank,
pressure
place.
of combustible
Never
bring
gas in a well
fire
near the
tanks.
regulator, etc.
@
Inspect the work area carefully.
near inflammable
materials
Do not work
Store
tanks
of combustible
such as gasoline,
@
gunpowder, etc.
When working
in an enclosed container,
method
in separate places.
Keep
below 4OC.
exam-
and procedure.
Do
Cautions on use
special
handles.
while welding.
*
Always
If an accident occurs
If
the
oxygen
do not touch
keep acetylene
tanks
upright
during
use.
it.
cm.
Do not consume all the gas in the bomb.
minimum
@
- 86 -
Keep
11.
COST OF WELDING
CONSUMABLES
11-l
COST OF PREPARATION
* Gas consumption
-
Cutting
Thickness
(mm)
Cutting speed
(mm/min)
hole
(mm)
Gas consumption
Cutting
oxygen
Acetylene
(m/h)
Natural
Propane
gas
3.2
0.51
to 1.02
400 to 800
0.4 to
1.30
0.080
to 0.250
0.25
to 0.70
0.08
to 0.28
6.4
0.76
to 1.52
400 to 660
0.8 to
1.50
0.080
to 0.250
1.25
to 0.70
0.14
to 0.34
9.4
0.76
to 1.52
380 to 600
1.1 to
2.00
0.170
to 0.340
0.28
to 0.70
0.14
to 0.42
12.7
1.01
to1.52
300 to 580
1.5 to
2.40
0.170
to 0.340
0.42
to 0.84
0.14
to 0.42
20
1.14
to1.52
300 to 530
2.8 to
4.20
0.200
to 0.390
0.42
to 0.84
0.17
to 0.50
25.4
1.14
to1.52
230
to 460
3.1 to
4.50
0.200
to 0.390
0.50
to 0.98
0.17
to 0.50
38.4
1.52
to 2.03
150 to 350
3.1 to
4.90
0.230
to 0.450
0.50
to 0.98
0.22
to 0.56
50.8
1.52
to 2.03
150 to 330
3.6 to
5.30
0.220
to 0.450
0.56
to 1 .I 2
0.22
to 0.56
76.2
1.65
to 2.16
100 to 280
5.3 to
8.40
0.220
to 0.560
0.56
to 1 .I 2
0.25
to 0.62
100
2.03
to 2.29
100 to 250
6.7 to 10.00
0.250
to 0.560
0.56
to 1 .I 2
0.25
to 0.67
127
2.03
to 2.41
100 to 200
7.6 to 10.00
0.280
to 0.670
0.70
to 1.40
0.28
to 0.70
150
2.41
to 2.67
76 to 180
7.3 to 14.00
0.280
to 0.670
0.70
to 1.40
0.28
to 0.84
200
2.41
to 2.79
76 to 130
12.9
to 17.40
0.420
to 0.840
0.84
to 1.54
0.42
to 0.90
254
2.41 to 2.79
50 to 100
16.2
to 19.60
0.420
to 1.060
0.98
to 1.96
0.42
to 0.98
300
2.99to
50 to 100
20.0
to 23.80
0.560
tu 1 .120
1.26
to 2.66
0.56
to 1.26
(smoothness
The standard
3.30
conditions
for
gas cutting
mild steel
quality
of the cutting
hole,
the volume
of
On the other
hand, if quality
cut surface
in Table 1.
is another
cutting condition.
factor
which determines
the
87 -
11-2
1j
EXPENDITURES
Consumption
The major
welding
ON WELDING
of weld metal
amount
weld, etc.
of the
The consump-
the
material
reinforced
to be welded,
the welding
position,
the
plates
are grooved
on the assumption
as shown
in
Fig.
that
2 and
properly.
Thickness
Thickness
(mm)
Fig. 1
(mm)
(2)
(1)
(shown in kg/m)
* Deposition efficiency
The deposition
of
deposited
used.
efficiency
metal
of welding
core
rods
V-groove butt
welded joint
wires.
Calculated
weight of welding
rods if calculated
(1)
to the weight
on the
(2)
Both sides V-
(3)
U-groove butt
(4)
welded joint
Double-U-groove
(5)
Fillet welded
joint
joint
t 'go
1;;o 263;
3g
"c&
8=60"
t 19to
32
33 to
45
4:5fo 67;;
t,ct,
tsl6
1.5
2.0
2.0
2.0
3.0
2.0
2.0
2.0
3.0
t,=!J
a=2
1.5
1.5
1.5
1.5
2.0
1.5
2.0
2.0
2.5
h = 0.7~
b=1.5to2.5c
t'= 1/2t
R5
t*
89R5678
R'
13.5"
88 -
r'
(mm)
2/3t
13.5O
2)
Consumption
Thickness
(mm)
Thickness
(2)
lmm)
30
Thickness
(3)
40
0
5 6 7 8 9 IO II I2 13 14 ,5 16
60
(mm)
Thickness
Fig. 3
The
weight
of consumed
10% depending
positions.
welding
welding
and welding
under
various
conditions
rates of
which
are
89 -
(4)
(mm)
Fillet welding
3)
80
I
zo-
6 7 8 9 I II II 13 IP 15
Thickness
(1)
I
16
17
I
18
1,
18
I
19 20
(mm)
21
I
27
23
Thickness
(2)
I
24
26
I
26
27
28
29
(mm)
Surface
70
60
60
40
30
20
IO
I
4
Thickness
IO
15
Thickness
(mm)
20
(mm)
90 -
I
25
I
30
4)
Power consumption
The
electric
power
for
melting
power
a given
consumption
is shown
in
Fig.
1.
Power
consumption
the type
of current
Diameter
An outline
of the
I
60
I
50
I
40
used, etc.
of welding
rod (n?m)
I7
18 19 20 21
(1)
Thickness
(3)
Fig. 2
(4)
Double Vgroove
butt joint
Fillet welding
25 26 27
Power consumption
(2)
22 23 24
continuous
to 48%
This
be performed
rate is poor,
are good and
-91
welding
can
be carried
out,
and
50%
on a conveyer.
12.
EXAMPLES OF TROUBLES
AND COUNTERMEASURES
addition,
the repair
be designed to
ability
of
or reinforcement
simplify
IN WELDED
operation
of stress
method
and
In
must
machining
welded
joints
coefficient
(residual
stress, joint
efficiency,
tures.
To attain
experience.
occurred
Actual
in welded structures
examples
be described
countermeasures
stress is concentrated
the figures)
cated
type,
by symbols
to study past
trouble
which
the
The effects of
positions
where
the
shown as follows:
The
for
of
(kg/cm)
--f
(kg/cm*).
and location
or arrows
in the figures.
The
Torsional moment
M:
Bending moment
w:
Load
0:
Shearing force
92 -
STRUCTURES
12-1
BOX TYPE
No
WELDED
STRUCTURES
Countermeasure
Trouble
Frame is twisted,
cracks started from
defects in welds
Crack
h
Improve Section A -A
shown above.
A -A
BUTT
NI
WELDING
Crack
05016
E7016
Fatigue failure
started from joints
of back plates at
places where stress
was high. Use single
back plate without
connection. Shaped
steel is more stable.
_-
----
WELDED
STRUCTURES
Countermeasure
Cause
Crack
T
iecrion
OF BOX TYPE
as
I
----
B - 6
Trouble
c-,Q
Crack
Denetrarion
12-2
I-
Breaking started
from joints of back
plates that received
high stress.
Crack
Section
If welded without a
back plate, penetration cannot be
guaranteed, and
durability will be only
about 112 of welding
with a back plate.
Install back
plate
Insufficient
penetration
Remarks
D5016
E7016
Beveled (or l-groove)
welding
/
Crack
Section
N&ding rod
Welded at
corner.
on straight
corners.
(2) Use tolerance so
that no gaps
occur at corners
of back plates.
(3) Use same thickness fort, and
?I?
t,, and lengthen
Q sufficiently.
jection
A-A
93 -
por-
Welding rod
Remarks
D5016
E7016
Number of breaks
in fatigue test
doubled.
12-3
WELDED
No
STRUCTURES
WITH
ADDED
SUBSTANCES
Velding rod
Cause
Trouble
Crack
D5016
E7016
Since pressing
stress caused by
bent frame is high,
stress is concentrated on welded
area of boss,
resulting in cracks.
D5016
E7016
Crack
stress at portion A
-21, -27 + +7. -19
Remarks
D5016
E7016
Stress at portion A
t13,-19*+6,-4
Support
D5016
E7016
Support receives
load from above.
If side plate are
thin, stress is highly concentrated.
Y /
w
Crack
Stress concentrates
on bracket causes
cracking.
Remove
D5016
E7016
end of
Straighten the
corners.
Smooth the
shape of and
of bracket.
SUPP~
C&k
Crack
D5816
E8016
,(,/L//lj,ljll,l,l,,/
If straightened, precision of edge preparation will be improved
and weld strength
will be stabilized.
ti
Do not weld at end.
Bending stress is
applied to frame
and is concentratec
on front and rear
ends of attached
materials on upper
and lower surfaces.
D5016
E7016
94 -
124
CONNECTION
No.
Trouble
OF WELDED
WITH
CONNECTORS
Frame is twisted
and bent, and strer
is concentrated on
weld zone of connector.
Connectors are
twisted and stress
is concentrated on
weld zone.
Lengthen ends of
trumpet up to where
base metal is thick
and stress is low.
D5016
E7016
Stress at portion A
+46, -32 -+ +26, - 10
I
D5016
E7016
Stress at portion A
+42, -27 + +6, +I 5
D5016
E7016
As deformed shape
steel with sufficient
thickness is used as
upper and lower
plates of box, strength
of weld zone is secured
without back plates.
If side plate
is thin,
lengthen weld
line up to
thick portion.
Section
6 - B
Large torsional
stress is applied to
connector.
Back welding
welded areas.
Make in single
structure and
do not install
cast holes.
Crack
\
from cast holes.
Section C - C
D5016
E7016
Frame connector
Crack
Remarks
Welding rod
Countermeasure
CaUSe
Crack
9
STRUCTURES
shape steel
Section
L -C
I
Torsional load is
applied to connectors and stress is
concentrated on
weld zone of
connectors.
!
//
FTend
/A
95 -
of this
plate to reduce
concentration
of
*tress.
D5016
E7016
at portion A
I Stress
+15,-36++7.-13
12-5
NO
CONNECTION
OF BOX TYPE
WELDED
STRUCTURES
Cause
Trouble
TO PLANES
Countermeasure
Tensile stress is
applied to front,
and pressing stress
is applied to rear.
Round end of
plate to reduce concentration of stress.
Welding rod
Remarks
D5016
E7016
Stress at portion A
+26, -6 + +13, -8
Stress at portion B
+4, -24 -, +5, -16
D5016
E7016
Bending load is
applied to frame,
and tensile stress
is applied to its
base.
Stress at portion A
+42++15
12-6
-
Nc
HOW TO PLACE
REINFORCEMENT
PATCHES
D5016
E7016
Crack
Remarks
Melding rod
Countermeasure
Trouble
Stress in chart is
indicated by following symbols
A
B
c
D
+45-++22
+39++12
+30++19
+41 ++31
Install patches.
D5016
E7016
Stress at portion A
+47. -1 -+ +14. -4
D5016
E7016
Stress at portion A
+30, +31 -* +10, -20
D4301
-
Stress at portion A
+I 3, -6 + +7, -1
Id
2
Patch
Crack
Because of load
caused by vibration of case, stress
is concentrated on
weld zones at ends
of legs for the case
Crack
Bracket
R\educe concentratior
of stress around
bracket with patch.
Cover end of
Frame is bent.
Welding of patch
was finished at
upper and lower
places where stress
is concentrated.
Place plate, and weld its
ends to center
96 -
12-7
WELDING
No
BETWEEN
CAST OR FORGED
MATERIALS
D5016
E7016
Frame is bent,
tensile stress is applied to front, and
pressing stress to
rear.
Section
Nelding rod
Countermeasure
Cause
Trouble
OR TO SHEET
METAL
FRAME
Remarks
Stress at portion A
+8, -27 -+ +5. +20
B -8
weld line
Section 6 - B
Crack
Dimension
Section
C -C
ma
cast steel
If pipe is bent or
twisted, weld defects will crack. If
welding between
large cast steel products, quality cannot be guaranteed
because of error in
dimensions.
cast,Steel
0%)
C
penetration
D5016
E7016
large bending
and pressing stress
is applied to end 01
frame, the weld
defects have
cracked.
As
Frame
Insufficient
D5016
E7016
%ction
D.
D
Employ faucent
joint and
prepare edges.
Welding on
preparededger
;ection D - D
Cast iron
Crack
97 -
D5016
E7016
Stress at portion A
+o, -19 -+ +o. +7
12-8 MATERIALS
ON WHICH
OF RIGIDITY
STRESS
IS CONCENTRATED
BECAUSE
OF DIFFERENCE
No
Trouble
Cause
Countermeasure
wed
Remarks
D5016
E7016
Stress at portion A
+2, -2l-,
+6, -10
D5016
E7016
Stress at portion A
+20, -12 + +15. -6
D5016
E7016
When installating a
block to the thin
plate, strengthen the
surface with patches,
or increase thickness
of base metal.
As installation end:
of additional matGals are at the sami
level, stress is concentrated because
of difference in
rigidity.
Nelding rod
&ck
Stress at portion A
MO. -23 + +18, -10
12-9
NO
BOX TYPE
WELDED
Trouble
STRUCTURE
WITH
BOSSES
Cause
Countermeasure
Load is applied
through pin, and
weld defects have
crack.
05016
E7016
rl
n
Use joggled
boss and
prepare its
edges (or
I-groove).
Crack
lnsufficie
penetration
or melt down
Section A.
fielding rod
98 -
Remarks
13.
LIST OF STANDARDS
COUNTRIES
Although
the standards
countries
are similar,
they
of welding
rods of various
they do differ
a little because
were established
Therefore,
shown
the
under different
welding
in the table
OF WELDING
backgrounds.
rods of various
below
RODS BY
standards
do not correspond
with
for reference.
Types of covered arc welding rods for mild steel (JIS 23211-1978)
Type of covering
material
Type of
welding rod
/
1
DIN 1913-1976
BS 639-l 976
II
llmenite
04301
E4343 AR24
D4303
1 Lime-titania
D4311
High cellulose
E6011
E4333 Cl 6
E4333 C4
D4313
E6013
E4300 RI2
E4300 R3
E4343 826(H)
E4343 Bl 0
E4333 RR(B) 7
Low hydrogen,
E7016,
D4324
Iron powder-titanium
nui&a
E7024
E4300 RR12031
E4300
RR1 1
E7028
E4333 B36(H)
E4333
B12
E6027
E4333 A35
E4343 Bl 0
D4326
1 Low
hydrogen
Iron powder-iron
oxide
E7018
E4333 RR24
D4316
D4327
E4333 Ar7
AWS A5.1-1978
I
Types of covered arc welding rods for high tensile steel (JIS 23212-1976)
Type of
welding rod
Type of covering
material
D5001
D5003
AWS A5.5-1969
I
llmenite
1 Lime-titania
14
D;26
BS 639-l 976
DIN 1913-1976
E5133 AR24
E5133 AR7
E5133 RR24
E5133 RR(B)7
E5133 B261H)
E5154 BlO
E7016
Low hydrogen
E8016
E9016
E7026
E5133 B36(H)
99 -
E5154
BIO
E5133 B12
13-1
1)
CLASSIFICATION
OF COVERED
ARC
WELDING
JIS Z 3211-1978
JIS Z 3212-1978
Japan
Method of classification
Example:
D p-p-j
D4301
D 4327
D 5016
D5326,
etc.
Classification
Symbol
Min. tensile
strength kgf/mm
(N/mm)
(N/mm)
NOTE:
The yield point and tensile strength of D4327
may
be reduced
by 1 kgf/mm*
(9.8 N/mm*
the
kgf/mm*
yield
point
(323 N/mm*),
must
be at least
and the
(402N/mm*
tensile
).
Type of welding positions and covering materials (including elongation and impact value of deposited metal,
power source, amount of hydrogen, etc.)
Impact value
(2V Charpy)
gationTemper-Min.
ayre
C
D43
impact value
kgf * m(J)*
22
4.8 (47)
llmenite
22
2.8 (27)
Lime-titania
High cellulose
I1
22
2.8 (27)
13
I7
I6
25
24
26
I7
25
4.8 (47)
27
25
2.8 (27)
lk0powderi0whydroqe
(Iron powder)iron oxide
40
22
2.8 (27)
Special
4.8 (47)
-
Welding position
High titanium
Oxside
z
zl
z
titanum oxide
D50
Welding positions:
F, V, OH, H, H-Fil
F.V.0H.H
AC or DC (+)
F.V.0H.H
AC or DC (*)
F.V.0H.H
F.H.Fil
Welding positions:
F. V. OH. H. H-Fil
I6
2.
4.8 (47.1)
26
D58
1618
26
Low hydrogen
-iron powder-low
hydrogen
-5
4.8 (47.1)
AC or DC (t)
s
._
LOW hydrogen
Ironpowder-
Special
D53
Power source
Amount
of hydrogem ml/
cv
F.V.0.H
01
03
Efficien_
Type of covering
material
Low hydrogen
,r0powderlowtwdrcqen
F.V.0H.H
AC or DC (k)
AC or DC (+I
Below IO
AC or DC (+I
AC or DC (+)
Below 8
AC or DC (+)
Below 6
F.H-Fil
F.V.0H.H
F.H.Fil
NOTES:
(I)
Symbol of welding position (apply to rods of 5 mm diameter or less)
F: Flat V: Vertical
0: Overhead H: Horizontal or horizontal fillet weld
AC: Alternating current
DC (?I: Direct current, electrode positive and
(2) Meaning of symbols of power source:
electrode negative
DC(-):
Direct current, electrode negative
DC(+): Direct current, electrode positive
-lOO-
2)
Classification
r
American Welding Society
AWS A5 1-1978
Covered arc welding rod for mild
steel
Method of classification
E
lF((ol
Example:
E 6011
E 7018 etc.
REMARKS:
1.
Unit of figures in
2.
Yield
point
reduce by 1,000
elongation
mum
is SI.
be
value.
However,
tensile
strength
48,000
must
yield
not
be
point
and
less than
may
58,000
PSI and
PSI series.
Welding positions and type of covering materials (including elongation and impact value of deposited metal,
efficiency,
:/zgm
Sym- M:a;;An,
tion
bol
2%
10
22
11
22
20(2.8)(27)
Type of covering
material
High cellulose
zed titanium
Efficiency %
Welding position
Power source
Amount
dof,,h,;
DC(R)
AC or DC(R)
F.V.0H.H
AC or DC(S)
F.V.0H.H
AC or DC(R.S)
H-Fil
AC or DC(S)
tF
AC or DC(R.S)
H-Fil, F
AC or DC(S)
F.V.0H.H
AC or DC(R.S)
F.V.0H.H
DC(R)
F.V.0H.H
AC or DC(R)
F.V.0H.H
AC or DC(R)
H-Fi1.F
AC or DC(R.S)
H-FiI.F
AC or DC(S)
H-Fi1.F
F.0H.H.V
.-6
3
z?
?!
;
AC or DC(R)
-down
AC or DC(R)
REMARKS:
1.
Although the deposition efficiency is not stipulated, rods of 14,18,24,
27 and 28 contain iron powder and have a high
deoosition efficiencv. (However. Exxl8: 105% or above. Exx28: 130% or above)
2.
Meaning of welding bosition: F:Flat,
V: Vertical,
oh: Ov&head.
H: Horizontal,
H-Fil: Horizontal fillet welding
3.
Meaning of symbol of power source: AC: alternating current,
DC(S): Direct current (Electrode negative),
DC(R):
Direct current (Electrode positive),
DC(R,S): Direct current (Electrode positive and negative)
4.
Although amount of hydrogen is not stipulated, all water (1650 to 13OOF extraction) is (899) i982C).
iO1 -
3)
Covered arc welding rod for carbon steel and carbonmanganese steel
Method of classification
xamples:
E43
21
R13
E51
33
B160
20(H)
Tensile
/
Elongation and impact value of deoosited metal (No. I)
E43
Efficiency
Symbol
Efficiency %
None
Below 105
0
@
No regulation
WI
110
105<115
120
115<
150
>145<155
125
47
No regulation
ETC.
ETC.
18
L
FJOTE:
G
TvPe
Acidic (Iron oxide)
Welding position
All positions
Flat position
Power source
Symbol
21
3
Amount
AC no-load
voltage
DC polarity
Detail
07
Symbol
47
Svmbol 1
-50
50
of hydrogen
-102-
4)
DIN 1913-1976
Germany
Method of classification
E
p]
pi
DIN1913
mlml
Exampes:
;5;;;;;
;D,l;;;;;_,g,3
Efficiency
No regulation
Remarks:
Applied to rods of
Remarks:
RRII,
ARII,
B12, B(4112.
the efficiency of which is
135% or above.
Power source
Symbol
, .. __ .
of hydrogen
position
Al
Acidic (thin)
A2
Acidic (thin)
R2
1Rutile
R3
&tile
R(C)3
(thin)
(medium)
2(l)
c4
Cellulose (medium)
Acidic (thick)
RR6
Rutile (thick)
Rutile-cellulose
RR(B)7
RR(B)8
em!U
,Ob (Glycer,ni&hod1
code
1
2
5
2
t-
(thick)
AR7
RR8
I
j
dro
Rutile-cellulose (medium)
A5
RR(C)6
~,
Rutile (thick)
Basic rutile (thick)
B9
Basic (thick)
B(R)9
1Basic*(thick)
1
1
O(6)
1Oorless
Remarks:
Figures in ( ) are
thickness of cover and
efficiency.
2105%)
NOTE:
-103-
*:
14.
LIST OF STANDARDS
COUNTRIES
OF METAL
MATERIALS
Although
If there is no corresponding
countries
are similar,
carbon
they
were
Therefore,
they do differ
established
the metal
under
a little because
different
materials
background.
other
exactly.
(Ceq)
material,
spond.
of various standards
equivalent
BY
Carbon
to each
+I/40
Equivalent
Ni + l/6
(Ceq)
= C + l/6
Mn + l/24
Cr + l/4 MO + 1/14V
reference.
1)
Type
Tvpe 1
2)
Symbol
(JIS)
Tensile
strength
(kg/mm)
ss34
34 to 41
Corresponding standards
Ceq
ASTM
KES
I
0.20
AZ83 Gr. B
A283 Gr. D
BS
I
17100
ust37-2
15-l 964
17100
ust42
17100 st50
0.22
sS41
0.40
4360-Gr50
0.56
A678 Gr.B
SM41 A
Type 1
SM41 B
41 to 52
SM41 C
SM50A
Tw
SM50B
SM50C
5Oto62
SMSOYA
Type 3
SM50B
53 to 65
Type 4
Tvpe 5
SM58
58 to 73
0.45
SHTGO
-104-
DIN
I
Si
3)
Tensile
strength
(kg/mm*
TVP~ 1
SPCC
(228)
Type 2
SPCD
Type 3
SPCE
Type
Corresponding standards
Ceq
KES
ASTM
228
4)
5)
Ly-$o
Type 1
SF34
Type 2 I
SF40
Type 3
SF45
45 to 55
0.35
A668C
Type 4
SF50
50 to 60
0.40
A668D
Type 5
SF55
55 to 65
0.48
A668 E
SF60
Ceq
34 to 42
0.20
A668A
40 to 50
0.25
A6686
60 to 70
0.53
KES
AsT~rres~ndingsta~~ds
Type 6
$i$j
Type
-105-
A668F
--/
D,N
6)
7)
STK41
Corresponding standards
Ceq
KES
Ir 30
STK30
Type I
Tvpe 2
Tensile
strength
(kg/mm*)
Symbol
(JIS)
Type
>
0.25
41
0.30
Tvpe 3
STK51
z 51
0.40
Tvpa 4
STK50
P 50
0.35
ASTM
STKBO-E
BS
DIN
ASOO-GrA
1775~ERWI
1626 St34
A252-Gr2
1775-HFWI
1626 St42
1775-HFW23
1629 St45
1629 St52
Type
Type 11
Tensile
strength
(kg/mm*
Symbol
(JIS)
STKMllA
230
Corresponding standards
Ceq
KES
0.23
ASTM
STKMIlA
A519-MT1010
BS
1717-ERW-101
DIN
1
2391 St35
Type I2
,s.li,-,
0.31
A519-MT1015
980-ERW-2
A51 3-MT-1020
A519-64
980-CDS-4
3602-l 962
1717-ERW-102
STKMlBA
980-ERW-3
Type I3
239 1-St45.2
1629lSt35)
>
2391 st35.1
A519-MT1020
1717~CDS-104
980~CDS-5
A513-1026
A519-1026
Type I4
0.48
980-CDSB
A51 3-1030
Type 15
A51 9-l 030
STKMlGA
252
STKMIGC
~63
STKMl7A
2 56
STKMlGA
0.63
Type 16
STKMI 7C
STKM18A
STKMl7A
266
980-CDS-7
2391-St55.2
1717-CDS-105
0.73
Type 17
A519-64
A519-1050
245
-106-
3602-l 962
1629(St55)
8)
Treatment
Refined
(Quenched
and tempered)
Non-refined
(Rolled or
annealed)
-107-
(50 to 80 kg/cm*
class)
15.
MELTING TEMPERATURES
AND ALLOYS
Metal/alloy
Chemical
symbol
Aluminium
Al
Al forging alloy
Antimony
OF VARIOUS
Celsius f)
Metal/alloy
BASE METALS
Chemical
symbol
Celsius ()
660
Molybdenum
MO
650
German silver
Sb
630
Nickel
Ni
1453
Beryllium
Be
1285
Niobium
Nb
2470
Lead
Pb
327
Palladium
Pd
1552
Boron
2300
Platinum
Pt
1770
Bronze
1000
Rhodium
1960
Cadmium
Cd
321
Red brass
1150
Chromium
Cr
1900
Selenium
Se
220
Iron pure
Fe
1536
Silver
Ag
961
Germanium
Ge
958
Silicon
Si
1420
Gold
AU
1063
Steel
Cast iron
approx.
1200
Tantalum
Ta
2997
approx.
1420
Titanium
Ti
1700
1730
lnox 1818
S40 to
approx.
2620
900
approx.
1500
iridium
Ir
2454
Vanadium
Cobalt
co
1495
Bismuth
Bi
271
Copper
CU
1083
Tungsten
3410
Magnesium
Mg
650
Zinc
Zn
419
Manganese
Mn
1245
Tin
Sn
232
Brass
Zr
1700
approx.
900
-108-
16.
16-1
CONVERSION
TABLE
STRENGTH
N/mm
kg/mm
N/mm
kg/mm
N/mm
10
31
304
61
598
20
32
314
62
608
29
33
324
63
618
39
34
333
64
628
49
35
343
65
638
59
36
353
66
647
69
37
363
67
657
78
38
373
68
667
88
39
382
69
677
10
98
40
392
70
687
11
108
41
402
71
697
12
118
42
412
72
706
13
128
43
422
73
716
14
137
44
431
74
726
15
147
45
441
75
736
16
157
46
451
76
746
17
167
47
461
77
755
18
177
48
471
78
765
19
186
49
480
79
775
20
196
50
490
80
785
21
206
51
500
81
795
22
216
52
510
82
805
23
226
53
519
83
815
24
235
54
529
84
824
25
245
55
539
85
834
26
255
56
549
86
844
87
854
27
265
57
558
28
275
58
568
88
864
29
284
59
578
89
873
30
294
60
588
90
883
100
981
kg/mm2
New unit:
N/mm2
Conversion:
1 kg/mm2
(Newton)
= 9.81 N/mm2
-109-
16-2
TEMPERATURE
OF
OC
OF
OF
-40.0
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
177.8
-37.2
-35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
48
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
-28.3
-19
-2.2
-8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1
-15
5.0
-6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
-25.6
-14
6.8
-6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3
-10
14.0
-3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
-22.8
-9
15.8
-3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
-22.2
-8
17.6
-2.8
27 .
80.6
16.7
62
143.6
36.1
97
206.6
-21.7
-7
19.4
-2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
-21.1
-6
21.2
-1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
-20.6
-5
23.0
-1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
-20.0
-4
24.8
-0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
-19.4
-3
26.6
32
89.6
19.4
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
68
164.4
46.1
115
239.0
-18.3
-1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
-17.8
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
-17.2
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
-16.7
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
-16.1
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
-15.6
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
-15.0
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
-14.4
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
-13.9
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
OF = (C . 9/5) + 32
C = (OF - 32) * 5/9
llO-
16-3
PRESSURE
kg/cm* to lb/in'
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.0
455.1
469.4
483.6
497.8
512.0
526.3
640.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
I437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
I877
1892
1906
1920
1934
1949
1963
I977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
I80
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
995.6
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
1 kg/cm2 = 14.2233
1 lb/in
= 0.0703
lb/in
kg/cm2
-111
16-4
LENGTH
Millimeterstoinches
T
2
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
IO
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0,945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.664
1.693
1.732
1.772
1.811
1.850
1.800
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3,228
3.268
3-307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3,898
2.323
Inches to Millimeters
0
0.01
0.02
0.254
0.508
L
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.762
1.016
1.270
1.524
1.778
2.032
2.286
0.1
2.540
2.794
3.048
3.302
3.556
3.810
4.064
4.318
4.572
4.826
0.2
5.080
5.334
5.588
5.842
6.096
6.350
6.604
6.858
7.112
7.366
0.3
7.620
7.874
8.128
8.382
8.636
8.890
9.144
9.398
9.652
9.906
0.4
10.160
10.414
10.668
10.922
11.176
11.430
11.684
11.938
12.192
12.446
0.5
12.700
12.954
13.462
13.462
13.716
13.970
14.224
14.478
14.732
14.986
0.6
15.240
15.494
15.748
16.002
16.256
16.510
16.764
17.018
17.272
17.526
0.7
19.558
19.812
20.066
17.780
18.034
18.288
18.642
18.796
19.050
19.304
0.8
20.320
20.574
20.828
21.082
21.336
21.590
21.844
22.098
22.352
22.606
0.9
22.660
23.114
23.368
23.622
23.876
24.130
24.384
24.638
24.892
25.146
1 mm = 0.03937
in
1 in = 25.4 mm
-112-
16-5
WEIGHT
Kilogram t
1
Kilogram
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.52
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
167.55
169.76
171.96
174.17
189.60
191.80
194.01
196.21
211.64
213.85
216.05
218.26
70
154.32
156.53
158.73
160.94
163.14
165.35
80
176.37
178.57
180.78
182.98
185.19
187.39
90
198.42
200.62
202.83
205.03
207.24
209.44
Pound to kilogram
Pound
10
4.536
0.464
0.907
1.361
1.814
2.268
2.722
3.175
3.629
4.082
4.990
5.443
5.897
6.350
6.804
7.257
7.711
8.165
8.618
20
9.072
9.525
9.979
10.433
10.886
11.340
11.793
12.247
12.701
13.154
30
13.608
14.061
14.515
14.969
15.422
15.876
16.329
16.783
17.237
17.690
40
18.144
18.597
19.051
19.505
19.958
20.412
20.865
21.319
21.772
22.226
50
22.680
23.133
23.587
24.040
24.494
24.948
25.401
25.855
26.308
26.762
60
27.216
27.669
28.123
28.576
29.030
29.484
29.937
30.391
30.844
31.298
70
31.752
32.205
32.659
33.112
33.566
34.019
34.473
34.927
35.380
35.834
80
36.287
36.741
37.195
37.648
38.102
38.555
39.001
39.463
39.916
40.370
90
40.823
41.277
41.731
42.184
42.638
43.091
43.545
43.999
44.452
44.906
1 kg= 2.2046lb
llb=0.4536
kg
-113-
17.
NAMES
OF STANDARDS
country
IN VARIOUS
No.
Standard
COUNTRIES
country
Standard
International
IS0
England
BS - LR
Japan
JIS * JRS - NK
U.S.S.R.
GOST
U.S.A
Germany
DIN - GL
France
NF
Norway
NV
Italy
UNI - RlNa
ABBREVIATION
Abbreviation
I so:
AND
LEGAL
- BV
NAME
Organization
for Standardization
J I S:
J RS:
Japan National
(Architects)
Architectural
N K:
A WS:
American
Welding Standard
A B S:
American
I L:
B S:
L R:
Military
Railways
Institute of Japan (Rules of welding work)
Specifications
tests of ships)
and Standards
and Classification
of
Steel Ships)
GOST:
Gosudarstbennie
D I N:
G L:
Germanifcher
B V:
N F:
Norme Francaise
N V:
U N I:
Unificazione
I Na:
Standart
Lloyd
ltaliana
ASTM:
American
K ES:
-114-
and Classification
of Steel Ships)
18.
A GUIDE
TERMS
TO WELDING
A
Welding carried out by using the arc of an AC current.
AC arc welding
Acetylene
gas generator
Equipment
Actual
Actual throat
throat
of fillet
weld:
Shortest
distance from
root of a fillet
Minimum
depth of weld
metal at the section passing through the root of weld in butt welding.
Actual throat
Theoretical
Theoretical
throat
throat
Actual throat
Leg
Leg
blow-
ing the metal fused by the heat of the arc with compressed air.
Arc cutting
Arc length
Spot welding
wherein
Arc voltage
Arc welding
Atomic-hydrogen
welding
Arc
welding
produced
carried
out
in hydrogen current.
-115-
between
of hydrogen
Automatic
arc welding
Axis of a weld
and continue
manual operation.
to the cross-section,
Back chipping
In butt welding,
chipping
penetration
or the first
Back fire
Backhand welding
Welding
technique
whereby
or gun is directed
op-
Backing
Application
of a metal,
to the back of a
Backing strip
Backing weld
Back run
out from
Bare electrode
Base metal
-116-
Bead
Bevel angle
Blowhole/Gas
A device which controls the mixing ratio of gas and its flow; the por-
Blowpipe/torch
Braze welding
are in the fusion welding, flux is placed on them, and filler metal with
the fusion point lower than them are melted with the flame of gas. As
the filler
Copper:
of
Brazing
solder
fusing them.
Buttering
(See surfacing)
Butt joint
Joint
between
two
metal
members
welded
on approximately
the
same plane.
Resistance welding carried out by butting surfaces of two metal members against each other while applying
welding.
A kind of resistance welding, wherein the end faces of metal are butted
against each other, heated with an electric current
butted
faces simultaneously
welding
of pipe material.
-117-
by applying
along
joint.
Used mainly
for
Butt welding
C
Carburizing flame
Covered electrode
A filler
metal
core wire
with
electrode,
a thick
consisting
of a metal
A weld
from
to the
other.
Cone/flame
core
portion
Core wire
The metal wire used as filler metal for shield arc welding.
-118-
Corner joint
Cover glass
A clear glass used in goggles, hand shields and helmets to protect the
filter glass from spattering material.
Crater
device
used in oxygen
cutting
for controlling
and directing
the
gases.
Cutting shoulder
Cutting tip
The part of an oxygen cutting torch from which the gasses come out.
DC arc welding
Deposited metal
Deposition efficiency
The ratio of the weight of deposited metal to the net weight of electrodes
consumed,
excluding
the stubs.
Usually,
Deposition
rate
Die-burn
transmitting
welding current.
Dissolved acetylene
Acetylene
container.
-119-
Drag
In a gas cutting
distance between
Kerf
The
Double - Bevel -
Double -
-120-
V-
Groove weld
Groove weld
E
Edge joint
Edge preparation
proportioned
cross-section exists.
Electrode holder
current to it.
Electrode tip
In spot welding,
a bar electrode
which
directly
contacts
the metal
A welding
process wherein
coalescence is produced
of high velocity
A welding
process wherein
coalescence
is produced
by molten
slag
which melts the filler metal and the surfaces of the work to be welded.
The weld pool is shielded by this slag which moves along the full crosssection
of the joint
maintained
molten
as welding
progresses.
The
conductive
slag is
Guide
wherein
Electroslag
filler
metal
Welding
is supplied
A method
of electroslag
by an electrode
and its
guiding member.
Reinforcing
plates attached
-121-
to the starting
point
Exposed core
Scattering
itself.
excessive current,
insufficient
F
Face-bond specimen
Test specimen bent so that the face of the butt welded joint is tensile.
Filler metal
Fillet weld
A weld of approximately
. approximately
triangular
corner joint.
Fillet
direction
of stress.
A filter,
usually colored,
Filter lens
shield harmful
Welding
right angle to
in
contact with the joint and held down with a copper jig, then generating
an arc from one end of the electrode.
Fish eye
A defective portion,
of a welded metal.
-122-
Flash burr
Phenomenon
metal solidified
A resistance-welding
neously over the entire area of abutting surfaces, by the heat obtained
.from
the application
of pressure after
is substantially
by expulsion
completed.
of metal from
the joint.
Flat position
Flux
Material
used to prevent,
dissolve or facilitate
horizontal.
Forehand welding
A welding technique
wherein
Forge welding
Welding
carried
Furnace brazing
Fusion welding
out
to metal
by applying
applying
members
mechnical
in their
pressure or hammer-
fused condition;
used in gas
welding, etc.
G
Gas cutting
Cutting carried out by heating metals with a gas flame and utilizing the
intense chemical reaction of metals and oxygen.
Gas gouging
-123-
Gas welding
A kind of automatic
fillet welding
can weld evenly and securely using many devices at the same
is very high.
bridge construction,
building construction,
Goggles with
Goggles
which
tinted
protect
harmful
welding
radiation
or oxygen
and flying
cutting,
particles.
The opening provided between two metal members for a groove weld.
Groove
)g
fg
"J'g"b'p """
RDouble
""ii--g
Square
Bevel
Fillet
Groove angle
The
total
Double bevel
groove weld.
Groove angle
Groove angle
52
-124-
Double U
by a
Groove depth
Groove weld
The
weld
Single-Vee-Groove
Weld
Single-Bevel-Groove
Single-U-Groove
Weld
Weld
Single-J-Groove Weld
Single-Flare-Vee-Groove
Weld
Single-Flare-Bevel-Groove
Double-Vee-Groove
Double-Bevel-Groove
Doulbe-U-Groove
Double-J-Groove
Weld
Weld
Weld
Weld
Weld
Double-Flare-Vee-Groove
Weld
Double-Flare-Bevel-Groove
Ground connection
An
electrical
connection
Weld
frame
to the earth
for safety.
a member
jigs.
H
Hand shield/face shield
In arc welding,
to
Hard facing
Depositing
hardness.
-125-
Heat-affected
zone
That portion of the base metal which has not been melted,
mechanical
properties
or microstructure
have
but whose
been altered
by the
A protective
Helmet
neck.
High frequency
induction
welding
induction
High frequency
resistance welding
directly,
through
an electric current
of
pres-
Horizontal
position
Fillet weld -
vertical surface.
horizontal
position of welding
on
plane
vertical plane.
I
Ice-flower-like
structure
of ice columns,
non-metallic
inclusions
Fractures with
In lap
Indentation
resistance
welding,
depression
Induction
brazing
Brazing
carried
current.
126-
out
from
an induction
An
arc-welding
process wherein
coalescence
is produced
by heating
electrode
and
(which may
Intermittent
fillet weld
welded spaces.
J
Joggled lap joint
Lap joint wherein one member is stepped so that both members are on
approximately
L
Layer
Leg length
-127-
Lap joint
an overlapped
joint,
projection
welding,
and
seam welding.
The
Liquidus
lowest temperature
at which
liquid.
M
Phenomenon
Magnetic blow
wherein
action of an
electric current.
Manual welding/hand
welding
Welding performed
by hand.
Melting rate
welding rods.
Mixing chamber
The part of a torch wherein the combustion gas and oxygen are mixed.
Multiple-impulse
welding
Welding
machine
which
-128-
can
be operated
by two
or more welding
N
Neutral flame
Notch brittleness
Brittleness
of a metal member.
Ductility
is satisfactory
when there is
An attachment
Nozzle/tip
A flame comes
Nugget
at
0
Overhead position
Overlap
Overlap
Overlap
Oxidizing
falme
A gas flame
containing
An oxygen-cutting
means
Overlap
more
oxygen
than
that
elevated temperatures,
reaction
of oxygen
129-
with
of a neutral
frame.
of the chemical
metal.
Overlap
the
base metal
being maintained
electrode
at
by
Oxyacetylene
welding
heat of acetylene
with
heat of hydrogen
with
oxygen.
Oxyhydrogen
welding
Welding
oxygen.
P
A single welding operation
Pass/run
The result of
a pass is a bead.
Peening
Penetration
The minimum
(Joint penetration)
(Root penetration)
Penetration/weld
penetration
Distance
surface to be welded.
Penetration
Percussion welding
Welding
wherein
discharging
a joint
electric
energy
previously
stored
through
butt
faces of
Pit
Platen
Component
surface
mounted,
on
electrode
and which
upsetting force.
-130-
dies,
transmits
locating
welding
equipment,
etc. can be
pressure of an electrode
or
Plug weld
and joining
Porosity
Postheating
The application
Preheating
The application
before a welding
or cutting operation.
A resistance-welding
process wherein
resistance to electric
coalescence is produced
current
at predetermined
reaction is employed
of pressure.
through
by the
the work
points by projections,
embossments or
intersections.
Pulsation welding
See Multiple-impulse
welding.
R
Rate of deposition
Reducing flame
-131-
Reinforcement
of weld
Weld metal on the face of a weld in excess of the metal required for the
specified weld size.
Residual stress
Resistance welding
Welding
an electric
current
through
con-
tact portions of metal members and heating with the heat of resistance
thus generated while pressure is applied.
Reverse polarity
Method
Direction of force
Rollers
Roller electrode
round
electrode
etc.
fixed distance.
Root face
That
portion
Root face
Root of joint
-132-
l-l
to the
line of intersection
Root of fillet
of a joint of two
welded joint:
In
Root opening
Root opening
C!5
Root opening
Root radius
The
Root of weld
points at which the back of the weld intersects the base metal
surfaces.
S
A notch provided in a metal member to prevent weld lines from inter-
Scallop
secting.
A kind
Seam weld
of resistance welding
while flowing
along a joint
being rotated
Semiautomatic
arc welding
capable of automatically
Resistance
welding
wherein
welded by transmitting
Sheet separation
two
or more joints
are simultaneously
-133-
Arc welding carried out while shielding the arc and deposit metal from
the atmosphere with a protecting medium.
Shrinkage stress
Side-bend specimen
Seal weld
Joint
to obtain tightness.
with a groove scraped out on one side only of two metal mem-
basic forms:
Square
J
U
right-triangle
can be inscribed
which
within
the fillet-weld
cross-
section.
For
unequal
triangle
leg fillet
Skip weld
Slag
Non-metallic
Slag hammer
Slag inclusion
Non-metallic
-134-
the fillet-weld
cross-section.
Slot weld
joining that member to that portion of the surface of the other member
which is exposed through the hole.
and may be partially
or completely
Soldering
(A fillet-
to this definition.)
by heat-
(427C)
metals.
In arc and gas welding, the metal particles expelled during welding and
Spatter
Spatter loss
Spot weld
or upon overlapping
members
wherein coales-
cence may start and occur on the laying surfaces or may have proceeded
from
the
surface
Staggered intermittent
fillet welding
Two
lines of intermittent
weld increments
of one
member.
The
weld cross-section
circular.
fillet
welding on a joint
wherein
the fillet
other line.
Straight polarity
A connecting
welded
method
is connected
in DC arc welding,
whereby
the metal to be
Strapped joint
Joint
doubling plate.
-135-
welded
Depositing
Surfacing
a filler
metal
of a metal to obtain
the
T
A weld made to hold parts of a weldment
Tack weld
in proper alignment
until
Tee joint
A joint
formed
other.
Theoretical
A weld of approximately
throat
approximately
triangular
corner joint.
Actual throat
Theoretical
Theoretical
throat
Legs
Thermit
mixture
Mixture
of metallic
for thermit
reaction.
-136-
oxide,
aluminum
powder
Thermit
welding
reaction.
See a theoretical
A kind
throat
wherein
tungsten
or another
non-
Tip holder
Toe of weld
The junction
Groove weld
Tpe of weld
Fillt weld
Toe of weld
Toe of weld
Toe weld
Torch head
The portion
tached.
Transition
temoerature
The
temperature
at which
the
breaking
form
of a metal drastically
changes.
U
Ultrasonic welding
application
of
high frequency
vibratory
energy
as the
by the
work
Underbead crack
-137-
Undercut
Portion
R
_
Underlaying
Undercut
Undercut
Undercut
A covered electrode
Welding by means of joining butt faces of metal under heat while applying pressure.
Vertical position
Wandering sequence
longitudinal
sequence wherein
the weld
bead increments
are de-
posited at random.
Weaving
alternately
direction.
Weldability
into a specific,
satisfactorily
suitably
designed structure
-138-
conditions
and to perform
Weld bead
Weld length
See bead.
Length of portion
of uninterrupted
crater.
Weld line
Weld line
Weld metal
Heat-Affected
PA
zone
Weld time
Weld zone
The
Welding current
The
electric
current
transmitted
welding.
Welding force
-139-
to
for
Welding position
during welding.
Welding rod
Welding symbol
Welding transformer
A transformer
140-
Includes
APPLIED INSTRUCTIONS
11 BASIC
WELDING
. q
I!!!!3
. ll-
2
2
6
9
11-27
11-29
11-31
PREFACE
The Applied Instruction section of the Shop Manual has been compiled to explain
how to reinforce, repair, and rebuild construction machinery easily and economically by welding, and how to ensure quality after the welding to improve machine
availability.
welded structures and major parts which are often repaired by welding.
t
STANDARDS
OF STANDARDS
ERAL
WELDING
OF
WELDING
OF METAL
RODS
MATERIALS
BY
COUNTRIES
BY COUNTRIESin
GEN-
INSTRUCTIONS.
11 -1
cc
APPLIED
BASIC WELDING
INSTRUCTION
ITEMS
REQUIRED
The following
FOR WELDING
REPAIRS
j.
Hammers
hammer)
pairs by welding.
k. Wire brush
a. Chemicals required for dye penetrant checks
m.Set
C.
n. C-clamp
o. Centering punch, scriber
p. Centeralized
pressed air
q. Other items
Pneumatic hammer
PROCEDURE
500 A min.)
of protectors
dust respirator,
FOR CHECKING
FOR CRACKS
other
inspection,
it is necessary to know
(1) dye
inspection,
current
destructive
penetrant
flaw
(3)
supersonic
or (5)
correct
check),
inspection,
radioactive
meth-
checks (color
detection,
the
(2)
The procedure and cautions for the dye penetrant check
(4)
non-
1. PROCEDURE
Description
Step
wire brush,
temperature
40C
check
nearby
11-2
0
and
wait 5 to 20 minutes.
WELDING
APPLIED
Description
Step
BASIC
INSTRUCTION
WELIDNG
developer.
spray on the
of the surface to
flow out.
Table 1
After confirming
the locations of both ends of the crack, make holes 6 to 8 mm diameter at a distance 5 to 10 mm
WELDING
11-3
0
APPLIED
2.
EXAMPLE
1) Washing
11-4
0
BASIC
INSTRUCTION
OF DYE
PENETRANT
CHECK
WELDING
PROCEDURE
2)
Penetration
WELDING
APPLIED
BASIC
INSTRUCTION
3.
PRECAUTIONS
1)
Spray
IN THE
DYE
PENETRANT
WELDING
CHECK
h
the
chemicals
lightly
at first,
then
spray
strongly.
,
Fig. 1
2)
Spray the chemicals at a 45 degree angle to the surface which will be checked.
3)
horizontally
Fig. 2
4)
After
spraying
the developer,
Fig. 3
5)
After
the can.
6)
Before
disposing
the
used (empty)
cans, make
WELDING
1 l-5
APPLIED
PREPARATION
After
BASIC WELDiNG
INSTRUCTION
confirming
OF EDGES BY GOUGING
the location
edges.
1.
TYPES
OF GOUGING
No.
ed below.
Method
perform,
it does
and it is relatively
Possible
gouging position
inexpensive.
Description
Melt the base metal with a carbon rod, and blow it off with
Arc air gouging
All positions
air.
(Tools:
Heat the base metal with a gas cutter, and blow it off with
Gas gouging
All positions
oxygen.
(Tools:
Overhead
and vertical
smoke is produced.
positions
Table 1.
1 l-6
Types of gouging
WELDING
APPLIED
2.
ARC
BASIC
INSTRUCTION
AIR
GOUGING
WELDING
PROCEDURE
Remarks
Description
Step
spatters.
flow.
_I
As a rule, therefore,
use a DC welder.
heating temperature,
terminal.
(1)
than 20 mm
Carbon
Splashing direction
of melted metal
(2)
1 to 1.5 times of
gouging depth
Length of crack:
\
Depth of gouging
\
(DC)
1 Diameter
(mm)
1 Standard current(A)
[When the crack is extended through the plate]
Q 4.0
100 to 2071
(1)
40 to 50
/=essx
15
Length of crack
(2)
Back plate
-u--
Flat position: 2 mm
Vertical position: 2 to 3 mm
WELDING
1 1-7
0
APPLIED
INSTRUCTION
BASIC
Remarks
Description
Step
WELDING
\\\\\\\\\\\\\
-v
gouged surface.
Finish the worked surface smoothly.
Dimension of
carbon rod (mm)
Diameter
Length
Steel cover
Current
(A)
Gouging speed
(mm/min)
Depth
5.0
305
Installed
100 to 200
900 to 1200
3 to 4
7 to 9
6.5
305
Installed
200 to 350
900 to 1200
4to
9to11
8.0
305
Installed
250 to 400
700 to 1000
5to
10 to 12
9.9
305
Installed
300 to 450
400 to 700
6 to 7
11to13
11.0
305
Installed
400 to 550
300 to 400
8 to 9
13to
15
13.0
305
Installed
450 to 600
200 to 300
9tolO
15to
17
Table 3. Condition
Normally,
a groove of 1.5 to 3 m can be made with one carbon rod (305 mm long).
11-8
0
WELDING
APPLIED
INSTRUCTION
WELDING
BASIC.
WELIDNG
PROCEDURE
1. PREPARATION
FOR WELDING
covered welding
rods, welding
(sledge hammer,
hand hammer
and chipping
hammer),
wire brush,
WELDING
2.
RODS AND
PRECAUTIONS
shown in Table 1.
gen type welding rods are made to reduce the moisture in the coating, they
If
moist
welding
being
Drying time
(minutes)
Available time
(hours)
30 to 60
JIS D4301
llmenite type
Lime-titania
Redrying temperature
(C)
Standard
type
J IS D4303
70 to 100
Cellulose type
High titanium
oxide
We
Low hydrogen type
JIS D4311
AWS E6011
JIS D4313
AWS
E6013
AWS
E7016
(E6027)
300
to 350
I
150 to 300
Notes:
(cracked,
discolored,
the drier.
rods
is abnormal
WELDING
1 l-9
0
APPLIED
3.
INSTRUCTION
PRECAUTIONS
1)
BASIC WELDING
BEFORE
WELDING
burn that
2)
to prevent
and postheating
cracking.
conditions
The pre-
3)
the
the grounding
place to be welded
as near to
It must be
as possible.
cable
will be installed.
Although
4)
should be determined
bon equivalent)
1 200Cand
III
up
590to
68OC
Carbon equivalent:
lated
to
following
the
A very important
weldability,
figure re-
obtained
from
the
expression.
Carbon equivalent
Weldability:
GENERAL
WELDING
1) Welding condition:
proper
arc
voltage,
Arc voltage:
current,
to weld with
welding
0.6
0.7
0.8
0.i-
%()
speed,
Generally,
If it is
11-10
0
in
equivalent
METHOD
0.5
Carbon
Table 2. Determination
It is important
arc
0.4
great caution
must be taken.
4.
0.3
WELDING
APPLIED
(b)
BASIC
INSTRUCTION
Arc
current:
Adjust
to the
The
melting
speed of welding
WELiDNG
Generally,
position
should
a large current
to
is
The
be 20 to 30%
Therefore,
lower
position.
*
r
2. Penetration
2. Penetration
becomes large.
is not sufficient.
Welding
speed:
Although
the welding
speed
welding
current
to
170 A
is deter-
if
current.
and the
ing.)
3)
rod 3.2 mm or
4.0 mm in diameter.
4)
to occur.
Therefore,
use caution
Take
(Fig. 1).
3z
I I
-I--
Oto3mm
Fig. 1
WELDING
11-11
0
APPLIED
BASIC WELDING
INSTRUCTION
(b)
opening
by depositing
Fill the
beads twice,
then
Fig. 2
(c)
backing
procedure
strips
for
the
according
sections
to
to
the
be
In-
repair
repaired
(Fig. 3).
*
Backing strip
I
4!F
targer than 6 mm
Fig. 3
Welding rod
Fig. 4
5)
depositing
each
layer.
6)
If
necessary,
fatigue
strength.
see
page 11-25.
7)
After
welding,
nearby
surface
penetrant
for
check
cracks
method.
by
means of the
dye
gouge it again.
8)
Other precautions
(a)
Starting an arc
Start
the
dummy
part.
to be welded
or a
these troubles,
at
To prevent
start method.
11-12
0
WELDING
APPLIED
INSTRUCTION
BASIC
WELDING
Permanent wel
generate sufficient
gas from
to
the starting
mm
,n
@ Starting point
of arc
0Lg
permanent welding
Fig. 5
Welding direction
in Fig. 6 if they
are connected
carelessly.
Lengthen
to preheat
the
crater.
(5)
While
(b)
preheating,
just before
the
molten
base metal, shake the welding rod to separate the molten metal of the rod, then immediately
move the
rod forward
a little
(c)
shorter
than
the diameter
(to be
Defective (dented)
Fig. 6
of the
welding.
The manipulation
of
above proce-
Fig. 7
WELDING
1 l-13
0
APPLIED
BASIC
INSTRUCTION
Basic manipulations
of welding rods
Manipulation
Type of welding
Position
1
Flat
Horizontal
-U.QJStringer
fillet welding
First layer of
butt welding
Without
-.-_
root face
Upper layers of
butt welding
WELDING
/WI
Q-form
Triangle
Weaving
\sa,
Fillet welding
Vertical
Butt welding
Fillet welding
Overhead
Butt welding
5.
MANIPULATION
I)
BUTT
OF COVERED
WELDING
RODS
Root opening
WELDING
IN
FLAT
POSITION
Welding direction
[Knack of manipulating
(a)
welding rods1
(2)
layers, weave in
(3)
(4)
Precautions
If the width of weaving is too large:
0
The bead becomes concave and the root may
not melt.
\
Not melted.
11-14
0
Not melted
WELDING
APPLIED
b)
INSTRUCTION
BASIC ,WELDING
backing strip)
procedure.
Apply
Arc point.
Straight
(2)
opening
is approximately
3 mm:
,
I
Arc point.
Semi-weaving (4 to 5 mm wide)
Precautions
If weaving more narrowly
WELDING
11-15
a
APPLIED
INSTRUCTION
BASIC
WELIDNG
of welding
[Root opening:
5 mm min.]
Welding direction
*Y
0.
>
*
a-
Penetration is often
insufficient.
11-16
0
WELDING
APPLIED
INSTRUCTION
HORIZONTAL
FILLET
[Knack of manipulating
(a)
BASIC
WELDING
WELDING
welding rods]
undercuts and
(b)
Manipulation
(1)
of welding rod
Straight method
Suitable for a leg 3 mm long or so.
(2)
Weaving method
Suitable for a leg 4 to 6 mm long.
(3)
Multi-layer
Aim at 1 to 2 mm
from the vertical
plate.
WELDING
Completion drawing
11-17
E'
APPLIED
3)
BUTT
INSTRUCTION
WELDING
BASIC
IN VERTICAL
[Knack of manipulating
POSITION
(UPWARD
WELDING)
welding rods]
(a)
(b)
Correct method of
holding the holder
in vertical position.
(c)
Manipulation
WELDING
Incorrect method of
holding the holder
in vertical position.
k?kaving width
Pitch is large.
Pitch is small.
melted by the
next pass.
Note:
is to be 20 mm or
30 ..jm
m max.
__
Weaving width
If all the
necessary
at one time,
defects
0
Weld twice to
complete.
11-18
0
WELDING
APPLIED
4)
INSTRUCTEON
FILLET
WELDING
BASIC
IN
[Knack of manipulating
(a)
(b)
VERTICAL
POSITION
(UPWARD
WELDING
WELDING)
welding rods]
Knack
of
manipulating
the welding
rod and
point aimed at
(0 mark:
(I
) Short leg
Melt corners
(3)
Middle leg
Note:
(2)
building up)
WELDING
11-19
CD
APPLIED
5)
BASIC
INSTRUCTION
BUTT
WELDING
IN
HORIZONTAL
[Knack of manipulating
(a)
WELDING
POSITION
Welding direction
(b)
Manipulation
(1)
Straight
(Root
opening:
3 mm max.)
Root opening
(2)
Weaving
method
(Root opening:
3 to 5 mm)
L-Stop
The
straight
method
should
be used for
(for approximately
0.5 seconds)
0.3 seconds)
the
11-20
0
WELDING
APPLIED
(c)
INSTRUCTION
BASIC.
WELDING
Building
up method
(2)
3 mm max.]
@I
Straight
* Second layer
When welding the lower side of the groove,
aim at the corner of the previous bead.
* Third layer
[Root opening:
4 to 8 mm]
a9
49
Weaving
2to3mm
WELDING
11-21
0
APPLIED
BASIC
INSTRUCTION
* Next-to-last
WELIDNG
layer
Leave3mm
or so.
up method
and points
aimed at for
Angle of aim
80 or so for pass Nos. I,3
each layer
and 7.
5 and 6.
6)
BUTT
WELDING
IN
[Knack of manipulating
(a)
OVERHEAD
welding rods1
r
90"
1 l-22
0
POSITION
[Bad example]
/ i\\
If the angle of the welding
rod is reduced to 85
or
WELDING
APPLIED
BASIC
INSTRUCTION
FINISHING
PROCEDURE
1.
surface with
WITH
WELDING
A GRINDER
a grinder
procedure.
PREPARATION
Cover the wiring
to
protect
them
from
the
sparks made
by the
grinder.
i.
WORK
PROCEDURE
I)
mm
max.
Finish smoothly
all of them.
notches.
0.5 mm max.*
Fig. 1
(b)
If there
is an overlap,
notch is eliminated
as shown
right.
0.5 mm max.I
(c)
Fig. 2
if the undercut
as shown right.
is 0.5 mm or deeper,
weld again.)
WELDING
11-23
a
APPLIED
BASIC
INSTRUCTION
Finish smoothlv
2)
WELDING
notches.
Fig. 4
[Reference]
mlmmi
After finishing with grinder
After welding
3)
Other cautions
Finish the toe of the weld completely.
Fig. 5
After finishing, paint the finished surface.
11-24
0
WELDING
APPLIED
BASIC
INSTRUCTION
PEENING
PROCEDURE
1.
WELIDNG
procedure.
PREPARATION
For the peening, a high speed pneumatic
can be an effective tool.
and
specification
of
hammer
the
high
speed
pneumatic
Item
Model
Number of hits
Specification
AA-9
3200 BPM
Diameter of piston
16.0 mm
Stroke
75.0 mm
Round
Overall length
245 mm
Weight
2.0 kg
Air consumption
0.35 m3 /min.
9.5 mm
hammer,
2.
WORK
PROCEDURE
fatigue
strength
measure to in-
of the welded
joints,
Pee
Just
10 mm
The toe
WELDING
11-25
G
WELDABILITY
Classification
OF STEEL MATERIALS
Preheating/Postheating
Thickness -
of materials
@@@0000
El--k
Caststeel
for welded
@
structures
0
07
135mm
70
35
18
Cast iron
Diameter
( C)
Welding rod
Step
*
JIS
INSTRUCTION.
AWS
D4316
D4326
E7016
E7028
D5016
E7016
D5816
E9016
Preheating
Postheating
I
Parts which must not be repaired by welding
Group
Power line parts
Engine parts
All parts except for the oil pan and other parts made of sheet metal
of repair
parts
The strength of the weld zone is lowered greatly, and the parts are
broken easily again.
Other parts
Cast iron:
Cast iron
/I
Cast steel n
-%
Cast steel:
The flow line is dim, and a pale red drip is made at the end.
The flow line is bright, and a yellow drip sparks into several lines in
three stages at the end (C + 0.4% class).
APPLIED
BASIC
INSTRUCTION
AND
[Reference)
JIS D4316
WELDING
(AWS E7016)
PC400)
JIS D5016
D65A)
(AWS E7016)
HD460,
HD680, HD780.785,
HD1200)
L-frame of work equipment
(WF22A)
(WS23S)
thru D455A)
JIS D5816
D85A)
(AWS E9016)
Blade (D155,
D355,
WELDING
Bucket (D75S.
D455A)
(D80A
thru D57S)
thru D455A)
Dl55S)
thru D455A)
11-27
0
st13zoaiinfi
30
siww3~vw
t~orww
40
ISII
APPLIED
POINTS
1)
BASIC
INSTRUCTION
FOR ENSURING
QUALITY
11)
the
welding
rods according
WELDING
If the mounting
position
of the grounding
cable
to the tensile
AFTER
WELDING
For general
below:
After
the
JIS D5816
welding
weld
reduce the
residual
strain.
(AWS E9016)
zone
peen
stress and
welding,
peen
each iayer.
2)
welding
rods, especially
low hydrogen
type,
After
repairing by welding,
finish smoothly
with a
grinder.
14)
Drying time:
3)
After
repairing
by welding,
zone
30 to 60 minutes
holes 6 to 8 mm in diameter
at 5 to 10 mm
Removing slag
After
an arc to connect
surface to be welded.
While
welding
a part,
blow
Preheating/postheating
materials
Preheat
the
and postheat
materials
to be welded
conditions.
8)
9)
and manipulate
Round
the
line of welding
on the
welding.
Extend
concentrated.
19) Take care not to make overlaps or undercuts.
WELDING
11-31
a
APPLIED INSTRUCTIONS
12 HARD-FACING
OF WEAR PARTS
HARD
FACING
PROCEDURE
3.
......................
................
...........
Build-up welding procedure
4.
5.
Examples of hard-facing
1.
Hard-facing
12- 2
2.
Typeof
12- 2
metal wear
(1) Sprocket
12- 4
. 12- 5
.............
....................
12-l 1
12-11
.......
12-15
. 12-20
....
12-28
.....
12-38
..........
12-29
of roller inside
.....
...........
12-47
12-49
...................
12-52
................
12-54
WELDING
..........
......
12-55
12-59
12-1
0
APPLIED
HARD
FACING
TYPES OF METAL
WEAR
INSTRUCTION
HARD-FACING
2.
the
PARTS
PROCEDURE
1. HARD-FACING
Hard-facing
OF WEAR
worn
mechanical
parts
when
and when
In actual situations,
only,
this method
method,
while
presents a comparatively
cheap
giving excellent
For example,
wear resistance.
process. This
more complex.
construction
work.
including
civil engineering
and
so they
of various situa-
are extremely
com-
Therefore,
if
makes
we
the
consider
wear
the
phenomenon
wear
phenomena
(2)
Select
welding
rod
for
the
wear
environment.
(3)
If
we cannot
12-2
0
even
WELDING
APPLIED
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
Adhesion
Wear between
(rolling
wear)
Erosion
Wear
from
Scratch wear
sand
t
Abrasion
wear
Gouge wear
Wear caused by gringing
during
impact
I
Impact wear
(1)
Adhesion
Wear which
wear
ther.
Abrasion
(a)
when two
occurs
pieces of metal
in both
Wear which
is caused
occurs between
by
rub toge-
small contact
which
(2)
occurs
Adhesion
the
metal is torn.
rubbing
between
metal,
etc.
wear
Wear caused by fine particles
Erosion
in fluids
moving
at high
Scratch wear
Wear which
catching
mainly
occurs
of a metal surface
caused by non-metal
when
there
due to medium
particles;
is rubbing
or
or low stress
etc.
(c)
Abrasion
wear
or medium
protruding
hard
or cutting
of a metal surface by
wear
caused
by
particles
or
hard
soil or
of a metal surface
due to
rock, etc.
(d)
Gouge wear
(3)
Impact
wear
shearing force)
caused by impact.
WELDING
12-3
0
APPLIED
3.
HARD
INSTRUCCTION
BUILD-UP
WELDING
damage
to
putting
the
damage to be repaired.
of the built-up
an expensive
lead
to
the
Table of comparative
( @ Extremelygood,
performances
(1)
Abrasive
wear
(2)
Erosion
part when it is
welding
separated
@ Good,
OF WEAR
PARTS
PROCEDURE
FACING
metal
in
piece causing
other
parts of the
machine
out
machine,
of action
thereby
Therefore,
impactant
preheating
Average,
(3)
Impact
wear
A Fair, X
Poor)
Crack
Heat
c orrosion
resistance resistance resistance
Ease of
cutting
Ease of
operation
Hardness
(I+)
Remarks
Note
(1)
(2)
(3)
12-4
0
If there is friction
between tvvo surfaces, wear progresses due to cutting or grooving caused by particles
harder than the base metal getting between the two surfaces.
Wear caused when objects move at high speed in a fluid.
Wear caused when one object hits the surface of another object, breaks into small pieces and is dispersed.
which
are
WELDING
APPLIED
4.
(1)
HARD
INSTRUCTION
GENERAL
BUILD-UP
DRYING
When
PRECAUTIONS
WELDING
WELDING
carrying
carriage
parts,
normally
covered electrode
is a low-oxygen
(3)
build-up
rebuilding
of under-
low-hydrogen
is used. However,
type,
OF WEAR
PARTS
FOR
ROD
out
FACING
type
if the covering
for 30
PREHEATING
AND
TEMPERATURE
CONTROL
DURING
OF
WELDING
up weld
and deformation
When drying,
use a heater-type
dryer as shown in
the photograph.
In addition,
prevent contraction
the deposition
Capacity of dryer
and cracking
50 kg
7AO-125-0010
As a basic condition
5 kg
7AO-125-0020
but for
carrying
undercarriage
out hard-facing,
kept at a minimum
It is important
the base
temperature
parts (rollers),
the temperature
at
when
must be
of 150 to 200C.
to maintain
this temperature
not
achieve
furnace
this,
at 200
place the
to 3OOC
parts in a preheating
for at least 30 minutes
the temperature
be allowed
to
CLEANING
build-up
BASE METAL
roller
To carry out high quality welding, it is necessary for
the surface of the base metal to be clean. Before
starting
welding,
remove
from
material
will
decompose
hardening
phenomenon
makes
machine
is troublesome,
where
so the trend
an automatic
is used,
replacing
the
is to continue
ture.
On the D80/85
levels of build-up welding are carried out in succesof the flange outside
shoes, the
arc welding
welding
the metamorphosis
will
submerged
go above
Wait
for
IOOC,
consider
the
roller
temperature
to
drop
below
or
during build-
for
temperature
middle of welding.
WELDING
12-5
a
APPLIED
HARD
INSTRUCTION
has to be
again before
Even with
welding
during
paint
of more than
and thick
efficiency
of welding.
rebuilding
of the
this
of the
is ample.
If
the
white
momentarily
intervals of 3 - 6C.
at that time.
welding,
204C.
Thermal crayon
In the same way as above, 22 types from 40C
The
range
of
temperature
difference
is slightly
wear at the
place for
build-up
welding
is
temperature
of build-up welding.
out preheating
underlaying
with a low-hydrogen
If this is neglected,
facing.
In cases where
there
metal, underlaying
is also necessary.
repairing
first
12-6
0
to
are available.
In particular,
it is
343C,
and 399C.
530C
UNDERLAYING
when
condition
leads not to
but to destruction
they
From 38 to 1204C
However,
roller
roller
direction;
parts in a crayon
welding
For
lines on the
transparent
there is a tendency
high current
welding.
temperature,
375A.
Therefore,
PARTS
melt
diametric
to 350A;
Therm0
generation of heat.
400 to 450A
OF WEAR
Memo
FACING
welding rod.
WELDING
APPLIED
(5)
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
HARD-FACING
I)
Electric current
3)
melting
fusion
If
For manual
welding,
much effect
on the fusion.
the
arc
increases,
current
is increased,
so the deposited
merged
the
metal
on
fushion
is diluted
effect
in
arc
the polarity
welding,
the
current
rod
The correct
object
being welded.
it is common
(composition)
of
deposited
the
metal
speaking,
the
toughness
and
to
be
metal
wear
resistance],
and
different
soft,
is not
it
the
level
desirable
the
higher
for
submerged
fushion
arc welding,
is greater than
the distortion
with
the
amount
manual welding,
sub-
positive,
the
of deposit
rod (electrode)
polarity
polarity
is
is smaller;
if
is negative,
there is
of deposit
is
current
(AC),
the value
is in the middle.
The reason for this is that about 30% of the arc
heat generated
at the
if the
the
positive
welding
fusion
speed
higher,
so
rod
of the
reduced,
pole.
of
with
has a big
greater.
pole,
is
of
but
so
normal
[generally
has a high
is comparatively
(hard-facing)
large amount
base
base metal
weld
(electrode)
the welding
For hard-facing,
polarity
on the fusion.
However,
is the negative
welding
rod
is
of heat is lower
at
is
rate becomes
larger.
Voltage
For
higher
electrode
the fusion
determined
The
used affects
the
voltage
is from
the
width
metal
of the
and shape is
used.
is,
the
base metal.
becomes
further
the
these
facing,
reasons,
the object
when
carrying
is to reduce
out
the fusion
rate, so generally
the
normal
polarity
hardand
speaking,
rod is
As a result,
wider
and the
becomes flatter.
On the other
narrower
the width
of arced contact
of fuse metal
is, the
becomes.
is deposited
bead is formed.
in
_
Opposite polarity
IP
Electrode
Normal polarity
WELDING
12-7
a
APPLIED
4)
INSTRUCTION
Welding
HARD
welding
rod is
5)
moved)
affects the amount
PARTS
melting speed.
The
OF WEAR
Melting speed
The size (diameter)
FACING
the amount of
melting
speed is decided
by the electric
current density
current
density
The amount
heat is produced
heating is shorter
reduced.
The
bead
because the
melted
fusion)
unit
per
width
welding
time
of fusion is
becomes
rod
adheres
to
narrower
(amount
a
and
of
longer
build-up
wire,
the
rate
is about
20%
6) Lead
(Off-set
between
rotation
&
Suitable bead
Too far from top dead center
12-8
0
WELDING
APPLIED
HARD
INSTRUCTION
(8)
10)Movement
it is impor-
a.
To
transmit
the
electric
current
thereby
of about 12 -
C.
or l/3.
To
preventing
preserve the
d.
To maintain
the
and impurities
alternate
the
concentrating
welding
in one
direction
place,
and welding
order.
For materials
cooling
or
completion
other
of
welding
at
150 - 200C
is effective
and
of the bead.
are melting
to
maintain
the
temperature
by
COOLING
postheating
base metal
air
GRADUAL
the
metal.
e.
POSTHEATING,
melted
with
and wire
from
contact
and to
carefully.
8 mm will
PARTS
FLUX
(6)
OF WEAR
Function of flux
FACING
f.
after
needed by the
metal (bead).
in preventing
on the amount
metal,
the
cooling
differs
markedly.
Thickness of flux
metal
rod is
on the
b.
welding rod.
It
is difficult
formed
(7)
repair
of undercarriage
parts produces a
so machining
a.
with lathes or
the
gas
when
carrying
out
hard-facing,
it
is
flies
off.
is not completely
discharge
welding,
to
during
FINISHING
Welding
appearance and
appearance
the
c.
The cooling
parts
suitable
following
with a grinder.
flux
thickness
should
fulfil
the
conditions.
trode
1,
approx.
burnt
20 - 30 mm
base metal.
12-10
0
WELDING
by
from
APPLIED
5.
EXAMPLES
(I)
HARD-FACING
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
OF HARD-FACING
OF SPROCKET
Cleaning machine
track assembly
r-b
Sprocket
Measurement
WELDING
Painting
12-11
0
APPLIED
HARD
INSTRUCTION
2.
Remove
rust
OF WEAR
Content of operation
Operation
1.
FACING
and
from
teeth
Measurement
wear
welding
of the
teeth.
Decide
the
build-up
measurement.
3.
Build-up welding
a.
Preheating
Before
heat the
tooth
surface
to
welding,
about
pre-
150C
with a burner.
b.
Underlaying
If the measurements
more
welding
than
5 mm,
an
underlaying
underlaying
should
be
one
layer,
The
and
12-12
0
WELDING
PARTS
APPLIED
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
Content of operation
Operation
c.
wear gauge.
2)
width
of the
tooth
is worn,
3)
building
up the tooth
surface,
sprocket
and build
wear
gauge in contact,
up in the direction
of the
tooth width.
4.
Postheating
After
completing
the
build-up
of
the
tooth
by distortion
of the weld,
carry
out
WELDING
12-13
a
APPLIED
HARD
INSTRUCTION
OF WEAR
Content of operation
Operation
5.
FACING
Inspection,
Using a sprocket
measurement
Welding rods
Welding rod
Welding
current (A)
Step
140 -
D5016
Not needed
190-240
05316
Note.
Martensite
12-14
0
180
Min. 15OC
4 or 5
190 -240
Deposited metal
140 -
DF2B-6
(hard facing)
180
4 or 5
E7016
Underlaying
Overlaying
Preheating
AWS
JIS
C
0.30 - 0.44
of DF2B-B
(%).
Si
Mn
Cr
MO
0.88 - 1.47
2.48 - 0.46
2.57 - 3.91
0.50
WELDING
PARTS
APPLIED
INSTRUCTION
(2)
BUILD-UP
LINK
HARD
WELDING
Machine
(MANUAL
FACING
OF WEAR
PARTS
WELDING)
1
I
Initial inspection
7IdI
Trackassembly
Inspection, measurement
Preheating
I
Build-up welding
[
I
Inspection
[
i
r
WELDING
Painting
12-15
0
APPLIED
HARD
INSTRUCTION
OF WEAR
Setting track
assembly in
and build-up
position
link tread,
work
If the
work
is carried
out
outside,
build
cooling
the
welded
portion.
At the
same time, also prevent sudden cooling by preventing the heat from
surface.
Remove
mud
rust
and
Inspection,
measurement
PARTS
Content of operation
Operation
1.
FACING
a.
Inspection
Before carrying
If a crack
link
is cracked,
it cannot
be used
WELDING
APPLIED
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
Content of operation
Operation
b.
Measurement
Measure the link height and decide the amount of build-up.
If there is excessive wear of the top surface of the link boss, and it is impossible to
obtain
the specified
press-fitting
force
even after
press fitting
an
oversize
Pin,
4.
Preheating
Preheat
temperature
of
200 - 3OOC
to
remove
the
the deposit of
when
carrying
any underlaying,
out
there
hard-facing
is a danger of
5.
Build-up welding
When
carrying
out welding,
connect
the
a.
high-tensile
a straight
bead
welding
WELDING
12-17
a
APPLIED
HARD
INSTRUCTION
Operation
FACING
OF WEAR
PARTS
Content of operation
b.
Hard-facing
Start
build-up
welding
from
the
narrow
the
pleted,
welding
at both
ends is com-
method
to
will
be distributed
evenly,
so this
out the end welding of the next link first, and wait for the overheated part to cool
down gradually
to a suitable temperature.
three
facing of the link. If four of more layers are welded, there is a risk of cracking in
the deposited metal or separation of the under-bead.
c.
track
flange,
roller
flange
contact
with
Therefore,
build-up
that
it
part) or in
or carrier
roller
andard
width
orn width
is necessary
welding
to
carry
out
side face,
welding
prevent
roller
rod with
contact
flange
it
is necessary to
use a
during
wear with
steering
to
the
prevent
12-18
0
WELDING
APPLIED
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
Content of operation
Operation
as JIS
DF2B-B
or equivalent.
current
Use a low
bottom
Welding direction
beads.pile up.
d.
wear of the link pin boss top surface, the press-fitting force of
uilding
up top face
Round bar
Welding rods
Welding rod
Dia. of rod (mm)
step
JIS
E7016
4 or 5
(hard facing)
WELDING
DF2B-B
140 -
180
Not needed
190-240
D5316
Overlaying
Preheating
AWS
D5016
Underlaying
Welding
current (A)
4 or 5
140 -
180
Min. 15OC
190 -240
12-19
a
APPLIED
(3)
INSTRUCTION
t
1
Shipping rpection
Transportation
from repair shop
Cleaning machine
I
installation of
track assembly
t
Installation of
track shoes
1
Link assembly
Removql of rust
Setting pattern
12-20
0
Painting
WELDING
APPLIED
HARD
INSTRUCTION
Removing shoe
OF WEAR
PARTS
Content of operation
Operation
1.
FACING
2.
Removing rust
Remove
all the
rust from
surface
surface. If
it will be impossi-
3.
Inspection,
measurement
Inspection
Before carrying
If a crack
link
is cracked,
again, so mark
it cannot
it show that
be used
it does not
Measurement
If there is excessive wear of the top surface
of the link
carry
out
build-up
welding
on such
parts.
If the distance
meter
between
the outside
dia-
the
problem
so
WELDING
12-21
0
APPLIED
HARD
INSTRUCTION
5.
OF WEAR
PARTS
Content of operation
Operation
3.
FACING
on bed
contact surface
out properly,
raise the link assembly and set on the bed with the shoe
so if the alignment
keep a uniform clearance for the left and right link contact faces.
For the spacer, use a flat washer of 2 - 3 mm thickness, and make the clearance equal
on the left and right.
Select a thickness for the spacer which allows it to be inserted easily by hand.
The reason for this is that in the next process, when setting the link in position,
it is
necessary to allow enough room so that the links on either side do not move at the same
time, so use a slightly thinner spacer.
i.
Setting link in
position
alignment
machine,
of the link assembly using the spacer inserted in the link contact face as the
base.
12-22
a
WELDING
APPLIED
HARD
INSTRUCTION
Operation
7.
FACING
OF WEAR
PARTS
Content of operation
A photoelectric
conductor
is used to cut the welding at the joint between link and link,
conductor.
a.
Align the scribing block with the position of the welding machine wire.
b.
C.
Set the
center
photoelectric
of the
allow an adjustment
d.
pattern
conductor
pulled
at a position
in fully.
Move the bed, align the scribing block with the end face of the pin hole, then move
the center of the pattern to the center of the photoelectric
e.
the
Next,
6
_
;02
;j
.-6
.E
:
0.
.-6
C
conductor.
machine,
at the position
where the
1
WELDING
12-23
a
APPLIED
HARD
INSTRUCTION
Operation
1B.
FACING
OF WEAR
PARTS
Content of operation
of flux
Blocks
,3.
Removing spacers
Using
pliers,
remove
the
spacers inserted
to
removing
heat
IO. Preheating
After
the
welding
machine
to
preheat
both
Preheating
by heating the surface may add heat only to the welding surface and not to
the internal
parts, so the best way to preheat the whole link is to pass a nichrome wire
12-24
0
WELDING
APPLIED
HARD
INSTRUCTION
Build-up welding
OF WEAR
PARTS
Content of operation
Operation
Il.
FACING
a.
Align the end of the wire with the part to be welded (link), and weld.
Both ends of the link tread are heavily worn, so start at the end which is more worn.
Start welding
metal.
When feeding the bead width, aligning with the
end face of the first layer of deposited
metal
4
b.
I-
Welding cut
Stepped wear of the link end face is caused by contact with the idler tread and
difference
surface.
If there is extreme
stepped
C.
Set
the wire
holder
about
surface with flux from the flux holder while proceeding with the welding.
WELDING
12-25
0
APPLIED
IfUSTRUCTION
HARD
Operation
FACING
OF WEAR
PARTS
Content of operation
d.
defects
will
be
caused
in
the
welding.
After
direct
maintain
contact
with
the temperature
air and to
cooling.
When carrying
out build-up welding of the link tread with the oil-seald track still
to the built-in
After building up the tread, disassemble, and replace the dust seals.
NITTETSU
WELDING
KOGYO
FIUX
Dia. of wire
(mm)
Welding
current (A)
USH400N
G-50
$3.2
300 - 350
USH450N
G-50
USH-BOON
G-50
w.0
350 - 550
G3.2
400
Wire
28-334
40 - 50
Preheat
(C)
150 -200
NF45
30
75
150-200
FVA-56
Mfl
Si
Cr
MO
USH400N/G50
0.13
2.02
0.65
1.78
0.36
0.17
40
USH450NIG50
0.19
2.22
0.72
2.69
0.60
0.31
45
USH500N/G50
0.22
2.26
0.85
2.85
1 .lO
0.32
50
12-26
0
Welding speed
(cmlmin)
FVA-5
Wire/Flux
Voltage
(V)
1.45
WELDING
APPLIED
HARD
INSTRUCTION
OF WEAR
PARTS
Content of operation
Operation
FACING
After
completing
build-up
welding
of the link
after
in structure
which
resulting in
13.
Removing link
After
completion
of
gradual
cooling,
use a
14. Shaping
If the cutting of the deposit is poor and the bead is too long, to avoid contact with each
link, so it is necessary to shape it with gas cutting.
If there is too much deposit metal, and the link contact surface is lost, also shape with
gas cutting.
If the cut is made at right angles, it will cause separation of the bead or cracking of the
link, so always cut at an angle.
Good
No good
----X--
WELDING
12-27
a
APPLIED
(4)
HARD
INSTRUCTION
PRECAUTIONS
WHEN
BUILDING
UP LINK
TREAD
OF OIL-SEALED
FACING
OF WEAR
PARTS
TRACK
When carrying out build-up welding of the tread surface with the track still as an assembly. it is impossible to avoid heat,
so the seals cannot be reused. In addition,
before starting build-up welding of the tread surface, drain all the oil from
If it is necessary to build-up
the link tread and also to turn the bushing, choose one of the following
two methods
After
carrying out build-up welding of the tread surface with the track as an assembly, disassemble, and replace all
After
disassembling the link, remove the seals, then carry out build-up welding of the link alone. In this case, the
12-28
a
WELDING
APPLIED
(5)
HARD
INSTRUCTION
BUILD-UP
WELDING
OF ROLLER
(MANUAL
FACING
OF WEAR
PARTS
WELDING)
Machine
t
Shipping inspection
I
Transportation
from repair shop
t
1 Roller assembly
I.
Disassembly
1
r---GE&
3
Cleaning parts
Inspection, measurement
Build-up welding
Gradual,cooling
WELDING
1
1
12
Air check
I
Filling with oil
13
I
Painting
-1
1
12-29
0
APPLIED
HARD
INSTRUCTION
Disassembly
OF WEAR
PARTS
Content of operation
Operation
FACING
Completely
part.
details
of
of
disassembly
AND
the
roller
ASSEMB-
LY.)
Cleaning parts
details,
see
DISASSEMBLY
AND
AS-
SEMBLY.)
Inspection,
Inspection
measurement
Before carrying
(for judgement
tread
values table)
and flange.
If a crack is suspected,
flaw detector.
If any crack is found in the roller, remove
the crack by gouging or grinding according
to the size of the crack. Form the part with
an underlaying
hard-facing.
Measurement
Using calipers, vernier
12-30
0
of the
WELDING
APPLIED
HARD
INSTRUCTION
Removing rust
OF WEAR
PARTS
Content of operation
Operation
5.
FACING
removed, it may
5.
To
as individual part
make the
build-up
welding
the photograph.
7.
Preheating
a.
b.
150C.
it is common
surface to become very hot while the temperature of the internal parts does not rise.
Therefore,
it
is important
to
bring
the
and
15OC.
When
furnace,
using a preheating
of
preheat
WELDING
12-31
a
APPLIED
HARD
INSTRUCTION
Build-up welding
OF WEAR
PARTS
Content of operation
Operation
3.
FACING
a.
For idler
In the box-type
idler, there is a 5 mm@ air hole in the side of the idler body. This
Prevents distortion
b.
welding.
Underlaying
If there is extreme
layers of build-up
If the wear is less than 8 mm, and only two layers of build-up are needed, making
one layer of underlaying
with
facing
from
being obtained.
of
hard
c.
Hard-facing
The procedure
Part in
the case of idler; and to start with the flange in the case of the track roller or carrier
roller.
12-32
0
WELDING
APPLIED
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
Content of operation
Operation
Idler
a.
part of idler
idler on a flat surface, and rotate the idler to carry out edging with
at outside edge 0.
EdgingQ
Edging Q
Edging 0
Next,
part.
When carrying
welding
@ of the protruding
rod current
part.
space between the edging with wide weaving concentric with the idler.
TO
spread
welding
100 -
the
point
welding
@
for
heat
100 -
evenly,
after
120 mm,
weld
of the protruding
- l/2
part.
between the
completing
the
first
layer
of welding,
hammer,
layers.
WELDING
12-33
a
APPLIED
INSTRUCTION
HARD
b.
FACING
OF WEAR
PARTS
completion
of the
Next, carry out edging with a straight bead at inside edge @ of the tread.
When carrying
out edging of the outside edge, if a low value is not used for the
After
completion
to carry out
part.
of the tread edging, build up the space between the edges with
the
l/3 -
width
of the weaving
from
welding
Next.
of
the
a
width
and
of
carry
100 -
out
120 mm
build-up
welding
0.
Weld points @
in turn to complete
the whole of
completing
12-34
a
WELDING
APPLIED
HARD
INSTRUCTION
FACING
OF WEAR
PARTS
Content of operation
Operation
*
a.
at outside edge @ of
the flange.
Next, carry out edging with a straight bead at inside corner @ of the flange.
When carrying
out edging of the outside edge, if a low value is not used for the
to carry out
wide
weaving concentric
passes, and
be careful
l/2
to
metal
between
keep
the
as flat as
possible.
After
completing
WELDING
12-35
0
APPLIED
HARD
INSTRUCTION
Operation
FACING
OF WEAR
PARTS
Content of operation
b.
completion
of welding
of the roller
in the center,
start
in the
wears to form a
center
and weld
the
For
single-flange
rollers,
carry
track
out
rollers
or carrier
edging with
a straight
After
completion
- l/2
is a contraction
of
during welding.
umference
12-36
0
WELDING
APPLIED
HARD
INSTRUCTION
OF WEAR
PARTS
Content of operation
Operation
*
I
FACING
Welding rods
Welding rod
Step
E7016
140 - 180
4 or 5
D5016
DF2B-B
WELDING
Not needed
190 - 240
Overlaying
(hard facing)
Preheating
AWS
D4316
Underlaying
I
Welding
current (A)
140 -
180
4 or 5
Min. 150C
190 -240
12-37
0
APPLIED
(6)
HARD
INSTRUCTION
BUILD-UP
WELDING
OF ROLLER
(SUBMERGED
FACING
OF WEAR
PARTS
ARC WELDING)
Machine
t
Initial inspection
Shipping inspection
t
Transportation
from repair shop
t
Installation of
track assembly
I
Installation of
roller assembly
L-i
Rollerassembly
+,
10
t
Filling with
lubricaring oil
I Inspection,
12-38
Cc
measurement
WELDING
APPLIED
HARD
INSTRUCTION
Operation
I.
Removing rust
FACING
OF WEAR
PARTS
Content of operation
removed, it may
!.
Inspection,
measurement
a.
Inspection
Before carrying
and flange.
If a crack is suspected,
hard-facing.
Check that there
b.
Measurement
Using calipers, vernier calipers, and a scale, measure-the
tread and the thickness of the flange to determine
WELDING
outside diameter
of the
12-39
0
APPLIED
HARD
INSTRUCTION
OF WEAR
PARTS
Content of operation
Operation
5.
FACING
on welding machine
(
I ;:~
4?
~~2
/
j
II I/ 6 _~I, I I II
/ : ,, w,?
fl;~~g*
/,,/ #i/ I
For box type idlers, the welding heat will cause
dangerous high pressure inside the box, so make:
an escape hole of $5 diameter
in the body.
:
i
/:
yoke.
1. Preheating
a.
WELDING
APPLIED
HARD
INSTRUCTION
Operation
FACING
OF WEAR
PARTS
Content of operation
of the
b.
face to become very hot while the temperature of the internal parts does not rise.
If there
from
is a large temperature
the
together
internal
parts,
the
difference
welding
in the cooling
it
is important
to
bring
the
and
is to use a pre-
heating furnace.
For the D355 class, leave for two or three
hours inside a furnace at a temperature
of
150 - 2OOC
of
5.
Build-up welding
Carry
out
build-up
welding
15OC.
starting
with
the
parts.
WELDING
12-41
a
APPLIED
INSTRUCTION
HARD
Operation
FACING
OF WEAR
PARTS
Content of operation
To improve the dissipation of heat, when building up the tread of the idler, carry out
edging on the outside, then build up both treads working from the inside to the outside.
When building
To
keep
the
temperature
constant
when
the
plug
hole
in
the
shaft
water circulation
cooling)
of
O-rings
rollers
and
bushings
to
the
minimum.
Use a chipping
which
hammer
forms
on
to
prevent
welding
the
to
remove
deposit
defects
the slag
surface
during
in the deposited
6.
Gradual cooling
welding
is completed,
pass
water through
about 2OOC.
Following
completing
the
build-up
welding
and
then allow it to
outside
prevents
circumference
cracking,
and
is delayed.
This
distortion.
12-42
0
WELDING
APPLIED
HARD
INSTRUCTION
Inspection of roller
OF WEAR
PARTS
Content of operation
Operation
r.
FACING
a.
External
inspection
Use a
assembly
magnetic
flaw
detector
or color
again.
b.
Rotation
inspection
internal
smoothly,
contraction
there has
caused
by
c.
Side clearance
Set the roller assembly on the bench, put a
dial gauge in contact with the end face of
the shaft,
measure
then
the
side clearance
(amount
of
disassemble
and
replace
the
Top clearance
Set the roller assembly on a bench, mark
the horizontal
the
shaft
lower
with
the shaft
a marker,
vertically
then
raise and
to measure the
of the
is more than
the repair
and shaft.
WELDING
12-43
0
APPLIED
INSTRUCTION
HARD
Operation
8.
FACING
OF WEAR
Content of operation
Replace O-ring of
If
is not carried
out during
floating seal
due to the
internal
effect
cooling
of the welding
heat.
Therefore,
use a
9.
Air check
After
replacing
rotate
the
contact
the
roller
of the
through
the
floating
4 or
5 times
to settle the
plug
hole
and
pump
check
in air
for
any
applying
check first
at 0.5 kg/cm.
If there
is no
hold at 3 kg/cm2
After
completion
of the
welding,
flush
the
until
no more
the plug
bubbles come
plug after
checking
the
gone down.
If a special nozzle and volume pump are used to
pump in the oil, the air bleeding can be carried
out
smoothly
completed
12-44
0
and the
filling
of
oil
can be
in a short time.
WELDING
PARTS
APPLIED
HARD
INSTRUCTION
Operation
AND
ASSEMBLY.
AND
ASSEMBLY.
measurement of part
OF WEAR
PARTS
Content of operation
11. Disassembly
FACING
Measure
diameter
calipers.
the
outside
diameter
of the
shaft with
a cylinder
a micrometer;
measure the
inside
with
Standards Table.
14. Correcting
diameter
inside
2)
Lathe method
For
details
of these
methods,
see Correcting
methods.
distortion
of inside diameter
after
build-up welding.
I5
Assembly
WELDING
AND
ASSEMBLY.
12-45
0
APPLIED
HARD
INSTRUCTION
Operation
FACING
OF WEAR
Content of operation
SEIKO
Wire
FIUX
Dia. of wire
(mm)
Welding current
(A)
Q3.2
300 - 500
w.0
400 - 550
US-36
MF-38
us-43
G-50
USH-250N
G-50
Voltage
(V)
28-34
Welding speed
(cm/min)
40 - 50
JIS
Example of chemical
composition
(%I
AWS
US-36XMF-38
YSF53-W41
US-43XG-50
YSF43-Wll
F74-EH14
F62-E L8
USH-250XG-50
0.:6
Mfl
1.84
Si
0.60
MO
0.76
SEIKO
N ITTETSU
WELDING
K6GYO
12-46
0
PARTS
FIUX
Dia. of wire
(mm)
Welding
current (A)
USH400N
G-50
$3.2
300 - 350
USH450N
G-50
USH-500N
G-50
$4.0
350 - 550
NF-45
$3.2
400
Wire
Voltage
(V)
Welding speed
(cmlmin)
Preheat
( C)
28 - 34
40 - 50
150 -200
30
75
150 -200
FVAQ
FVA-56
WELDING
APPLIED
(7)
HARD
INSTRUCTION
CORRECTING
DISTORTION
When hard-facing
DIAMETER
AFTER
BUILD-UP
OF WEAR
PARTS
WELDING
is carried out on the track roller, carrier roller, or idler, the welding heat will cause contraction
OF INSIDE
FACING
of
However,
to a certain extent
it cannot be completely
by control
avoided. Therefore,
smaller.
(The contraction
or distortion
of the roller
during welding.)
of the roller must be measured after carrying out the build-up welding. The inside
must be corrected to the standard dimension using a method such as one of the following
1)
2)
Lathe method
methods.
center part of the roller and softens it, so it loses its resilience.
Welding build-up which causes softening of the internal
desirable to give the roller heat treatment
Of the two
methods
so it is
portion
by cutting
and
grinding.
The build-up weld at the outside diameter
stress of the contracted
worn,
the internal
causes contraction
that
returns to that
during welding must be carried out carefully to make the amount to be repaired (amount of contraction)
as
small as possible.
Sizing disc method
The sizing disc (disc for short) is shaped rather like a tire as shown in
the diagram
completion
then remove all dirt and rust from the inside diameter
of the roller,
the measure-
Taking
WELDING
into account
12-47
0
APPLIED
INSTRUCTION
The press-fitting
D80/85
HARD
FACING
OF WEAR
PARTS
force is required,
so a
of contraction
first a small disc and then a large disc to correct the inside diameter
in
two stages.
Generally
a diameter
inside diameter of the roller is used to allow the resilience of the roller
to form the specified inside diameter for the roller. However, in some
cases, the core of the roller has been annealed and softened by the
welding heat, and has lost its resilience, so if an oversize disc is used,
the final inside diameter
Y)
OS
In addition,
20 tons
in America,
the following
kinds of combination
used.
(final disc:
a second and third stage of discs, each 0.07 larger than the
t-85-1
12-48
0
Stage
Stage 2
Stage 3
WELDING
APPLIED
(8)
INSTRUCTION
HARD
FACING
OF WEAR
PARTS
t
Shipping
lnstallatio,n
WELDING
inspection
Shoe
of shoe
12-49
a
APPLIED
INSTRUCTION
HARD
Operation
1.
2.
3.
FACING
OF WEAR
PARTS
Content of operation
After
rust
cleaning
Measurement
(for judgement
standard values,
in the diagram,
Cutting the
Generally
grouser
becomes an arc shape. Measure the standard dimension for the lug height from the plate,
speaking,
the
corners
so the grouser
Basic
dimension
Height
Of weld
lug material
Cutting
line
If there is extreme wear of the grouser below the cutting line, first build up the grouser
to make a level surface.
Build-up
Build-up
\G/
If there is little wear of the corners, weld on the lug, then build-up from the lug material
to fill in the gap.
r
12-50
a
--
Buid-up
WELDING
APPLIED
Operation
4.
HARD
INSTRUCTION
OF WEAR
PARTS
Content of operation
Set the lug material on the grouser, and spot weld at three places (edges and center).
material
Lug
5.
FACING
Welding lug
material completely
front
layer,
in turn
to
Spot
weld
the
back and
a bead of
less than
weld
make
from
layers,
then
finally
weld
a continuous
fully,
the
maximum
temperature
between
layers
to
the
With
if the welding
the shoes
installed to the link assembly, do not weld the lug on to each shoe as
a continuous
operation.
After
completing
units or
operation,
the
the lug
Welding
rod
Dia.
of rod
Welding
current
Remarks
(A)
(mm)
AWS
JIS
D4316
190
E7016
Covered
250
arc rod
rod
Dia.
of rod
Welding
AWS
YCWl
E70S-6
Y FW24
current
Remarks
(A)
(mm)
JIS
e1.6
170
550
@2.0
200
650
$1.6
200
450
Q2.0
300
550
. Solid wire
* Carbon dioxide
. Flux wire
* Carbon dioxide
Q5.0
200
450
E70T-1
arc welding
arc welding
D5016
E7016
Covered
arc rod
D5316
WELDING
12-51
0
APPLIED
(9)
INSTRUCTION
WELDING
FACING
OF WEAR
PARTS
HARD
from other shoes because they are made from high-manganese steel, which hardness is increased
on rock by peening.
the operation
shoes.
The rock shoe lugs presently available are for the D150/155
and D355.
On both models, if the grouser height approaches 30 mm, it is necessary to consider rebuilding with a lug.
1)
a.
b.
Generally
and the grouser forms an arc shape. Cut the grouser with a grinder
or arc, or use gouging to make the height of the grouser 30 mm
from the plate, then build up both corners to give a level finish to
the mounting surface for the lug.
cut
Build-up
3)
Build-up
Spot welding
Align the position of the side rib, then align the center line of the lug at right angles to the center line of the
grouser as shown in the diagram, and spot weld at the ends of the lug.
Spot welding
3)
1st layer
When
in the diagram.
4)
Following layers
When the first layer is finished, weld the following
layers in the
12-52
0
WELDING
APPLIED
5)
HARD
INSTRUCTION
l-2mm
FACING
OF WEAR
PARTS
Lw3
Grouser
6)
welding the lug, weld the side rib in the same way in the
When welding
so divide the main welding into two or three layers. In this case,
do not weld each layer on one shoe continuously.
Welding rods.
Welding rod
JIS
AWS
DFME-B
Welding current
(A)
Dia. of rod
(mm)
95 - 145
fl.0
135 -
@5.0
* equivalent 16 Mn -
a.
Welding bead
The
Used to:
180
Lug welding
C.
a medium
Time
until
making
20
the center
amount
of
underlaying
will
be needed
for
both
Cooling, drying
After
is carried
100 mm.
for
1 st layer
16 Cr.
Remarks
on
cooling,
brush,
then
blow
dry it completely
compressed
air
of welding.
Lug height
D355
195-32-l
1560
65
D150.155
175-32-l
1560
50
WELDING
Rebuild grouser
height
Material
30
SCMnH21
12-53
a
APPLIED
HARD
INSTRUCTION
(10) WELDING
LUG 0~
01 L-SEALED
FACING
If shaping of the grouser by gas cutting and welding of the lug is carried out continuously
high temperature.
PARTS
TRACK
OF WEAR
must be paid to
is carried out.
Example:
Process
1. Gas cutting
to shape
g1-0user
l
@
Example
Process
2.
of order
1426@i527@l628@1729@
I3
the
Process
Process
Process 6.
5.
Main
welding
of 2nd
layer
of face
Main
7.
welding
of 2nd
layer
of face
* Follow
the order for
the shoes given in the
the
shoes
diagram
12-54
a
given
in the
diagram
above.
above.
WELDING
APPLIED
HARD
INSTRUCCTION
(11) WELDING
REPAIR
Ripper teeth
Therefore,
OF RIPPER
include
OF WEAR
PARTS
TEETH
high-manganese
the method
FACING
of welding
teeth.
steel
teeth
can
be distinguished
by
using a
hardened
possible, then
carry
type or D316
(AWS.
out underlaying
E316)
with
a low-carbon
DFME
Underlaying
DF2B-4 or DF3G4
I-
1
Specified dimension
Angle build-up:
Fig. 1
WELDING
12-55
a
APPLIED
HARD
INSTRUCCTION
When selecting
conditions
the build-up
welding
FACING
OF WEAR
tion is not made simply from grinding wear. Other elements, such
as gouging wear
extent,
and
impact
to some
build-up
rod is selected for soft soil and sand, factors such as scratch wear
become
more important,
base metal
is high-manganese
good weldability
must be selected.
1 gives welding
Table
Table 1.
Finishing layer
Build-up
Underlay
Welding rod
Soil condition
JIS
Soft rock,
hard soil
AWS
DFME or
D308
D316 type
Si
Mn
Cr
DFMA type
DF2B-4
tvpe
l2
D308or
E3 16 type
AWS
JIS
Build-up method
JIS
AWS
DF2B-4 or
DF3C4
DFBC-B
+4
EFeCr-AI
Lattice build-up
Angle build-up or
Lattice build-up
MO
After
building
auxiliary
When
up as above,
the surface
finishing build-up.
building
up
high-manganese
steel teeth,
the
following
after
If this precaution
is neglected,
there
of the base
is a high risk of
peeling at the border between the base metal and the weld. The
DFMA
type welding
steel struc-
ture, so when depositing this type of welding rod, the same precautions are necessary.
12-56
a
WELDING
PARTS
APPLIED
2)
HARD
INSTRUCCTION
FACING
OF WEAR
PARTS
of welding
Underlaying
low-alloy
*;,;;
ziz,el
b.
When repairing,
Joint
Fig. 2
Procedure for welding repair of markedly worn
high-manganese steel teeth - Adding steel
welding.
Table 2.
Underlaying
Additional
JIS
High-manganese
Low-alloy
After
Main welding
steel
AWS
JIS
AWS
E316 type
DFME or
D316 type
E316 type
DFME or
D316 type
steel
steel
D316 type
completing
the joint,
type
of DF3C4
steel, carry
out layered
build-up
with
a tungsten
type.
When carrying out the welding, to prevent overheating,
carbide
follow the
Underlaying
Underlaying
The second method is to use soft steel. In this case, underlay the
tooth tip with
DFME
cut the mild steel to the correct shape and connect with a D316
type welding rod. After that, build-up until it reaches the original
shape.
When carrying out building up, use a welding rod shown in Table
3 to match the soil condition.
Fig. 3
_
,
,,
rroceaure ror welalng repafr ot markedly
type welding rod as shown, it is necessary to carry out underlaying with a DFME
type or D308
high-manganese
steel teeth -
Inserting
worn
soft steel
Underlaying
of tooth
tip
Underlaying
of soft metal
Build-up
Soil condition
JIS
AWS
JIS
AWS
E316 type
D316 type
JIS
AWS
JIS
AWS
DFME
D308
D316 type
E308
E316 type
DFME type
E308 type
E316 type
DF2B4
type
_
\(
WELDING
12-57
APPLIED
HARD
INSTRUCCTION
After
FACING
OF WEAR
3)
steel teeth
shape. However,
if the amount
of build-up
is up to
using the
if the amount
with a D4316
steel teeth
Build-up
Underlaying
Soil condition
200 - 25OC
12-58
0
-Temp.
Preheating
JIS
AWS
CM316 type
E7016 or
E70,B
JIS
between pass
AWS
WELDING
PARTS
APPLIED
INSTRUCCTION
(12) REBUILDING
HARD
CONICAL
NOSE
adapter
with
a conical
OF WEAR
PARTS
Conical
FACING
nose
Point gauge
nose surface
is made of a very
hard
rebuilding
the conical
the maker
nose surface.
However,
1.
Spot weld the black marks, and build-up the tip with a straight
bead.
2.
Grind the welded part with a grinder, insert the point, and tap the
tip of the point towards
If there is extreme wear of the whole nose, carry out spot welding
on other parts of the nose and finish in the same way as in Step 2.
Welding rod
JIS D4316
*1
or D5316
to align
first carry
out spot welding, then align these spots with the point to use
as a guide when finishing.
After
tion of contact.
After
4.
building up the nose surface, the back of the pin hole in the
point must be 0.8 - 2.4 mm in front of the pin hole in the nose.
To obtain
a suitable
the spot-welded
5.
6.
fit, correct
and
portion.
with
the point
need to be
WELDING
12-59
0
Procedure
for repairing
water from
1. Applicable
2. Action
leakage of
radiator
core
range
..
starts leaking
location
13-2
of water leakage
.
.
Disassembly
7.
8.
Repair procedure
10. Assembly
13-2
13-3
13-3
13-5
results
13-8
of core assembly
11. Pressurizing
Reassembly
13-2
13-2
.
.
6.
9. Checking
WELDING
13-2
5. Removal
12.
13-2
3. Confirming
4.
check
13-8
13-9
13-9
13-1
a
APPLIED
INSTRUCCTION
PROCEDURE
1.
REPAIR
FOR
APPLICABLE
REPAIRING
LEAKAGE
OF WATER
4.
RANGE
FROM
FACTORS
(1)
OF RADIATOR
RADIATOR
CAUSING
OIL COOLER
CORE
WATER
LEAKAGE
is important
Note:
This
repair
procedure
manual
is applicable
can be taken
problem.
tank
with
other
product
applicable
quality
to
problems.
Therefore,
and
to prevent
reoccurrence
of the
It is not
(2) If there
is water
leakage
from
around
the
stress around
deformation
the
soldered
of the
radiator
AND
ACTION
TO TAKE
WHEN WATER
STARTS
joints
caused
guard
LEAKING
(I)
the radiator
machine
apply
the
equipment
immediately
brake
by
and heat
to a
lock, then
then follow
the instructions
5.
in the
REMOVAL
Remove the radiator assembly from the machine.
filler cap
CONFIRMING
LOCATION
OF WATER
LEAKAGE
4- _
the
radiator
still
installed,
remove
the
upper
tank,
core,
and
lower
5
5
tank
through one
than 2 kg/cm2.
high,
the
upper
may be deformed
*
tank
or lower
tank
or damaged.
Another
leakage
between
soapy water,
to
to
method.
13-2
0
locate
the
leakage with
this
1.
Upper tank
2.
Lower tank
3.
Core
4.
Gasket
5.
Bracket
6.
Core clamp
WELDING
APPLIED
6.
REPAIR
INSTRUCCTION
OF RADIATOR
AND
OIL COOLER
DISASSEMBLY
Remove
the upper
tank
and dis-
plate
and tank,
to make
it easy to
-Core
Wedge
Lower tank
7.
REPAIR
(1)
TOOLS
AND
Repair equipment
EQUIPMENT
and replacement
parts
Qty
Gasket
For the mating surface between the core and the upper
and lower tanks (replace
when reassembling)
Shim
Solder
(15 kg)
Flux
(powder)
WELDING
and tools
Remark
Equipment
@
(2)
7.5 kg
45 mm type solder
JIS, H4341, H40A
ASTM, B32-70,40A
(equivalent)
500 g
13-3
a
APPLIED
REPAIR
INSTRUCCTION
Pressure detection
water bath
OF RADIATOR
AND
OIL COOLER
Propane burner
*
Adjust the size of the flame
as shown
in the photograph.
Pressure gauge
Pressure
gauge
pressure regulator
*
When testing
for
5 or
10 kg/cm,
and
It is also possible
and rubber
openings
seat to make
Brush:
For coating
Brush:
For cleaning
Wire:
For cleaning
flux
between
core
solder
WELDING
APPLIED
8.
REPAIR
INSTRUCCTION
REPAIR PROCEDURE
*
Regardless of the size of the leak, solder the
2)
OF RADIATOR
AND
OIL COOLER
again.
(1)
Burner
(2)
3)
Cleaning method
Remove
compressed air.
*
The whole
or grit with
of the
leakage,
and
must be
steam or
plate
surface.
*
the
nn
Wire
4)
brush
(small)
Tube
1) - 3) above.
WELDING
13-5
a
APPLIED
(3)
REPAIR
INSTRUCCTION
Removing
temporarily
repair
material.
If any
(4)
OF RADIATOR
AND
OIL COOLER
Coat
soldering
part
between
tube
and
stop the
1)
Bars
Leak
contact
hardens
with
when
air, so when
it
comes
2)
into
2)
Bars Leak,
3)
is repeated.
4)
Supply
small amount
of solder from
the
additional
operations again.
3)
cleaning cores
the
whole
circumference,
cleaning operation
repeat the
I)
//
/
B-(2).
II
If the burner is used to heat,
the supplied solder will penetrate
the inside and the surface will be
5)
First block
yond
1~
13-6
0
WELDING
a zig
and
APPLIED
REPAIR
INSTRUCCTION
6)
Continue
water
4)
moving continuously
OIL COOLER
to shape the
build-up.
*
AND
plate joint.
burner
OF RADIATOR
Header plate
000,
flow
off,
so always
keep the
burner moving.
*
block,
blocks
7)
lmm
Min. 1
out
back fillet
tube root.
1)
Section A-A
Detail of joint
5)
Tube root
whole
circumference
2R around
of
the
joint
2)
Coat
the
soldering
part
with
flux,
then
4%
So\der
-L-
flux,
then
Coat
Melt
the
the
solder
header
soldering
with
the
part
with
temperature
of the
WELDING
13-7
a
APPLIED
9.
REPAIR
INSTRUCCTION
CHECKING
RESULTS
OF RADIATOR
70. ASSEMBLY
AND
OIL COOLER
OF CORE ASSEMBLY
Header
Section X-X
Replace gasket
with new part
Tightening
fOrclue
3.5 - 7.5 kgm
----L
soldered
Check items
(1)
parts in
them completely.
*
To remove the gasket, scrape off with a
Is the condition
Is the condition
the
Is the condition
Is the condition
of the approx.
and
clean
the
surface of
surface so that
the
problem.
2R fillet at the
sur-
core,
(3)
Carry
for the
lower
(4)
horizontally
13-8
a
WELDING
APPLIED
(6)
REPAIR
INSTRUCCTIDN
OF RADIATOR
AND
OIL COOLER
Bolt:
inserting
all the
circumference,
tightening
two
bolts around
workers
should
the
start
(1) (2) -
(1) (2)
When all the bolts in line A are tightened,
tighten the bolts in line B.
(7)
Carry
out
to install
the
11.
PRESSURIZING
(1)
CHECK
(2)
After
fitting
in
1.5 kg/cm*.
A simple method
the
tank
tubes
and
plate
with
If the
pressurizing
of the
soapy water,
then
to check accurately.
there
is
12.
REASSEMBLY
(1)
If the
remove
radiator
passes the
pressurizing
check,
core
assembly.
(2)
Install
the
radiator
core
assembly
to
the
radiator frame.
*
Before tightening the bolts, if the clearance
between
the radiator
(4)
& Maintenance
see
Manual.
replace
WELDING
13-9
0
APPLIED INSTRUCTIONS
20
REPAIR OF BULLDOZERS
SHOVELS BY WELDING
MAIN
AND
DOZER
FRAME
Example
TRACK
FRAME
Example
Preventing
wear
Scheduled
repair of blades
Repair
of blades
and rebuilding
BUCKET
Types
WELDING
20-
20-I
20-I
a bucket
ADAPTER
20-20
20-23
. .
Replacing
of blades
of D455A
BLADE.........................
Types
20-
of D455A
20-70
20-70
of buckets
edge.
SHANK
20-3
..
20-73
20-81
20-83
APPLIED
INSTRUCTION
MAIN
FRAME
1. MAJOR
BULLDOZERS
AND
DOZER
SHOVELS
(Example of D455A)
MAT ERIALS
OF MAIN
FRAME
KES symbol
Metal group
High tensile strength rolled steel plates
SHTGO
SM41 B
SC63W, SC55W
Ir
The
materials
and dimensions
to change without
notice
provements in technology
2.
1)
CHECKING
of products
are subject
in order to incorporate
im-
or method of manufacture.
FOR CRACKS
Using a high-pressure washer or steam cleaner, carefully remove sand, soil, oil and grease from the main
frame.
2)
Check sections @
and @
in Fig. 1 especially
Fig. 1
20-2
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
3.
REPAIRING
CRACKED
SECTIONS
1)
AND
DOZER
SHOVELS
BY WELDING
Material:
KES SHTGO
Material:
KES SM41 B
Fig. 2
(a)
cover).
Recheck
for cracking
After confirming
: JIS D5816
AWS E90 16
(Preheating/postheating
(5)
the material.
After
corners
to the
dimensions
marked
* to
about C3.
Fig. 3
WELDlNG
20-3
0
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
cover).
(4)
Td be gouged.
Fig. 4
(5)
(6)
Clean
the
Material:
tack welding.
gouged section,
Fig. 5
KES SS41 P
ASTM A283Gr.D
Part @
JIS D4316
AWS E70 16
(Preheating/postheating
(7)
then
finish
smoothly
with
grinder.
(8)
Install
bracket
mudguard
(198-54-l
8790)
for
the
(198-61-15271)
or (198-61-15191)
for the
side cover
B&in
frame
Fig. 7
20-4
0
WELDING
APPLIED
2)
INSTRUCTION
BULLDOZERS
Material:
AND
DOZER. SHOVELS
0B
KES SHTGO
Material:
KES SC63W
Cracked section
Material:
KES SM41 B
Material:
KES SC55W
Fig. 8
(a)
Remove
the
cracked
gouging or with
surface with
section
by
arc air
a grinder.
cracking
by means of
Gouge the
ends
of
plate
the
30
mm
beyond
cracks
on
the
the
surface
(Fig. 7).
Range to be gouged
* Take care not to blow the air
through the plate.
.&eering caseside
Main frame side
Section A-A
6 mm in diameter
Fig. 9
Welding rod:
JIS D4316,
AWS E7016
(Preheating/postheating
WELDING
20-5
0
APPLIED
(b)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
replace it
finish
Then,
recheck
cracking
check,
the
gouged
it.
a grinder.
surface
for
penetrant
with a grinder.
Welding rod:
JIS D4316
AWS E7016
Preheating/postheating
not necessary.
are
Steering caseside
Area to be gouged
*Take care not to blow the air through the plate.
/
Main frame side
Fig. 10
plate @
shown at
(31 Make reinforcement
right, and install it to the bottom plate
according to the following
procedure.
l
(4)
Finish the surface to which the reinforcement plate will be welded with a grinder.
*
Remove
paint,
rust and
carbon
layer
Fit
reinforcement
plate
to the base
If there
ment
because of
Material
KES SS41 P
ASTM A283Gr.D
reinforcement
plate
to the bottom
plate.
Welding rod:
JIS D4316,
(Preheating/postheating
20-6
a
Thickness:
16 mm
Reinforcement plate @
Fig. 11
AWS E7016
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
AND
B-
1G-v
(D
Xl&
DOZER SHOVELS
125
Section A-A
Reinforcement
plate
Fig. 12
Remove this after welding, and finish the
surface of base metal with a grinder.
/
min.
Reinforcement
plate
Wedge
Fig. 13
*
(This
T is 2 mm or
more).
Fig. 14
WELDING
20-7
0
APPLIED
TRACK
(Equipped
1.
BULLDOZERS
INSTRUCTION
FRAME
DOZER
SHOVELS
(Example of D455A)
with a reinforced
MAJOR
AND
MATERIALS
OF
FRAMES
TRACK
[Reference]
\
SHTGOH
Metal group
KES symbol
SC55W. SC63W
ments in technology
2.
1)
CHECKING
improve-
or method of manufacture.
CRACKS
Remove the soil and sand from the track frame with
a high pressure washer or steam cleaner.
clean the surface with
a pneumatic
If rusted,
wire brush or
for cracking
by means of the
If it is difficult
remove
according
to the section
Assembly
20-8
0
welding,
the
track
frame
assembly
on Disassembly
and
WELDING
APPLIED
3.
INSTRUCTION
REPAIR
BULLDOZERS
OF CRACKED
SECTIONS
AND
DOZER
SHOVELS
BY WELDING
rame
and brace
Fig. 1
I)
@
Cracked section
Material:
Fig. 2
la)
KES SHTGO
Detail of section @
(I)
Remove
the
cracked
section
gouging
and
prepare
it for
by
arc air
rewelding
as
shown in Fig. 3.
(4)
After confirming
JIS D5816,
(Preheating/postheating
WELDING
Area to be gouged
AWS E9016
Fig. 3
20-9
0
APPLIED
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
(5)
up by welding,
on section @,
then
finish
with
After
with a grinder.
Fig. 4
(b)
Remove
the
cracked
section
by
Approx. 25
arc air
(3)
t---I/
gas as shown in
, insert it through
Fig. 5
(5)
JIS D5816,
Build
up the
AWS E9016
Detail of part
Material:
01
0
KES SS41 P
ASTM A283Gr.D
Fig. 6
20-10
0
WELDING
APPLIED
2)
INSTRUCTION
BULLDOZERS
AND
DOZER_ SHOVELS
Cracked sections
Area to be gouged
*Take
Section A-A
Fig. 7
(a)
Make
Fig. 8
holes 8 mm diameter
at IO mm from
and take
care
not
to
blow
the
air
Fig. 9
WELDING
20-11
0
APPLIED
3)
INSTRUCTION
BULLDOZERS
AND
DOZER
SHoVELS
-Reinforcement plate
Material: KES SHT80A
Cracked sections
Viewed from under the brace
Fig. 10
Remove the cracked section by arc air gouging
(a)
b)
er, weld
it as shown
in
Fig.
9, then
finish
(cl
Material:
plates.
Material:
Part @
The dimensions in
Part @
(d) Weld
reinforcement
the position
plates @
and @
and @
or 03
Reinforcement
plate
Welding
rod:
JIS D4316
AWS E7016
20-l 2
Cc
Fig. 12
WELDING
APPLIED
4)
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
No.
Part Name
Part No.
198-30-l
198-30-I
PLATE
1530
1540
Qty
Material
4
(one side)
KES SHTGO
(High tensile
steel plate in
60 kg/mm2
class)
2
(one side)
PLATE
Shape
6
32
KES SHTGO
Welding rod:
b)
Remove
the
gouging
as shown
weld
cracked
in Fig.
zone
by
arc air
13 to prepare
for
rewelding.
Deposited metal
Fig. 13
*
Gouge
not
also the
only
the
area shown
cracked
section
in
14,
Fig.
but
even if
WELDING
20-l 3
0
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
to be
Fig. 14
(c)
After
gouging,
with
a grinder
remove
or
the
pneumatic
chipping
Deposited metal
ham-
Do
not
more
build
than
terfere
with
and @
to
If
step).
up
2 mm
the
deposited
(so that
the
welding
be
performed
it will
for
parts
in
it is higher than
metal
not in@
the
2 mm,
next
cut it
with a grinder.
(e)
Weld
parts @
Fig. 15
and
as shown
in
Fig.
16.
x4
Four
daces
Fig. 16
*
Weld
parts @
and @
by
setting
their
with
a grinder.
and bending
them
Weld them
along the
by
base
20-14
0
WELDING
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
Detail of @
Fig. 17
WELDING
20-15
cc
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER
SHOVELS
BLADE
1.
MAJOR
1)
TYPES
TYPES
AND
AND
USES OF BLADES
USES
(a ) Angledozer
The frame
dozer
supporting
has a C-shape.
the
blade on an angle-
In addition
to carrying
of the
It also can
(b)
Straightdozer
The frame supporting
continuous
strengthening
the
heavy
frame
cutting
and
but can
work
by
its connection.
Straight tiltdozer
The
straight
draulic
tiltdozer
cylinder
is equipped
installed to straightdozers).
can perform
with
a hy-
tilting
is
I OOF349
(d)
Udozer
The Udozer
of a straight
I OOF350
20-l 6
0
WELDING
APPLIED
(e)
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
Coaldozer
The coaldozer
In-
blade
the
will
material
Therefore,
the
and is designed so
plates.
I OOF35
n
(f)
Chipdozer
.The chipdozer
In-
of very low
that
large capacity
so
at one time.
IOOF352
kl)
SnowplOw
The
(V-plow)
snowplow
has a V-shaped
blade, and is
I OOF353
(h
1 Pusher plate
The
pusher plate
front
is bolted
of blade to protect
or welded
it when
to the
pushing a
scraper, etc.
IOOF354
WELDING
20-17
0
APPLIED
BULLDOZERS
INSTRUCTION
2)
MAJOR MATERIALS
D150.155
OF BLADES
[Reference]
STRAIGHT
TILT
& STRAIGHT
SHTllOA
D60.65
AND
FRAME
----__
[ Reference1
STRAIGHT
TILT
DOZER SHOVELS
SCSiMn4
& STRAIGHT
FRAME
SCSiMn4
SC46
\
S43c
SHT60 _
ss41 P
s53c
Metal Group
Rolled steel for general structure
ss41 P
SM41
20-18
0
KES Symbol
SHT60,
SHTllOA
SC46
S43c. S45c, s53c
SCSiMnl H, SCSiMn2H.
SCSiMn4
WELDING
APPLIED
3)
INSTRUCTION
INSIDE
BULLDOZERS
STRUCTURE
SECTIONS
SUBJECT
OF
BLADES
AND
DOZER
SHOVELS
AND
TO WEAR
plate which
a rear
directly
plate
which
support
those parts.
worn.
used without
being repaired,
Rib plate
the front
&xztion A-A
new reinforcement
rib plates would
hours.
front
installed
is worn
too
much,
the
Detail @
the distributors
Tip of blade
//
\
Plate to which rib
plate is installed.
,
&tieal
Detail @
WELDING
20-19
a
APPLIED
2.
INSTRUCTION
PREVENTING
BULLDOZERS
WEAR
OF THE
DOZER SHOVELS
BLADE
AND
procedure
with reinforcement
on whether
those protective
measures have
been taken.
If plates are installed to a worn or deformed
front
out.
Therefore,
time.
I)
TYPICAL
PROTECTIVE
MEASURES
FOR
BLADE
(a)
procedure
the entire
front
face of the
For
large-sized models,
blade
is reinforced.
available as options.
The
reinforcement
three
or
five
face is
generally
divided
However,
pieces.
reinforcement
action B-B
smaller than the blade to account for the allround fillet welding allowance.
Reference
D155A
D65A
Section A-A
Material of front
reinforcement plate
9mm
Thickness
JIS
AWS
Welding rod
SHT
KES SHTllOA
KES SHTGO
ASTM A514-65(G)
(High
tensile
12mm
D5016
E7016
strength
rolled
JIS
AWS
D5816
E9016
Detail @
Section E-E
welded structures)
SHTGO:
Tensile strength
60 kg/mm2
class
SHTllO:
class
20-20
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
To further
reinforce
AND
DOZER
reinforcement
used without
SHOVELS
plates,
repair
until
the
blade can be
Section D-D
a hole is made on
those plates.
When
the
reinforcement
plates
are worn
so
install
the
reinforcement
Detail @
plates.
plates
Section
C-C
snugly
another
machine,
then
tack-weld them.
Reference
Material of wear
plate at section QI
(b)
D85A
For
S53C
KES S53C
ASTM A576-1049
KES SHToA
Reinforcement
D155A
precautions
(ASTM
for
welding
A576-10491,
plates
see (d).
made
of
Installation
KES
of
* Reinforcement
plate
In this method,
reinforcement
strip plates of
front
face of
blades
reinforced
strong
as those
reinforcement
the
blade.
Although
by this method
reinforced
the
are not as
by the
all-surface
material
amount
of
standard
of cutting
addition,
work
width
Reinforcement
plat
bending roll,
* Pusher plate
is used, the
can be reduced.
In
Installation
of pusher plate
Reinforcement
Reference
D65A
KES SHTGO
Material of reinforcement plate ASTM A514-65(G)
Thickness
12mm
D155A
KES SHTGO
ASTM A514-65(G)
19 mm
For D60A
are available.
The reinforcement
pusher plates
WELDING
20-21
0
APPLIED
INSTRUCTION
Installation
(d)
Since
BULLDOZERS
AND
DOZER
SHOVELS
If
plates.
used as the
discarded
reinforcement
cutting
edges are
will increase.
Reference
D65A
Material of
wear plate
D155A
@
KESSS41P
ASTM 283Gr.D
@
0A
08
Thickness
KESS53C
ASTM
KESSM416
ASTM
A576-1049
A36
KES S53C
ASTM
0A
08
12mm
16mm
* Reinforcement
A576-1049
Reinforcement plate made of
a discarded cutting edge
19mm
22mm
The reinforcement
plates
Preheating temperature:
29OC
Postheating temperature:
590 to 68OC
Welding rod:
AWS E7016
(e)
JIS D5016,
the
face
bottom
and
outside
faces
of
* Reinforcement
of frame
the
frames.
Welding precautions
plates
and the base metal to 1 mm or less. (This is required to maintain the quality of welding.)
(2)
before
use.
rods, especially
If moisture
low hydrogen
remains
in the
Reinforcement
of frame
1 mm or less
i
I\
20-22
0
WELDING
APPLIED
3.
INSTRUCTION
PLANNED
BULLDOZERS
REPAIR
of the
SHOVELS
to reduce the
on the
Planned
machine.
repair
DOZER
OF BLADES
AND
to estimate when
will be required,
and prepare
required
time of the
can be prepared
in advance,
making
machines
according
I OOP80 I
it
To
Estimate of repair/rebuilding
BASIC
AND
CONCEPT
OF
REBUILDING
[Example]
ESTIMATING
REPAIR
When the
blade is new.
TIMES
If a blade is continuously
ditions,
time
to the operating
are worn
mated.
Omm
i)
2350H
OH
thickness
15mm
x=?H
3550H
X=?H
of the most-
length, in
9mm
1200H
Estimated time
to repair
18
Calculate the wear of the blade from the thickness of a new plate.
iii)
Read
the
hour
meter
of
the
machine
and
blade
(or
rebuilt
blade)
was installed.
2000
Operating time of blade (H)
VI
x = 1200 x (+,
repaired,
in
iv)
the
hour
meter
= 2000 (H)
the
reading
recorded
when
the
blade
should
be
Therefore,
the
blade
should
be
repaired
when
the
hours.
put into
operating
time
same.
WELDING
20-23
0
APPLIED
2)
FIELD
(a)
BULLDOZERS
INSTRUCTION
MEASUREMENT
DOZER
SHOVELS
OF WEAR
Sections to be measured for wear
AND
are
(2)
the field,
(3)
(4)
Since
End bit
plate
Measuring instruments
Auxiliary
The
instruments
(1)
Wire brush
(799-I 01-2000)
(2)
Sandpaper
(2)
(3)
(3)
Straight plate
(4)
Square plate
tools
Record binder
or notebook
Deformation
of
Ed
3
wear
center
of
allowance of
new one: 50mm
Remaining
allowace:
20-24
0
CuttInS
edge
26
45%
WELDING
APPLIED
3)
BULLDOZERS
INSTRUCTION
CHECKING
THE
FINDING
THE
WEAR
CONDITION
REMAINING
4.4
I
17. I
3.6
16.2
1.2
2.8
15.2
9.0
0.5
2.0
14.3
30
8.4
9.8
I .2
13.3
35
7.8
9.
0.4
12.4
40
7.2
8.4
45
6.6
7.7
50
6.0
7.0
zJ-
5.4
.--
6.3
--.
4.9
5.2
15
- one
been worn
for the
20
9.6
to the
25
ratio
of time taken
condition
blade.
The remaining
of time
life
wear allowance,
in case of a cutting
9.6
fi
18.
Il.4
BSUreC
ue
9.5
7.2
8.6
5.0
6.4
7.6
5.3
5.6
6.7
4.5
4.8
5.7
3.8
4.0
4.8
3.0
3.2
3.8
2.9
65
4.2
the top
70
75
)bta
lerce e
- wea,
80
2.4
2.6
85
I .8
2.
2.3
2.4
90
I .2
I .4
I .5
I .6
I .9
95
0.6
9.7
0.8
0.8
I .o
100
-0.0
0.C
0.0
0.0
column
(15
mm
in this example)
is found.
(6 mm in this
of
I9
I6
described before.
by the
service limit
ii)
IO
blade
i)
l7h
Vear %
SHOVELS
AND
DOZER.
LIFE
AND
If the obtained
0.0
-
remaining life
[Example]
is low.
iii)
On the remaining
operating
axis (1,200
the
line
H in this example)
of
percentage
until intersecting
wear obtained
before
Go to
left from
obtain
the remaining
the
C
6
E
;$
800
(H)
point
of intersection
to
ple).
v)
The time
vice meter)
maining
can be obtained
H on the ser-
so that
it can
be seen at a single
glance.
3550
2350
1000
2000
WELDING
3000
14000
4350
5000
Remaining life
20-25
a
APPLIED
INSTRUCTION
12
14
15
16
19
20
22
25
4.3
5.7
7.6
8.6
1 1.4
1 3.3
1 4.3
1 5.2
18.1
19.0
2 0.9
2 3.8
10
4.1
5.4
7.2
8.1
1 0.8
1 2.6
13.5
14.4
17.1
1 8.0
19.8
2 2.5
15
3.8
5.1
6.8
7.7
1 0.2
1 1.9
1 2.8
13.6
1 6.2
1 7.0
18.7
2 1.3
20
3.6
4.8
6.4
7.2
9.6
1 1.2
1 2.0
1 2.8
1 5.2
16.0
17.6
2 0.0
25
3.4
4.5
6.0
6.8
9.0
1 0.5
1 1.3
1 2.0
1 4.3
1 5.0
16.5
18.8
30
3.2
4.2
5.6
6.3
8.4
9.8
1 0.5
1 1.2
13.3
1 4.0
1 5.4
1 7.5
1 6.3
4.5
35
2.9
3.9
5.2
5.9
7.8
9.1
9.8
1 0.4
1 2.4
1 3.0
14.3
40
2.7
3.6
4.8
5.4
7.2
8.4
9.0
9.6
1 1.4
12.0
13.2
1 5.0
45
2.5
3.3
4.4
5.0
6.6
7.7
8.3
8.8
10.5
1 1.0
1 2.1
1 3.8
50
2.3
3.0
4.0
4.5
6.0
7.0
7.5
8.0
9.5
1 0.0
1 1.0
12.5
55
2.0
2.7
3.6
4.1
5.4
6.3
6.8
7.2
8.6
9.0
9.9
1 1.3
60
1.8
2.4
3.2
3.6
4.8
5.6
6.0
6.4
7.6
8.0
8.8
1 0.0
65
1.6
2.1
2.8
3.2
4.2
4.9
5.3
5.6
6.7
7.0
7.7
8.8
70
1.4
1.8
2.4
2.7
3.6
4.2
4.5
4.8
5.7
6.0
6.6
7.5
75
1.1
1.5
2.0
2.3
3.0
3.5
3.8
4.0
4.8
5.0
5.5
6.3
80
0.9
1.2
1.6
1.8
2.4
2.8
3.0
3.2
3.8
4.0
4.4
5.0
85
0.7
0.9
1.2
1.4
1.8
2.1
2.3
2.4
2.9
3.0
3.3
3.8
90
0.5
0.6
0.8
0.9
1.2
1.4
1.5
1.6
1.9
2.0
2.2
2.5
95
0.2
0.3
0.4
0.;
0.6
0.7
0.8
0.8
1.0
1.0
1.1
1.3
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
100
28
30
32
36
38
40
45
50
55
60
65
70
2 6.6
2 8.5
3 0.4
3 4.2
3 6.1
3 8.0
4 2.8
4 7.5
5 2.3
5 7.0
6 1.8
6 6.5
10
2 5.2
2 7.0
2 8.8
3 2.4
3 4.2
3 6.0
4 0.5
45.0
4 9.5
5 4.0
5 8.5
6 3.0
15
2 3.8
2 5.5
2 7.2
3 0.6
3 2.3
3 4.0
3 8.3
4 2.5
4 6.8
5 1.0
5 5.3
5 9.5
20
2 2.4
2 4.0
2 5.6
2 8.8
3 0.4
3 2.0
3 6.0
4 0.0
4 4.0
4 8.0
5 2.0
56.0
25
2 1.0
2 2.5
2 4.0
2 7.0
2 8.5
3 0.0
3 3.8
3 7.5
4 1.3
4 5.0
4 8.8
5 2.5
30
1 9.6
2 1.0
2 2.4
2 5.2
2 6.6
2 8.0
3 1.5
3 5.0
3 8.5
4 2.0
4 5.5
4 9.0
35
18.2
1 9.5
2 0.8
2 3.4
2 4.7
2 6.0
2 9.3
3 2.5
3 5.8
3 9.0
4 2.3
4 5.5
40
16.8
18.0
1 9.2
2 1.6
2 2.8
2 4.0
2 7.0
3 0.0
3 3.0
3 6.0
3 9.0
4 2.0
45
1 5.4
16.5
1 7.6
1 9.8
2 0.9
2 2.0
2 4.8
2 7.5
3 0.3
3 3.0
3 5.8
3 8.5
50
14.0
1 5.0
1 6.0
18.0
1 9.0
2 0.0
2 2.5
2 5.0
2 7.5
3 0.0
3 2.5
3 5.0
55
12.6
1 3.5
1 4.4
1 6.2
17.1
1 8.0
2 0.3
2 2.5
2 4.8
2 7.0
2 9.3
3 1.5
60
11.2
1 2.0
12.8
1 4.4
15.2
1 6.0
1 8.0
2 0.0
2 2.0
2 4.0
2 6.0
2 8.0
65
9.8
10.5
1 1.2
1 2.6
13.3
1 4.0
1 5.8
1 7.5
1 9.3
2 1.0
2 2.8
24.5
70
8.4
9.0
9.6
10.8
11.4
1 2.0
1 3.5
1 5.0
1 6.5
1 8.0
1 9.5
2 1.0
7.5
8.0
9.0
9.5
1 0.0
11.3
1 2.5
1 3.8
15.0
1 6.3
1 7.5
75
7.0
80
5.6
6.0
6.4
7.2
7.6
8.0
9.0
1 0.0
1 1.0
1 2.0
1 3.0
1 4.0
85
4.2
4.5
4.8
5.4
5.7
6.0
6.8
7.5
8.3
9.0
9.8
1 0.5
2.8
3.0
3.2
3.6
3.8
4.0
4.5
5.0
5.5
6.0
6.5
7.0
90
95
1.4
1.5
1.6
1.8
1.9
2.0
2.3
2.5
2.8
3.0
3.3
3.5
100
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
20-26
0
WELDING
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
75
80
85
90
95
100
105
110
115
120
125
130
7 1.3
7 6.0
8 0.8
8 5.5
9 0.3
9 5.0
99.8
10 4.5
10 9.3
1 14.0
1 18.8
12 3.5
10
6 7.5
7 2.0
7 6.5
8 1.0
8 5.5
9 0.0
9 4.5
9 9.0
10 3.5
1 08.0
1 1 2.5
11 7.0
15
6 3.8
6 8.0
7 2.3
7 6.5
8 0.8
8 5.0
89.3
9 3.5
9 7.8
10 2.0
106.3
1 10.5
20
6 0.0
6 4.0
6 8.0
7 2.0
7 6.0
80.0
8 4.0
8 8.0
9 2.0
96.0
100.0
104.0
25
5 6.3
6 0.0
6 3.8
6 7.5
7 1.3
7 5.0
7 8.8
8 2.5
8 6.3
9 0.0
9 3.8
30
52.5
5 6.0
5 9.5
6 3.0
6 6.5
7 0.0
7 3.5
7 7.0
8 0.5
8 4.0
8 7.5
9 1.0
35
4 8.8
52.0
5 5.3
5 8.5
6 1.8
6 5.0
6 8.3
7 1.5
7 4.8
7 8.0
8 1.3
8 4.5
40
4 5.0
4 8.0
5 1.0
5 4.0
5 7.0
6 0.0
6 3.0
6 6.0
6 9.0
7 2.0
7 5.0
78.0
45
4 1.3
4 4.0
4 6.8
4 9.5
5 2.3
5 5.0
5 7.8
6 0.5
6 3.3
6 6.0
6 8.8
7 1.5
50
3 7.5
4 0.0
42.5
4 5.0
4 7.5
5 0.0
5 2.5
5 5.0
5 7.5
6 0.0
6 2.5
6 5.0
55
3 3.8
3 6.0
3 8.3
4 0.5
4 2.8
4 5.0
4 7.3
4 9.5
5 1.8
5 4.0
5 6.3
5 8.5
4 2.0
4 4.0
4 6.0
4 8.0
5 0.0
5 2.0
60
3 0.0
3 2.0
3 4.0
3 6.0
3 8.0
4 0.0
9 7.5
65
2 6.3
2 8.0
2 9.8
3 1.5
33.3
3 5.0
3 6.8
3 8.5
4 0.3
4 2.0
4 3.8
45.5
70
22.5
2 4.0
2 5.5
2 7.0
2 8.5
3 0.0
3 1.5
3 3.0
3 4.5
3 6.0
3 7.5
3 9.0
75
18.8
2 0.0
2 1.3
2 2.5
2 3.8
2 5.0
2 6.3
2 7.5
2 8.8
3 0.0
3 1.3
3 2.5
80
1 5.0
1 6.0
17.0
1 8.0
1 9.0
2 0.0
2 1.0
2 2.0
2 3.0
2 4.0
2 5.0
2 6.0
85
1 1.3
1 2.0
1 2.8
13.5
14.3
15.0
1 5.8
16.5
1 7.3
1 8.0
1 8.8
19.5
90
7.5
8.0
8.5
9.0
9.5
1 0.0
1 0.5
1 1.0
1 1.5
12.0
12.5
13.0
95
3.8
4.0
4.3
4.5
4.8
5.0
5.3
5.5
5.8
6.0
6.3
6.5
100
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
135
140
145
150
155
160
165
170
175
180
12 8.3
13 3.0
13 7.8
14 2.5
147.3
15 2.0
15 6.8
16 1.5
16 6.3
17 1.0
10
121.5
126.0
130.5
135.0
139.5
144.0
148.5
153.0
157.5
162.0
15
114.8
119.0
123.3
127.5
131.8
136.0
140.3
144.5
148.8
153.0
144.0
20
108.0
112.0
116.0
120.0
124.0
128.0
132.0
136.0
140.0
25
101.3
105.0
108.8
112.5
116.3
120.0
123.8
127.5
131.3
135.0
30
94.5
98.0
101.5
105.0
108.5
112.0
115.5
119.0
122.5
126.0
35
8 7.8
9 1.0
9 4.3
9 7.5
100.8
104.0
10 7.3
11 0.;
11 3.8
11 7.0
40
8 1.0
8 4.0
8 7.0
9 0.0
93.0
9 6.0
99.0
102.0
105.0
108.0
45
7 4.3
77.0
7 9.8
8 2.5
8 5.3
8 8.0
9 0.8
9 3.5
96.3
9 9.0
7 2.5
7 5.0
77.5
8 0.0
8 2.5
8 5.0
87.5
9 0.0
8 1.0
50
67.5
70.0
55
6 0.8
6 3.0
6 5.3
6 7.5
6 9.8
7 2.0
7 4.3
76.5
7 8.8
60
5 4.0
5 6.0
5 8.0
60.0
6 2.0
6 4.0
6 6.0
6 8.0
7 0.0
7 2.0
65
4 7.3
4 9.0
5 0.8
5 2.5
5 4.3
5 6.0
5 7.8
5 9.5
6 1.3
6 3.0
70
4 0.5
4 2.0
43.5
4 5.0
4 6.5
4 8.0
4 9.5_
5 1.0
5 2.5
54.0
75
3 3.8
3 5.0
36.3
37.5
3 8.8
4 0.0
4 1.3
4 2.5
4 3.8
4 5.0
80
27.0
2 8.0
2 9.0
3 0.0
3 1.0
3 2.0
3 3.0
3 4.0
3 5.0
3 6.0
85
2 0.3
2 1.0
2 1.8
22.5
2 3.3
2 4.0
2 4.8
2 5.5
2 6.3
2 7.0
90
13.5
1 4.0
14.5
15.0
15.5
1 6.0
1 6.5
1 7.0
1 7.5
1 8.0
95
6.8
7.0
7.3
7.5
7.8
8.0
8.3
8.5
8.8
9.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
100
WELDING
0.0
0.0
0.0
20-27
0
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
Remaining-life
20-28
0
(H)
WELDING
APPLIED
INSTRUCTION
BULLDOZERS
[Example]
4)
AND
DOZER
SHOVELS
MAKING
After
the
plan
llil
REPORT
for
repair
or
rebuilding
based on that
result.
The following
of
wear
and
estimated
lives of
various sections
i
(3)
Measurement
(See
When newly
installed
Refering
When
measured
2350
Service
limit
3550
4350
of the
General-
(H)
Remaining
life
q must be repaired or
sections marked
1.
rebuilt.
Repair/rebuilding
time estimated from the
meawrement~ taken
Estimated hour meter
readlng:
H(
H later)
paired.
Estimated date of repair/rebuilding:
(cl
planning
sheet
should
repair
must be repaired.
the replacement
should
Determine
Cutting edge to be
replaced.
If re-
also be entered
2.
be made up which
on this sheet.
It must be previous to
has the
Other remarks
WELDING
20-29
0
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER
SHOVELS
INSPECTION
REPORT
mrj
Otherremarks
q Table of comparison
:
1
of wear and
estimated lives of various sections
from the
20-30
0
n!
( Hlater)
date of repair/rebuilding
WELDING
APPLIED
4.
a)
INSTRUCTION
BULLDOZERS
REPAIR/REBUILDING
PROCEDURE
AND
DOZER SHOVELS
FOR BLADES
in a
Work procedure
shown
at right.
The
rebuilding
work
to perform
procedure.
Therefore,
1lnqx9ztion
it
to eliminate
waiting time.
c)
Tack welding
How-
so that
must be arranged
ever required.
Especially, cracks and excessive wear must be examined carefully,
since they
Usually,
blade.
procedure
should be determined
must be
the
will
not interfere
I ooP602
WELDING
20-31
0
APPLIED
BULLDOZERS
INSTRUCTION
REMOVING
SOIL AND
In order to
AND
DOZER SHOVELS
RUST
inspect the
a pneumatic
grinder or
wire brush.
tions,
lines of reinforcement
weld
plates, and
INSPECTION
Generally,
However,
is very important
in order to make
Newly-found
in detail.
The result of
* Cutting edge
* End bit
* Front plate
- Side plate
- End of bottom plate
* Frame
- Various brackets
* Other sections
very important
Front plate
Since the wear of various sections of the blade
varies with how the machine is used, it is necessary to measure the wear at various sections to
know the overall wear condition.
rough condition
To know the
If the standard
their
be measured.
model)
20-32
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
If the reinforcement
installed,
their
AND
DOZER
SHOVELS
wear
- Reinforcement
- Pusher plate
plate
- Pusher plate
To
Thickness meter
. Tool No. 799-101-2000
* Measurement
range: 4 to 99 mm thickness
(Unit of 0.5 mm)
- Accuracy:
(2)
f 1 mm
Side plates
Since the structure
ing to
installed
model
in a different
wear
plate is
To meas-
WELDING
Wear plates
20-33
APPLIED
(3)
BULLDOZERS
INSTRUCTION
Tip of bottom
AND
DOZER
SHOVELS
plate
plate ad-
If this tip is
(4)
Worn a little
Frame
Since the outside and bottom
Check
all the
cracks.
To
a thickness meter.
Reinforcement
20-34
0
plates
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
Brackets
Check
AND
DOZER SHOVELS
._
- Installed bracneLs
_I__&_
each bracket
for
damage
and cracks.
pins in it,
(6)
check
deformation.
other
Deformation
of other sections
sections for
cracks and
Deformation
weld lines.
The cracks, holes and unevenness of the front
plate are very important
characteristics
symptoms
to see the
they
must also be
recorded.
Failing off
must be recorded in
record of inspection
Therefore,
the result of
repair work
WELDING
20-35
f&
APPLIED
3)
BULLDOZERS
INSTRUCTION
MAKING
THE
REPAIR
AND
DOZER
SHOVELS
PLAN
1. Determination
work
inspection in
the shop.
When
making
and deter-
Determination
cedure
2. Determination
of repair procedure
3. Determination
4. Selection
and
preparation
of
required
parts
and
materials
procedure
Determine
the
inspection
record
in-
structions.
The most important
according
* Replacement
of wear plate
Replacement
of the front
tion of a reinforcement
The front
the
plate or installa-
plate
following
methods,
Removal of present
wear plates
by one of
depending
on the
Replacement
forcement
or
installation
If the reinforcement
significantly
Most
a rein-
large models
method.
of
are repaired
by this
before the base plate starts to wear (before a hole is made on the wear plate al-
Reinfocement plate
(wear plate) for front
standard
replacement
plate,
Use the
or make a
D65A
a) Material
of front
reinforcement plate
KES SHTGO
ASTM A51 4-65(G)
Thickness
9mm
Welding rods
JIS D5016,
20-36
@
class)
12mm
AWS E7016
JIS D5816,
AWS E9016
=12mm,
JIS 05016,
A576-1049
@
=22mm
AWS E7016
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
Installation
ii)
of reinforcement
* Installation
plates
AND
DOZER SHQVELS
(wear plates)
If
the
standard
without
blade
has been
reinforcement
used
plates
(wear
In the same
of the rein-
forcement
wear
plates
are installed
the
to the worn
base plate.
Main work:
a) Welding of new wear plates
Material and parts:
a) Front reinforcement
plates
iii)
Reinforcement
- Reinforcement
plate
If the front plate is worn until it is very
thin or until a hole is made, the blade
can be repaired
method
by this method.
is especially
This
useful for
blades
the
the worn
reinforcement
rib plates to
be welded.
the
The wear
Main work:
a) Welding of reinforcement
ribs
Reinforcement p
Reference
D65A
c) Material of reinforcement
rib plate
Thickness
Welding rods
D155A
KES SS41 P
ASTM
A283Gr.D
KES SS41P
ASTM
6mm
A283Gr.D
9mm
JIS D4316
AWS E7016
WELDING
20-37
0
APPLIED
INSTRUCTION
iv)
BULLDOZERS
Reinforcement
AND
DOZER
SHOVELS
side
If a blade which
pact
receives frequent
loads is worn
scribed
before,
excessively
im-
as de-
it should be reinforced
plates
forcement
through
welding
them,
are welded
for
those holes.
reinAfter
for
ribs
reinforcement
from
back side
d) Restoration
Reinforcement of welded
sections of front plates
of back side
plates
rib plates
Reinforcement
plates
* Restoration
of back side
Reference
D65A
d) Plates for restoration of back side
Thickness
Welding rods
20-38
0
D155A
KES SS41 P
KES SHTGO
ASTM A283Gr.D
ASTM A5146!i(G)
6mm
JIS D4316
AWS E7016
9mm
JIS D5016
AWS E7016
WELDING
APPLIED
INSTRUCTION
Replacement
BULLDOZERS
or installation
AND
DOZER.
SHOVELS
. Large models
of side plates
tion of these sections detracts from the external appearance of the blade, they must be
replaced
or
covered
with
reinforcement
spilling,
forward
to
Replacement
Wear plate
only the wear plates and the plates to prevent the soil from
spilling.
If the side
unit-type
reinforcement
install
plates, then
- Replacement
from spilling
c) Installation
of wear plates
plates
Reference
D155A
@
Material of plate to
KES SM416
ASTM
Wear plate
A36
K ES S53C
AMST
Thickness
A576-1049
19 mm
86
Welding rods
Welding of plates
(when not worn much)
22 mm
JIS 05016
AWS E7016
Welding of plates
(when worn much)
fl
WELDING
20-39
0
APPLIED
INSTRUCTION
ii)
Replacement
BULLDOZERS
of plates of medium
and
AND
DOZER
SHOVELS
small models
The blades of medium and small models
whose side plates are used as plates to
prevent the soil from spilling should be
repaired according to the following
pro-
\:
worn or deformed,
plates
and
rib
plates.
Next,
bot-
tom.
Main work:
a) Gas cutting the present plates
b) installation
of sections to prevent
of unit-type
d) Installation
plates
b) Rib plates
cl Unit-type plates
4 Lower wear plates
Reference
D65A
@
Material of plate to
KES SS41 P
AMST
KES S53C
AMST
Thickness
Welding rod
283Gr.D
A576-1049
12mm
16mm
JIS D5016
AWS E7016
20-40
0
WELDING
APPLIED
INSTRUCTION
BULLDOZERS
Reinforcement
Although
DOZER.
SHOVELS
by the maintenance
condition
of the cutting
regardless of its
plate is repair-
ed.
AND
square bars.
The mounting
it with
be reinforced
in the same
way.
Main work:
a) Gas cutting the tip
b) Reinforcement
k!
Reference
To be cut
D65A
D155A
Material of
square bars
KES SS41 P
ASTM 283Gr.D
KES SHTGO
ASTM A514-65(G)
Dimension
22 x 22 mm
28 x 28 mm
Welding rod
JIS D4316
AWS E7016
JIS D5016
AWS E7016
Replacement
or installation
of plates on the
Reinforce with
- Replacement of reinforcement
plates
frame
If a reinforcement
of reinforcement
plates
and
lower
reinforcement
plates
Reference
Material of wear plate:
KES SHTGO
ASTM
or
A51 4-65(G)
KES SS41 P
ASTM 283Gr.D
Thickness:
9to12mm
Welding rod:
JIS D5016
AWS E7016
WELDING
20-41
0
APPLIED
BULLDOZERS
INSTRUCTION
Replacement
AND
DOZER
SHOVELS
of brackets
worn or dam-
of new brackets
Reference
D155A
D65A
Material
of brackets
@@
KESS43C
ASTM
@@@
Cast steel
A576-1040
@
Welding rods @ @
Cast steel
JIS 05016
AWS E7016
Sr When
JIS D5816
AWS E9016
JIS D5816
AWS E9016
Postheating
temperature
KES S43C
ASTM A576-1040
150 to 200C
590 to 680C
Cast steel
100 to 2ooc
200 to 250C
Material
20-42
0
at the root.
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
AND
DOZER SHOVELS
repair
it by welding.
Reference
Welding rods @
JIS D5016
JIS D5816
AWS E7016
AWS E9016
JIS 05816
AWS E9016
When
Postheating
temperature
KES S43C
ASTM A576-1040
150 to 2ooc
590 to 680C
Cast steel
100 to 2ooc
200 to 250c
Material
WELDING
20-43
0
APPLIED
(2)
BULLDOZERS
INSTRUCTION
DOZER
SHOVELS
Work procedure
After
AND
determining
special
consideration
to
the
following
points.
a)
them
is dangerous work.
tion,
many man-hours
pair
them.
are required
Therefore,
In addito re-
minimize
these
works as much as possible so that the repair work can be done efficiently.
anently weld the front plate
b)
The welding
work
the workers
welding
not
be subject
to
strain
in certain
areas.
(3)
be prepared
Frequently-
Replace brackets
the
blades
must
be strong
and wear-
Perm
weld
and safely,
20-44
0
WELDING
APPLIED
4)
INSTRUCTION
MAKING
THE
BULLDOZERS
FRONT
PLATE
OF
AND
DOZER
SHOVELS
A BLADE
How-
to the following
pro-
cedure.
(1)
Determine
Cutting materials
al Measure dimensions A (length of arc) and B
of the blade to be repaired.
b) Examine
at the standard
lowing points.
i)
Divide
the
front
pieces
as
possible
plate
into
to
as many
increase
the
Decide
the
dimensions
of
the
plates
reduced.
iii)
Cut
the
plates 50 to
than dimension
100
mm
A so that they
longer
can be
carefully
to maximize
its
yield.
When
drawing
allowance
in.
lines on the
material,
the
must be counted
crosswise dimension
often
it
is welded.
Therefore,
changes when
the crosswise
WELDING
20-45
0
APPLIED
(3)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
Cutting material
Cut the material
on it.
Since the
they
automatic
(4)
front
and rapidly
with
an
gas cutter.
wear
condition
of the
front
surface of
AA
1R
Therefore,
the
paper pattern
being done.
of the
bending
-50-
IOOmm
Cut longer than the blade.
on the front
by cutting
Looking
20-46
0
WELDING
APPLIED
6)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
the starting
face of the
points
so that
the
bending
panel of
the machine.
Precautions in bending
Even if the plates are bent correctly,
they can
not be fitted
has been
worn.
to a front
Therefore,
face which
radius is large.
Therefore,
bent to a radius a little smaller than specification to compensate for various errors.
In addition,
be eliminated
or checked easily.
* Correction
of too-large radius
Tack welding
\
* Correction
Tack welding
\
WELDING
of too-small radius
20-47
0
APPLIED
5)
BULLDOZERS
INSTRUCTION
blades will
depending
on
be repaired
the
DOZER SHOVELS
REBUILDING
or rebuilt
degree of
AND
wear,
differently
the
machine
model.
This section describes an example of a blade which
is repaired by the representative
method.
INSTRUCTIONS
in
and yokes,
Use
If the
the work.
(3)
modifying
the base
20-48
0
WELDING
APPLIED
ii)
BULLDOZERS
INSTRUCTION
Slanting
AND
DOZER.SHQVELS
up to
down.
that
(4)
Remove the worn side plates (which prevent soil from spilling) by gas cutting.
WELDING
20-49
0
APPLIED
(5)
INSTRUCTION
BULLDOZERS
AND
DOZER
SHOVELS
ii)
Remove
will be required.
side reinforcement
(6)
Grinding
i)
Use a grinder
(pneumatic
disc sander) to
ii)
Remove
the projections
corners
must
be ground
especially
carefully.
20-50
0
WELDING
APPLIED
INSTRUCTION
iii)
BULLDOZERS
(7)
Weld the
reinforcement
ii)
rib plates
If so,
(8)
i)
plates on
WELDING
AND
DOZER,.SHO\IELS
APPLIED
INSTRUCTION
ii)
BULLDOZERS
plates on the
AND
DOZER
SHOVELS
blade to check
Fitting
(9)
the front
plates by
tack welding
Position the plates on the cutting edge, taking
account of the fitting
allowance,
Plate to be installed
Base plate
(IO) Fitting
plates by tack
welding
i)
plate,
by tack welding)
if it has been
in order to snugly
drive
tack
welding.
Plate to be fitted
, by tack welding
Special plate
te or front plate
which has already been fitted
ii)
Many
made in advance.
iii)
20-52
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
(11) Fitting
AND
DOZER
SHOVELS
plates by
tack welding
i)
and
C-clam
late to be installed
ii)
by tack welding)
to fit the
iii)
(12)
of the tip
gas.
Use white
lines.
25 -3Omm
FittLng hole
WELDING
20-53
0
APPLIED
INSTRUCTION
If the fitting
ii)
BULLDOZERS
AND
DOZER
SHOVELS
lines in alignment
with the
o__-__0
t-
(13)
l- __-__-___
Cutting edge
End bit
ii)
Prepare
handles in ad-
vance.
(14)
the
(pneumatic
cut
surfaces with
a hand grinder
sander).
(15)
Installing
reinforcement
Temporarily
install
base plate.
a small
plate to the
as a guide,
edge
with the surface of the square bar, then install the bar by tack welding.
The sections
must be
20-54
0
WELDING
APPLIED
ii)
INSTRUCTION
Keeping
BULLDOZERS
the reinforcement
square bar at
the proper distance from the base plate, install it by tack welding.
To prevent strain, temporarily
plates to
the
base plate
weld special
and
adjust the
iii)
tack welding.
iv)
Install the square bar to the end bit by projecting it a little from the end bit, and cut
it in alignment
dutting line
(16)
&are
bar
WELDING
sand-
AND
DOZE6
SHQVELS
APPLIED
(17)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
rough
plates with
paper
Since
paper.
patterns
of the
a sheet of cardboard
only
side
or vinyl
it.
Looking
(19)
white
chalk
according
Draw
two
to the
paper
pattern.
pattern.
(19)
the side
20-56
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
ii)
AND
DOZER
SHOVELS
iii)
After the
ing.
(20)
by tack
welding.
I ooP850
(21)
Permanently
plate will
be welded
from outside.
IOOP85
WELDING
20-57
Co
APPLIED
(22)
BULLDOZERS
INSTRUCTION
Installing semicircular
Make
two
pattern
AND
DOZER
SHOVELS
semicircular
plates
using a paper
plates.
Tack welding
Semicircular rib plte
Permanent welding
Section A-A
(23)
Making
a paper pattern
of the unit-type
side
plates
Make the paper pattern of the unit-type
with
a sheet of cardboard
or vinyl paper.
plates
The
a
(24)
20-58
a
two
plates
side plates
draw the lines
WELDING
APPLIED.
(25)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
side plates
to the drawn
When
lines.
cutting
along
ii)
(26)
Installing unit-type
i)
ii)
Finish
fitting
surface
grinder (pneumatic
sander).
Hang
the
gas cutter.
the
side
plate
with
with
an
a hand
overhead
WELDING
20-59
0
APPLIED
iii)
BULLDOZERS
INSTRUCTION
be fitted
AND
DOZER SHOVELS
to the
,,
, : ,,:,
,, &Jcsmso
If
the
corners
are severely
worn,
repair
ii)
iii)
After
faces.
v)
Fix the
from the
20-60
0
WELDING
APPLIED
(28)
BULLDOZERS
INSTRUCTION
If
requested
more
by the
reinforcement
customer,
plate
install one
plates on the
unit-type
side plates
ii)
plates
of the cutting
edge.
iii)
plates according
iv)
WELDING
AND
DOZER
SHOVELS
APPLIED
(29)
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
by tack welding.
The
into
account
the
a
Lower wear plate
(30)
Permanently
round
the
angle of the
so that
When weld-
blade two
can be welded
surface,
or three
in the flat
position.
When welding
them at 2OOC.
20-62
a
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
ANI)
DOZER
SHOVELS
Permanent welding
plate
Section A-A
(31)
Grinding permanently-welded
Finish
the
weld
lines
sections
and
their
periphery
After
welding
permanently,
lines smoothly
concentration
(32)
Permanently
welding
plates with
UP
With the blade tip up, weld all the sections of
the unit-type
the
of the
bottom
can be
Permanent welding
Section A-A
(33)
Permanently
welding
of the blade up
i)
WELDING
surface
of blade down
which
(turncan be
position.
20-63
a
APPLIED
BULLDOZERS
INSTRUCTION
ii)
Permanently
weld
the
upper
section
AND
DOZER SHdVELS
of
Permanent weldi
iii)
round
perma-
nently.
Permanent welding
Saction A-A
(34)
of brackets
Manual.
20-64
0
WELDING
APPLIED
(36)
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
ii)
Melt and blow off the weld lines in alternation to remove the brackets.
iii)
not require
modifica-
tion.
iv)
After
the
v)
matic sander).
(36)
be sure to pre-
*
*
WELDING
20-65
0
APPLIED
(37)
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
The fitting
be reinforced
cracked or deformed
ii)
If
any
fitting
by rocks.
section
of the
bracket
is
iii)
Remove
iv)
with
sander).
a new stopper
by bending
a steel
20-66
0
WELDING
APPLIED
(38)
BULLDOZERS
INSTRUCTION
Permanently
welding
plates
with
the
AND
DOZER
SHOVELS
blade
stood up
i)
With
end
unit-type
Before welding,
be sure to preheat at
2oo c.
ii)
Weld the
upper
(39)
Modifying
the blade up
i)
Set the
again,
blade
and
with
cut the
its front
extra
surface
portion
up
of the
ii)
Finish
the
cut
surface
grinder (pneumatic
WELDING
smoothly
with
sander).
20-67
0
APPLIED
(40)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
(41)
(42)
the
worn
bracket
by gas cutting
it
When welding
heat
and
the bracket,
postheat
be sure to pre-
to prevent
cracking
of
Preheating
temperature
Postheating
temperature
KES S43C
ASTM A576-1040
156 to 2OOC
596 to 66OC
Cast steel
100 to 2ooc
200 to 250c
(43)
Cut off the present wear plates on the outside of the frame with
new wear plates.
20-68
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
ii)
Extend
the weld
AND
DOZER.
SHOVELS
of stress.
P895
Replacing
(44)
wear
of the
frame
i)
Cut off the present wear plates on the bottom of the frame with gas, then install new
wear plates.
I ooP896
ii)
Make
several
of the
Section
(45)
A-A
I OOP897
WELDING
20-69
a
APPLIED
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
BUCKET
1.
TYPES
1)
AND
USES OF BUCKETS
Large bucket
The volumetric
capacity
of standard
buckets.
There-
IOOF365
lb)
Rock bucket
The
rock
standard
bucket
bucket
is made
so that
stronger
than
the
100~366
(c)
Skeleton bucket
Gaps are made on the bottom
bucket
so that
large materials
of the skeleton
such as coffer
stones or rocks can be scooped while fine materials such as sand fall through the gaps.
I OOF367
20-70
0
WELDING
APPLIED
(d)
INSTRUCTION
Sidedump
BULLDOZERS
The side-dump
even
DOZER
SHOVELS
bucket
bucket
well as forward.
out
AND
changing
Therefore,
the
in a narrow
direction
the
machine
lOOF
(e)
Three-way
bucket
direction
only
bucket
(left
or right),
the three-
lOOF
(f)
Multi-purpose
bucket
This bucket
bucket can be
lOOF
WELDING
20-71
a
APPLIED
2)
BULLDOZERS
INSTRUCTION
AND
DOZER SHOVELS
D75SI
change without
improvements
notice
of technology
in order to incorporate
or for reasons of manu-
facture.
Metal group
SCMnMoH
KES symbol
20-72
a
SHTGO, SHT80,
SCMnMoH
SMnlH
s45c
SHTl IOA
WELDING
APPLIED
2.
INSTRUCTION
BULLDOZERS
REPAIR/REBUILDING
Various
PROCEDURE
DOZER .SHOVELS
BUCKETS
FOR
AND
describes
how
to
Therefore,
repairs which
are
often needed.
,I
Inspection of buckets
1)
.
It is very important
its condition
it.
Inspect the following
items to determine
how to
I OOP899
lb) Wearofcorners
(2)
(4
Wear
of
inside
surface
(5)
or reinforcement
plate (6)
(9)
(h) Cracking
and deformation
of
upper
edge of
bucket (9)
Ii)
(i)
Wear of bottom
of bucket
(11)
100P900
or wear plate
(12)
(k)
of other sections
2
8
WELDING
20-73
a
APPLIED
2)
Repair/rebuilding
(a)
BULLDOZERS
INSTRUCTION
Repairing
AND
DOZER
SHOVELS
of budtet
the
tip
of
the
edge by
build-up
welding
(I)
the teeth
worn,
build-up
repair
it
by
is not so
welding
as
described below.
[Welding rods for building up]
JIS DF2B-B
as martensitic
metal
that
for 30 to 60 minutes.
(2)
up/low
hydro-
as martensitic
metal that
hydrogen
type
JIS D4316,
mild
steel welding
* Preheat at 2OOC.
AWS E7016
(b)
welding
rods, then
build
them
up with
replace them.
(1) Cut
the
weld
lines
between
the
edges
Weld permanently,
l
Welding rod:
JIS D5816,
AWS E9016
Section A-A
20-74
0
&+
Section B-B
of body
kcornar
Section C-C
WELDING
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
Since difficult
work
section)
reinforcement
section
together
(beginning
of
Ed
plate.
a
/\
(2)
tion.
(3)
plate,
bottom
bottom
plate, re-
wear
plate,
bottom
plate
(1).
corners
(2)
and
Install bottom
reinforcement
WELDING
20-75
0
APPLIED
INSTRUCTION
BULLDOZERS
AND
DOZER SHOVELS
D75S
einforcement plate
. Material
Section A-A
Cutting edge:
Bottom plate:
Reinforcement
KES SMnl H
KES SHT80
plate:
KES SHT60
Fig. 1
Welding rod:
For the first layer and back run, use welding rods of 4 mm in diameter.
For the second and after layers, use welding rods of 5 mm in diameter.
welding,
zones gradually.
i)
plate to
shown
in
Fig.
1,
then
finish
the
iii)
weld
plate@to
the
Build
Fig. 1 by welding.
v)
vi)
plate @
20-76
0
WELDING
APPLIED
(d)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
plate
up
too.
technique,
Especially,
method
not be concentrated.
.
IS
Cut th,erib
plate of the
keep them
bottom
plate
bottom
plate.
(2)
Prepare
plate,
the
replacement
reinforcement,
bent
plate,
bottom
bottom
wear
(3)
install
bottom plate
(I),
corners
(2) and
(4)
reinforcement
(5)
Replacement
edge
Replacement corner
WELDING
20-77
0
APPLIED
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
plates (wear
plates)
of the
bucket
plates (wear
are worn,
remove
Thickness:
9 mm
Welding rod:
JIS D5016
(AWS E7016)
plates, bend a
sheet metal
proper
width,
work,
then
bend it changing
its
(f)
Remove
lines with
gussets of
corners
the
gas.
installed
them
Keep the
to
the
bottom plate.
SUPPOK
or
turnbuckle
(2)
Prepare
the
replacement
side blades.
(3)
[Reference]
D75S
(1)
Material
Side plate
KES SHTGO
Thickness
9mm
(2)
Side blade
20-78
0
WELDING
APPLIED
(g)
BULLDOZERS
INSTRUCTION
AND
DOZER
SHOVELS
of the budtet
of the
bucket,
the opening
often
made wider.
port
or turnbuckle.
of the
Generally,
narrow
bucket
is
with
the center of
Therefore,
a support
set it a
or turnbuckle
is widened)
wear
rapidly
(whose
and the
life of the
rebuilt
(h)
Replacing
budtet
The
often
cracked
or deformed
line
is
because of rocks.
it should be
replaced if possible.
(1)
(2)
install
the
replacement
plate
by
tack
welding.
[Reference]
Material
Thickness:
KES SHT80
9 mm
Welding rod:
(3)
or SS41 P
JIS D5816,
AWS E9916
plates to the out-
Weld
them
by tack welding.
permanently,
then
finish
the
I ooP907
WELDING
20-79
0
APPLIED
(i)
INSTRUCTION
Replacement
BULLDOZERS
AND
DOZER
SHOVELS
of boss of pad
D75S
JIS D4316,
AWS E7016
(j)
Preheating temperature:
150 to 2OOC
Postheating temperature:
590 to 66OC
20-80
0
WELDING
APPLIED
3.
1)
BULLDOZERS
INSTRUCTION
REPLACEMENT
PROCEDURE
FOR
BUCKET
EDGE
AND
DOZER SHOVELS
D155S-
2)
Weld the new corners and edges to the bucket according to the following
- Welding rod:
procedure.
JIS D5816
AWS E9016
of
of 4 mm in diameter.
For the second and after layers, use welding rods
SCMnCrBH
Fig. 1
of 5 mm in diameter.
KES
Section A-A
Fig. 2
Detail of (iiJ
Fig. 3
(4
smoothly
b)
to be welded to
Install
and finish
with a grinder.
tack welding.
in position
by
ing, too.
(cl
Temporarily
weld plates @
and @
as shown in Fig. 3.
Fig. 4
WELDING
20-81
0
APPLIED
BULLDOZERS
INSTRUCTION
AND
DOZER SHOVELS
as shown in Figs.
5 and 6.
KES SCMnCr BH
--IL%
(f)
(g)
KES
Section B-B
Section C-C
Fig. 5
Fig. 6
plates @
(Fig.
41,
and
finish
the
20-82
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
RIPPER ADAPTER
SHANK
1.
3 or D455-1
TYPES
18, D150,
AND
DOZER SHOVELS
a spare
This section
OF ADAPTERS
Model
D80.85A-12
154-78-l
5690
D80.85A-18
154-78-l
5691
D150.155A-1
175-78-21693
D355A-1,3
D455A-1
195-78-l
4359
198-79-l
1620
Table 1
WELDING
20-83
a
Table 2
Note:
Types of rippers
D80, 85-12
D95S1
Fixed type multishank
ripper
Serial No.
15429
- 15758
15759
- 18666
18667
_ 25000
C25001-25400
T27001-26000
D80, 85-l 8
Fixed type multishank
ripper
:$z;,,
154-78-I
Material
ripper on D355-3.
Part No.
of shank
Type of shank
5690
---I
154-78-.I 4344
154-78-14347
154-78-I
5691
C25401T26001-
154-78-l
4348
175-78-21612
D150,
155-1
175-78-21613
ripper
ripper
T 8651175-78-21693
6843-
D150,
175-78-21614
(Chromium-
175-79-31131
nolybdenum-
155-1
6859 - 7189
6858
KES SCM430
D150, 155-l
Variable siant rioper
iteels)
7190 -
175-79-31133
6843 -
175-79-32130
D3551
Fixed type multishank
175-79-31132
ripper
III
195-78-l
1313
195-78-I
1314
195-78-11315
0355-l
Fixed type giant ripper
1094 -
195-79-I
1132
IV
2,030
2,265
1230 - 1631
1,355
1,550
1632 -
1,190
1,385
1,724
1,925
1,771
1,992
1,770
63
1,535
1,756
1,534
63
2,006
2,246
195-78-14350
D355-I.
Variable multishank
i
F
II
ripper
1010 - 1210
0355-1,
II
1211 - 1631
2,087
103
III
5
1632 -
0455-l
Variable giant ripper
2-
198-79-I
1620
KES SNCM431
198-79-11630
I
* KES SNCM431
= Nickel Chromium
Molybdenum
Steels
APPLIED
INSTRUCTION
3.
TYPES
I)
AND
BULLDOZERS
DIMENSIONS
AND
DOZER SHOVELS
OF SHANKS
(b)
Draw
cutting
2)
line)
line
E.
(b)
Draw
cutting
line)
E.
3)
Shanktype
(a)
(Ill)
Second line
(b)
point
at distance
C from
lines (auxiliary
cut-
WELDING
20-85
0
APPLIED
INSTRUCTION
BULLDOZERS
4)
AND
DOZER
SHOVELS
.I/
point
at distance
C from
vertical
line at distance
D from
the rear
surface of shank.
(c)
lines (auxiliary
cut-
After
Fourth line
section.
l
Fig. 4
for D155-1)
Table 2,
175-79-32130
Dimensions of shank:
4.
I)
SHANK
it horizontally
by
Mark off
place the
Alternatively,
.
,/I/
AA
Float 50 mm
or so.
Fig. 5
2)
Cutter
Use a cutting torch.
An automatic
Guide plate
Fig. 6
3)
Cutting procedure
Preheat
15OC
auxiliary
the auxiliary
(over a width
cutting
line.
cutting
of 20 mm).
20436
Cc
line is cut.
WELDING
APPLIED
5.
1)
INSTRUCTION
PREPARATION
BULLDOZERS
AND
DOZER SHOVELS
FOR WELDING
arc welder,
mm or 6 mm in diameter
of the 80 kg/mm*
tensile
mm in diameter,
diameter.
welder.
mm in diameter
of the 60 kg/mm*
or D5816).
rods 4
tensile strength
JIS D5016
(AWS E7016)
JIS D5816
(AWS E9016)
JIS D8016
(AWS E11016)
Preparation of edges
If a gouging device is not available, URANAMI
welding
must be performed
on the root.
Use
To make good
properly.
not required.)
Fig. 7
(b)
the diffusion
of welding
heat, do
on a
fixing
place a
stretch on them to set them in parallel by adjusting the height of the jacks or blocks.
Stretch
Fig. 8
(c)
Other precautions
To make good and efficient
flat position
(Use a
crane, if available.)
Since the shank is hard and large stresses are
applied to it, never strike arcs which can reduce
the strength of the shank on any place other
than the prepared
Securely
WELDING
20-87
0
APPLIED
6.
I)
BULLDOZERS
INSTRUCTION
WELDING
THE
AND
DOZER SHOVELS
ADAPTER
30 mm as shown in Fig. 9.
IOO-mm
At this time,
preheat a
2o0c.
2)
When permanently
preheat
line
at 2OOC.
2OOC
preheating
must be maintained
temperature
of the periphery
ceeds 230C,
it
Check
again.)
thermochack
must
the
temperature
while welding.
of
If the
be cooled
surface
before
welding
temperature
with
or thermocouple.
Fig. 9
3)
manually.
rods 4 mm in diameter
or D5816
JIS D5016
type
(AWS
(AWS E9016).
line.
If any defect
is found,
craters, and
remove it with
Fig. IO
backward
start
method
(Fig.
11).
Turn
remove
Turn
layer.
rods 5 to
6 mm
and after
in diameter
D8016
(AWS
El 1016).
Fig. 11
9)
Turn over the shank every two layers until the root
is built
20-88
0
WELDING
APPLIED
BULLDOZERS
INSTRUCTION
10) The distance between the edges is wide near the surface of the shank and adapter.
condition
If welded by weav-
Therefore,
DOZER SHOVELS
in Section 6.)
AND
2)
After
grinder
Move the
of the shank so
rotate
3)
(of
be deposited
manually.
rods 4 mm in diameter
E7016)
or D5816
JIS D5016
a grinder,
on the finished
surface, re-
repair it by welding,
and
type
(AWS
*
(AWS E9016).
is found
If any defect
move it with
Precautions
150 mm
using a semi-automatic
positing
welder,
too
periphery
of the
weld by demuch
heat
The welding
line will
not
of
exceed
23OC.
*
Precautions
Before welding,
to 4OOC
for
rods at 35OC
horizontality.
Backing (Mold
flux)
by Unionmelt
metal from
as
drip-
may be used.
7.
FINISHING
AFTER
1)
After
welding
WELDING
plates which were welded to both ends of the adapter to prevent the melted metal from dripping.
On
The
WELDING
[Fig.
2 (B) and
and
Fig. 4 (D)l,
If a tempering
furnace is
available,
at
about
keep the
shank
2OOC
for
30
APPLIED
8.
INSTRUCTION
ASSEMBLY
BULLDOZERS
OF SHANK
AFTER
ADAPTER
AND
DOZER SHOVELS
IS WELDED
No. of adapter
Model/Part
~~~
~~
D80-12
D85-12
D80-18
D85-18
D150-1
154-78-l
5690
154-78-l
5691
195-78-21320
175-78-31230
154-78-31330
175-78-31290
175-78-21693
D155-1
D355-1
195-78-I
4350
198-79-l
1620
195-78-21320
(Std.1
195-78-21580
(Long)
195-78-21331
195-78-21560
D355-3
D455
198-79-l
1220 (Std.)
198-79-l
1640 (Long)
Table 3
Use pin
(175-78-2l740)
protector
on D80 through
11320)
20-90
0
1230
198-79-l
and
on D455.
WELDING
APPLIED INSTRUCTIONS
30
REPAIR OF DUMP
TRUCKS
MAIN FRAME
Examples of
DUMP BODY
Examples of
WELDING
BY WELDING
. .....
HD320-2
.. .
.
.. ..
and HD325-2
_. _. . .
_. . .
HD320-2
and HD325-2
_. . _. .
30-
APPLIED
DUMP
INSTRUCTION
MAJOR
MATERIALS
OF THE
MAIN
TRUCKS
and HD325-2)
FRAME
SHTGO
ss41 P
Fig. 1
KES symbol
Metal group
High tensile strength rolled steel plates
SHTGO
SC46
purposes
sS41 P
ments in technology
30-2
0
STKM
improve-
or method of manufacture.
WELDING
APPLIED
2.
CHECKING
1)
DUMP
INSTRUCTION
Remove
THE
MAIN
FRAME
TRU-CKS
FOR CRACKS
2)
Check sections
frames shown
to
in Fig. 2 especially
carefully
for
cracks.
Fig. 2
3.
SELECTION
OF WELDING
RODS
welding
rods.
E7016/BS
E5133
B 26(H)
Used for
overlaps or undercuts.
-Take
1st to 3rd
layers on
Welding precautions
JIS D5016/AWS
3.2 mm -
WELDING
30-3
E
APPLIED
INSTRUCTION
DUMP
4.
REPAIR
1)
OF CRACKED
TRUCKS
SECTIONS
A
(a)
(b)
the
cracked
surface,
and
confirm
the
Bead cracks
* After
gouging,
(If a
Gouging length
Front
Top surface
kX46
Fig. 3
*
Clean
the
gouged
surface,
remove
the
Section A-A
*
and weld
layer.
30-4
0
WELDING
APPLIED
DUMP
INSTRUCTION
TRUCKS
$6 - 7 (depth) x 2 (places)
Detail
0A
Fig. 4
-
- Clean
gouged
surface,
remove
and weld
gouging,
with
a grinder,
finish
again.
after
- After
welding,
finish
View Z
Fig. 5
WELDING
the
- After
(3)
the
the
weld
surface
DUMP TRUCKS
APPLIED INSTRUCTION
with
grinder.
-
Remove all the slag from the gouged surface with a grinder or chipping hammer.
To
remove the
residual stress,
each
layer.
stress
(which
lowers
the
fatigue
SectionA-A
Fig. 6
30-6
0
WELDING
APPLIED
DUMP
INSTRUCTION
TRUCKS
is melted sufficiently.
-4-P max.
Fig. 7
When
the root
mm (Fig. 8):
opening
is 3 to 6
in two passes.
_)
1 _3to6mm
Fig. 8
After
welding,
finish
the
weld
Bad !
Welding rod
zone
Repair
procedure
for
section @
of the transmis-
Clean
the
cracked
section,
and
confirm
the
the
(2)
crack
and
(3)
cracks on section
(a)
After
welding,
on
section @
of the
Repair
according
procedure
to
for
.
finish the weld zone smoothly
with a grinder.
WELDING
30-7
0
APPLIED
DUMP
INSTRUCTION
KES
, @
SS41P.
and
ASTM
TRUCKS
_
A283Gr.D
or
equivalent
Thickness:
Plate (iiJ
9 mm
Plate
x 2 pieces
x 1 piece
transmission bracket.
120
285
Plate @
x 1 piece
30-8
0
_/
WELDING
APPLIED
(c)
DUMP
INSTRUCTION
Reinforcement
TRUCKS
mTopof
frame
Front of machine
---Lx
Bottom of frame
60
-f 8
k-r
10
\
Secure a distance of 5 to 7 mm between the bottom 01
the frame and the bead. When welding, take care not
\
Extend the bead smoothly within this
range, then finish with a grinder.
(Extend the beads at four places)
Fig. 9
WELDING
30-9
0
APPLIED
(d)
INSTRUCTION
Reinforcement
DUMP
TRUCKS
Front of vehicle
Bottom of fr,a;
10
///
Extend the bead smoothly within this
range, then finish with a grinder.
(Extend the beads at five places)
Fig. 10
30-10
a
WELDING
APPLIED
DUMP
INSTRUCTION
TRUCKS
Reinforcement
Material
Plate (566-99-97650)
plate
A283Gr.D
or
equivalent
Thickness:
9 mm
665
(b)
Reinforcement
drawing
Upper plate
Front of vehicle
Fig. 11
WELDING
30-11
cc
APPLIED
3)
INSTRUCTION
Repair
procedure
for
DUMP
cracked
section @
TRUCKS
of the
hoist bracket
(a)
(d)
Make plate
shown below.
(b)
Clean
the
cracked
surface,
and
confirm
(cl
Repair
cracked
section
0
C
according
Material:
A283Gr.D.
or equivalent
to Step
Thickness:
0.
on Section
x 1 piece
the
16 mm
Fig. 12
(4
Reinforcement
/.
KES SS41 P (9 t)
Top of frame
30-l 2
a
WELDING
APPLIED
4)
DUMP
INSTRUCTION
Repair
procedure
TRUCKS
of seats
with
the work.
b)
Clean
the
cracked
surface,
and
confirm
the
(cl
at both ends of
the crack.
(4
(4
After
again.
(9)
To
remove the
zone sufficiently
h)
After
welding,
finish
the
welded
surface
Make
reinforcement
plates
, @
and
@Material:
KES
SS41P.
ASTM
A283Gr.D.
or
equivalent
Thickness:
WELDING
6 mm
30-13
0
APPLIED
INSTRUCTION
DUMP
230
t=
Plate
_,_
100
6 mm thick
Fig. 14
Plate
6 mm thick
255
Fig. 15
Plate
6 mm thick
Fig. 16
30-14
0
WELDING
TRUCKS
APPLIED
INSTRUCTION
REINFORCEMENT
DRAWING
DUMP
FOR
SEATS
OF THE
HYDRAULIC
TANK
AND
TRUCKS
FILTER
.o
r-
i
*
.c
o-
LL
6
al
3
0.
WELDING
30-15
@
LIST OF SERVICE
- BULLDOZER,
TO WELDING
No.
Date of
Issued
to 1983lMAY
Subject
GN-163
JUL 76
GN-026
APR 72
and D6OS-6
GN938
JUN 72
New lugs for repair of rock bed shoes and their repair procedure for D150, D155 and D355
GN-116
JUL 75
GN-124
MAY 76
GN-163
JUL 76
GN-189
APR 79
GN-142
NOV 79
D20-70906
OCT 80
Introducing bucket with reinforced spill guard and the method of reinforced the spill guard
10
D30-30-001
OCT 66
11
D30-70426
DEC 77
12
D30-21903
JUN 79
13
030~54-007
FEB 83
14
D40-30-001
AUG 80
15
D40-21-001
JAN 83
16
D40-30-092
APR 83
17
D50-70-018
DEC 65
18
D50-70919
FEB 66
D150,155-1
19
D50-27-003
MAY 66
20
D50-27-004
SEP 66
21
D50-70-036
NOV 67
22
D50-70638
FEB 68
23
D50-70-044
JUL 68
24
050-70952
DEC 68
Introducing the bucket spill guard for use on D5OS15 and D55S-2 machines
25
D50-60-032
MAR 76
Prevention of cracking of flanges on the tilting and dumping circuit tubes (on the tank side)
26
D50-70-062
FE8 77
27
D50-54913
MAY 78
28
D50-54-014
JUN 78
29
D50-30-014
DEC 78
30
D50-70-076
AUG 79
Modification procedure for side dump chute pin bushing on D5OS. D53S, D57S. D75S dozer
shovels
31
050-70-077
DEC 79
D50-70-078
MAR 80
Repairing cracks in straight frames of straight tiltdozer blades used on D5OA-16 or D53A-16
machines
32
and 11
and 11 machine
machine
machine
No.
Date of
Issued
APR 80
Subject
Repair of cracked C-frame on D5OA and D53A bulldozer (Angle dozers)
33
D50-70-079
34
D50-70-080
NOV 80
Repairing a cracked chute pin bracket on two side dump buckets on D57S-1 machine
35
D50-54-019
OCT 81
36
D50-78-016
APR 83
37
D55-70-003
JUL 68
38
D55-70-016
FEB 77
39
D60-30-003
JUL 65
40
D60-70-008
OCT 65
41
D6078605
DEC 65
42
D60-50-001
MAR 66
43
D60:70-009
MAR 66
44
D60-27-001
MAY 66
45
D60-30608
MAY 66
46
D60-78-009
JUN 66
47
D60-70-018
NOV 66
48
D60-70-025
OCT 67
49
D60-70627
NOV 67
50
D60-70628
JAN 68
51
D60-78-014
MAY 68
52
D60-30-013
JAN 73
53
D60-78-018
JAN 73
54
D60-22609
NOV 73
55
D60-70-045
SEP 75
Repair of the power tiltdozer blade cracked on the back side on the D60P-6 machine
56
D60-22610
MAR 76
Repair of the cracked under side of steering case on the models D60.65A.E-6
57
D6062-011
OCT 76
58
D60-03-013
OCT 76
In-field reinforcement of the core grid to prevent water leakage due to the damaged radiator
core on D60.65A,P,PL.E-6
machines
59
D60-30-016
FEB 77
60
D60-70-048
FEB 77
61
D60-70-047
APR 77
62
D60-70-050
JUN 77
63
D60-78622
JAN 78
64
D60-30-018
JUN 78
65
D60-03-015
JUN 78
66
D60-54-017
FE8 79
67
D60-70058
FEB 81
68
D60-70-057
FEB 81
69
060-70-055
JUN 81
Repair of cracked C-frame on D60A, D60E. D65,A and D65E-6 bulldozer (Angle dozers) in
the field
70
D60-30-019
JUN 82
D50,53S-16
and D57S1
bucket
and -3
machines
machines
machines
for D60.65A.S-6
No.
Date of
Issued
Subject
t,
Reinforcement of weld zone on foot rests on floor plate of D6OA,E,F,P-7
71
D60-54919
J&I
72
D60-54-020
JAt&
73
D75-70-001
NOV 68
74
D75-70-002
DEC 68
75
D75-70-003
DEC 68
76
D75-70-007
JUL 72
77
075-70-008
NOV 76
Prevention of cracks between tilt rod securing bosses and tilt stoppers for standard bucket on
D75S2
78
D75-70-009
FE8 77
79
D75-70-012
MAY 78
80
D75-70-015
MAY 79
81
D75-21-001
JUL 79
Repair cracked steering case in D75S-3 machines equipped with hydraulic ripper
82
D75-78-006
JUL 79
83
D75-70-012
AUG 79
Modification procedure for side chute pin bushing on D5OS, D53S, D57S and D75S dozer
shovel
84
D75-54-007
OCT 79
85
D75-21-002
DEC 79
Repair of detective final drive 2nd pinion and steering case on D75S3
86
D75-04-001
MAY 81
87
D75-70-017
DEC 81
88
D75-70-019
APR 83
89
D80-70-016
MAR 66
90
D80-70-017
MAY 66
91
D80-78-007
MAY 66
In-field reinforcement of D80-8 ripper proper by welding reinforcing ribs to ripper brackets
92
D80-70-019
MAY 66
93
D80-70-020
MAY 66
94
D80-70-021
MAY 66
Reinforcing blade
95
D80-70-022
JUN 66
96
D80-54-006
JUL 66
97
D80-70-024
SEP 66
83
machine
machine
98
D80-54-007
NOV 66
99
D80-54-008
NOV 66
machine
100
D80-54-009
DEC 66
101
D80-70-025
DEC 66
102
D80-70-027
DEC 66
103
D80-70928
DEC 66
104
D80-70-029
JAN 67
105
D80-21-004
FEB 68
106
D80-70-034
MAR 68
107
D80-78-012
MAY 68
108
D80-70-039
DEC 68
machines
Date of
,ssued
No.
109
D80-70-040
FE8 69
110
D80-70-041
111
D80-27-008
112
Subject
Reinforcing the blade moldboard of D80.85A-12
APR 69
straight-tiltdozer
MAY 69
D80-70943
MAR 72
113
D80-30-014
JUL 72
114
080-70-044
SEP 74
115
D80-70947
JUL 77
116
D80-70-050
AUG 79
117
D80-54-020
JAN 80
118
080-70-051
MAR 80
119
D80-78-022
OCT 80
120
D80-03-013
JAN 81
Repair of a leaking radiator core in D8OA, 85A, D95S. D15OA. D155A or D355A machines
121
D80-70953
MAY 81
122
080-70-054
JUL 81
123
D80-70-055
JUL 82
124
D80-70-056
DEC 82
125
D80-70-057
FE8 83
Spare trunnion ball stud for work equipment for D80A to D455 machines
126
D80-54-024
MAY 83
127
D80-30-014
JUL 72
128
D95-70901
MAY 75
129
D95-70-002
JUN 75
130
095-70-003
JUN 76
131
D95-30-001
SEP 82
Repair of cracked hole for installing track roller and it guard of D95S2,l
and D80.85
angledozer
angledozer
angledozer
132
D95-70-004
JAN 83
133
D150-21-001
JAN 73
134
D 150-60-002
JAN 73
135
D150-30902
JAN 76
Repair method of cracked parts near the seventh track roller shaft hole of track frame on
D150A or Dl55A-1
136
0150-54-003
MAR 76
137
Dl50-54-007
JUN 79
138
D150-21-002
JUN 80
139
D150-54-010
MAY 81
140
D150-70-012
MAY 81
and D155A-1
D155A-1
machines
machine
machines
141
D150-70913
MAY 81
142
D150-54-007
MAR 82
143
D150-70014
NOV 82
144
D355-60-001
JAN 73
145
D355-70-002
MAY 76
Repair of cracked pivots and adjacent welds on the back on U-blade on D355A-3
146
D355-50-001
OCT 76
147
D355-70907
SEP 80
machines
No.
148
D355-54-005
Date of
Issued
Subject
OCT 80
149
D355-70-008
MAY 81
machines
150
D355-70-009
JUL 81
151
D355-70-010
MAY 82
152
D355-78-013
NOV 82
machines
153
D455-03-002
DEC 77
154
D455-30-001
DEC 77
155
D455-30-002
JAN 78
156
D455-50-001
JAN 78
157
D455-30-003
MAY 81
158
D455-70002
MAY 81
159
D455-54-005
JUL 82
160
D455-03-021
AUG 82
161
D455-91-005
OCT 82
machine
machine
machine
machine
162
D455-30-003
DEC 82
163
D455-50603
FE6 83
164
D45530603
APR 83
165
D455-30-005
APR 83
166
D455-54-006
APR 83
- DUMP TRUCK -
GN-189
APR 79
HD180-04-001
MAR 75
HD180-54-002
AUG 75
HD180-54-004
NOV 77
HD180-70-001
JAN 80
HD180-03-001
SEP 81
HD180-03-002
FEB 82
HD320-70-001
AUG 73
Instructions for attachment of reinforcement plate for vessel on dump truck HD320-2 to be
shipped to France
H D320-46-001
SEP 79
10
H D320-46-002
SEP 79
11
HD320-46-003
MAR 82
12
H D320-46-004
JUL 82
13
HD320-70-002
DEC 82
14
H D320-46-005
MAR 83
15
HD320-70-003
APR 83
16
H D460-46-001
NOV 79
truck
HD325-2
HD325-3
No.
Date of
Issued
Subject
17
HD460-46-002
OCT 82
18
HD680-46-002
APR 71
19
HD680-50-001
MAR 76
20
H D680-04-001
MAY 76
Repair of a cracked fuel outlet port flange weld in fuel tank on HD680
21
HD680-54-001
JAN 77
22
H D680-46-001
FEB 77
23
HD680-22-001
NOV 78
24
H D780-46-001
MAY 83
25
HDI 200-27-001
OCT 82
-HYDRAULIC
EXCAVATOR
PC-70-019
JUN 81
PC-70-025
SEP 81
PC-70626
APR 82
PC-70-028
APR 82
PC-70-030
MAY 82
PC-70-01 9
MAY 82
PC-70-027
MAY 82
PC-54-006
MAY 82
PC-70632
JUL 82
10
PC-70938
AUG 82
11
PC-70-037
AUG 82
12
PC-70-034
AUG 82
13
PC-70635
AUG 82
14
PC-46601
AUG 82
15
PC-30-004
AUG 82
16
PC-70039
OCT 82
Repair procedure for cracked boom and arm of PClOO, PCIOOL, PC120
17
PC-46-003
NOV 82
18
PC-46-002
NOV 82
19
PC-70-040
NOV 82
20
PC-70641
DEC 82
21
PC-46004
DEC 82
22
PC-70-042
DEC 82
23
PC-70946
MAR 83
24
PC-70947
MAR 83
25
PC-30-007
APR
-WHEEL
No.
LOADER
Service NewsNo.
Date of
Issued
APR 79
GN189
Subject
Repair of radiator core
W120-46-001
AUG 81
w170-54-004
SEP 81
How to repair front frame center hinge plate in W170 wheel loader
W120-46-082
OCT 81
-MOTOR
GRADER
1 GN189
APR 79
GD30-46-001
AUG 66
GD31-46-001
AUG 66
GD37-46-001
AUG 66
GD22-06-001
APR 75
Prevention of cracks in the front lamp brackets on the GD22 motor grader
GD600-70-001
MAY 80
Repair of cracked circle support rear rib on GDGOO series motor grader
GD600-22-002
FE8 81
GD500-70-002
MAY 81
GD500-46-001
JUN 81
10
GD40-70-008
SEP 81
11
GD700-70-003
SEP 81
12
GD600-22-004
JUL 82
13
GD500-70-004
JUL 82
14
GD600-70-005
JUL 82
15
GD500-46-001
AUG 82
16
G D600-46-00 1
SEP 82
motor graders
motor graders
or GD500R-1
GD500R-1
and GD655A-1
motor grader
17
GD40-70-008
SEP 82
18
G D700-79003
SEP 82
19
GD600-46-002
NOV 82
20
G D700-04-001
FEB 83
21
GD600-46-003
MAR 83
22
GD600-91-005
MAR 83
23
GD600-70-007
MAR 83
and GD705R-2
605R-1, 650R-1
- MOTOR SCRAPER -
No.
y::,,
GN189
APR 79
WSI 646-001
DEC 75
motor scraper
WS16-70903
JUN 78
WS23-70903
APR 82
motor scraper
WS23-46-001
MAY 82
WS23-46-004
FEB 83
WS23-46-005
FEB 83
motor scraper
- SOIL COMPACTOR -
WF22-30-001
JUL 82
WF22-54-002
DEC 82
soil compactor
compactor
PROPOSAL
FOR MANUAL
REVlslON
NAME OF COMPANY:
PHONE NO:
:
S
DEPARTMENT:
E
R
NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
PFMRl 081696
LOCATION:
DATE: