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oo;-1

CONTENTS
(Sections marked *

GENERAL

are in preparation.)

INSTRUCTIONS

01 GENERAL INSTRUCTIONS

No. of page
Ol-

11 BASIC WELDING .....................................................

ll-

12 HARD-FACING

12-

13-

APPLIED

. ..

. _. _.

.. . .

. .. .

INSTRUCTIONS
OF WEAR PARTS

13 REPAIR OF RADIATOR

AND OIL COOLER ............................

20 REPAIR OF BULLDOZERS
Mainframe

AND DOZER SHOVELS

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

..............................................................

50 REPAIR OF WHEEL LOADERS


Mainframe

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-

Ripper adapter shank ..............................................


30 REPAIR OF DUMP TRUCKS

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

how to check welded


How to read welding

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

of various base metals


108

.................................
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

How to handle gas (oxyacetylene)

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) Safety in gas cutting ....................................


3) Safety in welding ......................................
4) Safety in sheet metal work ................................
5) Preventing electric shocks. ................................
6) Cautions during welding and cutting. .........................
1 . 3 Types of welding methods ..................................

2.

FEATURES

OF WELDING

2-1

Gaswelding

2-2

Arcwelding..

....

METHODS

1
1
1
1
2
3

, ...........

, ......

4
4

............................................
..........................................

1) Arc welding with covered electrodes.


2) Submerged arc welding

5
5

.........................

..................................
..............................

6
7

3) COz gas shielded arc welding

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 ..............

Types of welding rods and how to select them

3) Types of wires for COz gas shielded arc welding

..................

17
18
19
20
20
21

.......................
................................

4) Types of gas welding rods for mild steel

22

5) How to select welding rods

23

5-2

Types of arc welders for arc welding with covered

5-3

...........................
........................................
Welding positions
Methods of deposition .....................................

25

welding rods and how to select them

5-4

17

26
27

1) Forehand welding

2) Backhand welding

3) Symmetric

welding

4) Skip welding

5) Prestrain welding

6) Restrain welding

7) Heat induction welding

8) Water cooling 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

. 2 Defective shapes of beads ...................................


1) Too thick or too thin throat depth ...........................
2) Overlaps ............................................
3) Undercuts ...........................................
4) Defective treatment of craters ..............................

48
49
52
52
53

against blow holes and pits

(manual welding and CO* gas shielded welding)

...................

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

...............................

for various kinds of welding

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

. 3 Example of entries .......................................

64

HOW TO HANDLE GAS (OXYACETYLENE)


WELDERS
AND CUTTERS ..........................................
Basic factors of oxyacetylene welders ...........................
9-l
9-2 Structure and use of welding torches ...........................
1) Low pressure type (Injector type, French type) ..................
2) Medium pressure type (German type) .........................
3) How to adjust the flame. .................................
4) Welding methods ......................................
9-3

Structure

and use of cutting torch

1) Low pressure type (Injection

...................................
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

Preventing accidents in welding work

4) Countermeasures
IO-2

84
84
84
85

against ailments caused by the smoke

produced in welding ....................................


Preventing accidents caused by gas .............................

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

3) Time required for arc welding with covered welding rods


4) Power consumption

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

How to handle oxyacetylene

9-7
9-8

71
72

74

9-5

1) Hoses and connectors

70

74

..........................

2) Medium pressure type

9-4

70

74

.............................

type)

62
62

8 . 1 Welding symbols.

for arc welding

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

Welded structures with added substances.

12-4

Connection

of welded structures with connectors

12-5

Connection

of box type welded structures to planes

...................

.................

89
90
91

92
93
93
94
95
96

How to place reinforcement

12-7

Welding between cast or forged materials or to sheet metal frame

12-8

patches.

...........................

12-6

Materials on which stress is concentrated

........

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

of covered arc welding rods based on JIS, AWS, BS, DIN

1) Classification

of welding rods based on JIS

2) Classification

of welding rods based on AWS

3) Classification

of welding rods based on BS

4) Classification

of welding rods based on DIN

.....................

.....

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

persons must not handle the gas

cutting machines.
(5)

of con-

As a rule, do not pile products or materials more


than one meter high.

Welding is often used to built up

of construction

machinery

portant

parts, and thus the quality

greatly

affect

the overall quality

and its im-

(6)

Observe the safety tips for transportation,

sling-

ing work, hoisting work, etc.

of the weld will

of the machinery.

This means that welding techniques play an essential


in the

(4)

is

used to connect metals. Many welding techniques are

role

TECHNIQUES

service department.

This

manual

will

3) Safety in welding

(1) When working in a small place or on a positioner

describe how to do welding work properly.

stand, take care so that the holder does not come


This book uses the symbols approved
nese Industrial
indicate

Standard).

Some tables, however, also

the symbols approved

by AWS/ASTM.

the relation of JIS and AWS/ASTM


other major coutries (BS or DIN),
List of Standards of Welding
Section

(2) Always use specified protectors (leg covers, arm

For

covers, apron, safety mask, etc.).

and standards of
refer to Section 13,

Rods by Countries, and

14, List of Standards

into contact with your body.

by JIS (Japa-

of Metal Materials by

(3)

Never

(4)

Never wear oily or torn clothes when welding.

(5)

Countries.

use damaged

holders or cabtyre

Use a noncombustible

cables.

screen. When gouging, set

the screen in the area where the sparks fly.

4) Safety in sheet metal work

1 -2
I)

HINTS

ON SAFETY

(1) Always

IN OPERATION

remove

hammer.

Use only

them.
means

protecting

yourself

and others

(3)

Sheet metal working


pass from

(making the

in each process different)

(4)

strictly

observe

the

and be-

standard

work

slinging

work,

and

must always be observed to prevent

hoisting

(1)

position

without

ignition

your

lighter.

face near the nozzle


If ignition

cock once and check

(Clse

place

working

screens

with

slings, always observe the

(1)

Always maintain welders in good condition.

(2)

Always

make sure that the housing of the welder


materials

to be welded

are grounded

securely.
Always

make

sure electrode

holders

are well

insulated.
(4)

Always

make sure welding cables are completely

insulated.
of an

fails, close the gas

for abnormalities.

a grinder,

place and wear safety goggles.

5) Preventing electric shocks

(3)

bring

with

standard work procedure.

soapy water to check for gas leakage.)


Never

working

When

(2) Before and after gas cutting, make sure there is


no gas leakage, then close the main valve.

a crane, never

(6)

good

reason.

(3)

When

and the
work

over with

Always wear the specified protectors.

2) Safety in gas cutting


leave your

material

work

accidents and

to create a bright working environment.

Never

jigs and tools.

(5)

The safety tips on material handling and

transportation,

When turning

around the work

must always arrange their surroundings

and

the specified

turned over.

change as

often need to handle heavy materials.

The workers
operations.

of the workpieces

one process to another

operations

cause workers
properly

a sledge

stand on the side on which the products will be

is especially dangerous because

the shape and weight


work

using

from

injury.

they

when

(2) Check jigs and tools for breakage before using

Introduction
Safety

gloves

Use earplugs if very noisy.

Then

try to ignite again.

-l-

(5)

Always wear dry welding gloves. The gloves must


be in good condition.

(6)

Never expose your

body to the welding

Do not let a sweaty shirt dangle.

flame.

Always wear

dry shoes.
(7)

Do not leave holders on the ground.

6) Cautions during welding and cutting


(1)

When working

in a closed room, always provide

ventilation.
(2)

Before

cutting

inflammable

a container

which

contained

an

or poisonous substance, make sure

that all residues of the dangerous substance have


been removed completely.
the inside completely

If a drum, wash out

before cutting.

Remember

that some substances which are not poisonous at


normal

temperatures

gas when heated.


which

may produce a poisonous

When working

has contained

on a container

an inflammable

substance,

first fill it with water as shown in the figure, and


make

sure there

is an opening

to

allow

any

remaining gas to mix with external air.


(3)

When heating, welding, or gas cutting an enclosed


container

or material which has a cavity, always

make sure that there is an opening for air.

If

there is not an air passage, drill a hole to make


one.
(4)

When

After

finishing the welding,

cutting

materials

with

fill the hole.

gas, protect

the

containers, hoses, legs, etc. from sparks.


(5)

When heating a cast iron product,


ings etc., which
sion coefficient.
out while

have a different

remove bear-

thermal

expan-

If not removed, they may pop

being heated

and may cause an ac-

cident.

-2-

l-3

TYPES

OF WELDING

METHODS

The welding methods used in various fields are shown


below.

The methods shown in boxes 0

used in the construction


ing with

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

Electron beam welding

Plasma arc welding

Pressure welding:

Joining

metals

by

heating

them

Brazing:

Fusion welding:

Joining metals by fusing them with

the heat of gas or an arc.

until they become soft and then lapping them.


Joining metals by depositing a molten alloy

with a much lower melting point (solder, hard solder,


etc.) between the metals to be joined.

-3-

2.

FEATURES

OF WELDING

METHODS

2 - 1 GAS WELDING
*

Gas welding is a method of joining metals by melting


parts of them
duced

with

a high temperature

by gas and oxygen

(welding rod).

Generally,

gas. Since temperatures


obtained

flame

and adding filler

pro-

Welding rod

metal

acetylene gas is used as the

of 3,OOOC and above can be

if the gas is burnt in oxygen, most common

metals can be melted.


This is called oxyacetylene
which

is shown at right.

gas welding, the outline of


Since the temperature

pro-

Core of flame

duced by gas welding is much lower than by arc welding and the concentration
not

efficient,

However,

it

is not

of heat is not high, that is,


used so widely

nowadays.

since the heat can be adjusted manually by

changing the distance between the torch and metals,


gas welding
easily

is suitable for joining

because of

sensitivity

(less the 1 mm thick),

metals

to heat,

that

formed

in places where
carrying

electric

the

equipment

simple

Weld metal

welding

Acetylene is dissolved in acetone and absorbed by

metals.

merit of the gas welding is that it can be perby

Basemetal

sheet metals

pipes, and nonferrous

Another
available

Solidified
weld metal

crack

a porous substance inside the pressurized tank.

is not
devices.

Gas welding

Disadvantages

Advantages

1) Wide range of application.

1)

Area heated is wider than in arc welding.

2)

Heat can be adjusted freely.

2)

Heating time is long.

3)

Devices can be transported

3)

The mechanical

easily.

4)

Equipment

5)

Metals that are highly sensitive to heat and that are

cost is low.
4)

Welded metals may be carbonized or oxidized.

5)

Depositing rate is low.

Suitable for welding sheet metals, pipes, nonferrous

6)

There is a large possibility of explosion.

metals,

7)

Cost of consumables is high.

likely to crack can be welded.


6)

strength of welded metals is lower-

ed in some cases.

and especially

metals

with

a low fusion

point.

-4-

2- 2
-

ARC WELDING

In arc welding,

an arc is produced between the base

metal and electrode

and the resulting heat is used as

the heat source for welding.


The temperature

of the arc is very high.

is used as the electrode,

When steel

the temperature

can exceed

6,OOOC.
The temperature

of the metal melted in this hot arc

is also high, and the melted

metal absorbs a lot of

oxygen

the

and

nitrogen

from

air

brittle. To prevent this phenomenon,

and becomes

various methods

are used to prevent the air from contacting the metal.

Transformer (AC)
Base metal

Grounding cable

Rectifier (AC)
Generator (AC)

I) Arc welding with covered electrodes


In this widely

used method,

the flux

covering the
Electrode

core wire prevents the air from contacting the melted


metals,

that

is, the

decomposed

flux

covers the
Welding direction-

melted metals.
The flux not only improves the chemical and mechanical properties

of the weld metal, but also improves


This

its workability.

method

has the

following

advantages:

(1) The arc is stabilized by the decomposed flux.


(2) The gas or slag protects the melted metals from
being exposed

to the air, which would

oxidize

and nitrify them.


(3)

Impurities
phur

(4)

(5)

such as oxides, phosphorus,

do not get mixed

Elements

and sul-

in the melted

metals.

of the alloy are added to the melted

metals.

6. Reinforcement

The slag protects the melted metals from cooling

C. Penetration

rapidly.

D. Weld metal

AC and DC current are used as the power source for


arc welding.
opment,

In the early stage of arc welding devel-

a DC current was widely

used because of its

stable of arc. However, the stability has been increased


by

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

F. Base metal not affected by heat


G. Base metal

2) Submerged arc welding


In this method, the portion to be welded and the end
of the electrode

are covered by the powder flux to

shut off the air and prevent


melted

it from

contacting

the

The arc is generated under the flux.

metals.

This is called submerged


arc is generated

arc welding

because the

under the powder flux and the blue

spark cannot be seen.


Since the core wire wound on a wire reel is sent out
continuously
the

instead

machines

Submerged

are

of

using covered

automated

or

electrodes,

semiautomated.

arc welding has the following

advantages

over arc welding with covered electrodes.

(1)

Since a large current can be used, the depositing


rate

and penetration

relatively

are extremely

high, and

thick steel plates can be welded

in a

single pass.

(2) The welding conditions

(3)

Therefore,

differences

minimized

and reliability

can be held constant.


in

welders,

skills

are

improves.

Since the amount of bevel and leg length of. the


fillet

weld can be decreased, the welding

mate-

rials can also be decreased.

Submerged

arc welding

is mainly

used to join mate-

rials in ship building, tanks, steel pipes, bridges, and


other

structures,

carriages

in

build

of construction

up welding
machinery,

for

and

underin wear

portions of machines used in civil engineering.


It is most suitable for welding

thick

materials con-

tinuously over a long weld line.

-6-

Contact tip

3) CO2 gas shielded arc welding


In this method,

CO2 gas or CO2 gas and other gases

are sent around

the weld metal to shut off the air

co,

- O2 arc welding
Fed continuously from steel

while welding.
Before it was confirmed

that CO2 gas can be used as

a shield gas, the inert gases, that is, argon, helium,


etc.

were

used.

However,

inert

gas shielded

arc
Bare steel wire containing
deoxidizing elements (DSI)

welding is limited to high alloy steels and nonferrous


metals,

and carbon

steel and

low alloy

steels are

usually welded by CO2 gas shielded welding.


CO2

gas shielded

welding

is roughly

(DC),

divided

-Mixture

into

gas of

three methods.

(1) Bare steel wire CO? method


CO2 gas is used as the shield gas, and bare steel
wire

containing

deoxidizing

nese, silicon, titanium,

etc.)

elements

(manga-

is used as the core

wire.

(2)

Grounding:
\
Grounding power source
(DC), 0
polarity

\
Deposited
metal

\
Melted
metal

\
Base
metal

Bare steel wire CO2 - O2 method


*

A mixture
shield

gas, and

relatively

Union arc welding

of CO2 gas and O2 gas is used as the


bare

large quantity

steel

wire

containing

of deoxidizing

Steel wire electrode

elements

and continuously)

is used as the core wire.


(3)

Various flux methods


CO2 gas, core wire, and flux (containing
nese, silicon, titanium,

manga-

etc.) are added in various

Flux stuck to ste


electrode

ways.
-

Method using a flux cored wire electrode


Method

where magnetic powder flux is stuck

to steel core (Union arc welding)

-7-

Arcosarc wire

Flux cored wire

Fuse arc wire

Since the core wire

is supplied

continously

in the

CO2 gas shielded arc welding

in the same way as in

the

described

submerged

machine

arc

welding

is automated

before,

or semiautomated

the

and is easy

to use.
Welding
highly

with the bare steel wire is mainly


efficient

thick plates.

welding

used for

of thin plates and medium

On the other hand, as welding with steel

wire and flux

has good workability

and produces a

good bead, it is used for fillet welding and in places


where good appearance is required.
In addition,
the flux,

since alloy elements

can be mixed into

it is also used for case hardening ouild up

welding.
The advantages common

to various CO2 gas shielded

welding are shown below.

(1)

Weld

metals

can

be

obtained

which

contain

little oxygen, nitrogen, and hydrogen.

(2)

Since

cheap CO2

gas (sometimes

with

a little

oxygen)

is used as the shield gas, high speed

welding

with thin wire can be done, so the cost

of welding is lower than other welding methods.


(3)

Because of the density


the peneration

of the welding currents,

is deep and the depositing rate is

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

Fillet weld joint

Butt joint

Thick,
25 or more

Medium,
3.2 to 25

4.

PREPARATIONS

To achieve good welds, you must not only choose the

priately

best welding

type of joints to be used.

method for the properties

rial to be welded,

4 - 1 TYPES
*

FOR WELDING

of the mate-

for the thickness

of the materials

and the

but also prepare the edges appro-

OF JOINTS

Barious types of joints are shown below.


Tee joint

Corner joint

Lap joint

Butt joint

Edge joint

Double-strapped joint

joint

Four welding methods are shown below:

Butt welding

Singlestrapped

Corner welding

Fillet welding

Plug welding

line is

When fillet welding on both sides of a plate, the weld

called continuous welding; one made in stages is call-

can be classified as either parallel welding or staggered

The

welding

ed intermittent

made continuously

on a weld

intermittent

welding.

fillet welding, according to the positions

of the weld zone.


Continuous 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

methods are shown below.

the edges of the metafs to melt their faces so that

A method is chosen according to the thickness of the

they can be joined completely.

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

- Used for welding


thick plates

- Without backing
6to

16

strip

- Back run may


be made.

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-

The carbon equivalent

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%

to the above rolled steel products, forged

steel and cast steel are also used.

factor in

the following

formula:

steel and high tensile steel) used for the structures,

In addition

(Ceq) is an important

It is obtained

+ 1/40Ni

+ 1/5Cr + 1/4Mo + lJ14V

High carbon steel

and low alloy steel are used for gears and wear resis-

In the

tant parts.

(Ceq is below 0.4).

Table

below,

A indicates that care is needed

indicates

and x indicates that a lot of care

The table below briefly

shows the chemical composi-

(Ceq is 0.4 to 0.5).

tion, carbon equivalent,

weldability,

is needed (Ceq is above 0.5).

and usage of the

good weldability

When welding materials

with a Ceq of 0.5 or higher, preheating and postheat-

main kinds of steel.

ing must be carried out.


1) Rolled steel for general structures (JIS G3101-1977/ASTM
Mechanical properties

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

2) Rolled steel for welded structures (JIS G3106-1977/ASTM


Mechanical properties

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

3) Cold rolled steel (JIS G3141-1977/ASTM

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

Cab and guard

Weld
ability

Usage

0.15

228
Tvpe 3

SPCE

4) Carbon steel for machine structural use (JIS G4051-1965/ASTM

Tensile
trength
(%
:g/mm*

Elongation

Yield
point

(kg/mm*

Hai,A,xq
-, ,.Mb)

(%I

SlOC

> 32

L? 21

zz 33

109 to 156 ;;3

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

137 to 197 O$y

s35c

2 52

> 31

223

149 to 207 $2

S4OC

255

2 33

>22

156to217

S45c

258

>20

167 to 229 &j

262

zz?37

218

179 to 235 o ;;io

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

183 to 255 O.&o

>I5

5) Carbon steel and forgings for general use (JIS G3201-1964/ASTM

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

6) Carbon steel tubes for general structural purposes (JIS G3444-1977/ASTM

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

7) Carbon steel tubes for machine structural

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

purposes (JIS G34451977/ASTM

Mechanical properties

SO.05

Weldability

usage

8) High tension rolled steel plates for welded structures (SHT)

(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

Alloys are added if necessary.

-<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

If the flux of the covered welding


workability

rods is wet, the

decreases, the moisture

holes or other defects,

and there

increase in hydrogen brittleness,


in the weld.

Therefore,

will cause blow

is likely

to be an

which causes cracks

always make sure that the

welding rods are sufficiently

dry.

Drying methods are

described in the table below.


Low hydrogen type welding rods, which are made to
decrease the moisture
300 to 350C

in the flux,

must be dried at

for about one hour before use. The

rods must be dried without fail.

Redrying
temperature
(C)

Standard

Type of rod

llmenite type

JIS D4301

Lime-titantia type

JIS D4303

Cellulose type

JIS D4311

AWS E6011

High titanium oxide type

JIS D4313

AWS E6013

Drying time
(minutes)

70 to 100
30to60

JIS D4316
Low hydrogen type

AWS E7016 (E6027)

300 to 350

JIS D5016
Flux for submergedarc
welding

4 -5
-

CLEANING

There

is a tendency

However,

150 to 300

WELD

ZONES

to neglect to clean weld zones.

since defects and accidents can be caused

by rust, paint,

oil, etc., the zone to be welded

must

always be clean.
Cloth,

wire

brushes, a grinder,

etc. can be used to

clean the surface.


Heating the zone to be welded

with a gas burner is

also fairly effective.

-16-

5.

WELDING

5-1

TYPES
OF WELDING
HOW TO SELECT THEM

Along

with

machine

TECHNIQUES

welding

skill and the type

used, the welding

component

of welding

the greatest

RODS

influence

AND

of welding

rods is the third

methods.

major

Welding rods have

on the mechanical

properties

of the weld zone.


Therefore,
welding

welders must know the basic facts about

rods and how to use them,

and be able to

select the most suitable one for the job.


Selection

of

welding

rods should

never

merely on low cost or high workability.

be based

On the other

hand, it is not economical to use high quality welding


rods on all material.
For the above reasons, always choose the welding rod
after careful consideration.

Classification
Various

of welding rods

welding

.For manual
welding

rods are available depending on the

welding methods.

r Bare welding

They are roughly divided into bare

rods

welding rods and covered arc welding rods. They are


further

divided

into

two

groups,

depending

whether

they are used for manual welding

on

Gas welding rods

Other filling rods

Core wire for


automatic welding

or auto-

matic welding, as shown in the table at right.

Welding rods.

For manual-Covered
rods
welding
. Covered welding
rods

When welding rods are used, the weld zone is covered


by gas (oxyacetylene
etc.)

and sometimes

from

contacting

welding

flame,

argon, COZ,

nitrogen,

by the flux to prevent the air

the melted

metals.

Some covered

rods protect the weld zone with the neutral

or reducing gases which are generated when the flux


burns, and other
weld

zone with

covering

covered

materials.

ing welding

welding

the slag which

rods protect

the

is made from

the

The former are called gas gnerat-

rods (gas shield type),

and the latter are

called slag generating welding rods (slag shield type).

-17-

welding

Fuses, arc
For automatic -welding
rods,
and others
welding

Exposed core

2) Types and features of covered welding rods

Arc welding with covered welding rods is used widely


because it has many general merits.

The welding rods

used in this method are called the covered arc welding


rods.

They are made of a metal core wire and have a

dried covering material as shown in the figure at right.

The core wire is made of rimmed


tains

only

small

phosphorous
rials

are

amount

to prevent cracks.

made

organic matters,

from

oxides,

fluorides,

steel, which con-

of carbon,

sulphur,

and

The covering matecarbonates,

silicates,

alloy iron, etc.

They are

divided into several groups according to the blending


ratio.
This is called the covering system.
The

covering

welding

rods are classified

according

to the metals to which they will be applied, that is,


mild steel, high tensile steel, medium and high carbon
steel,

low

nonferrous

alloy

steel,

alloys.

hard

facing,

cast iron,

and

They are also classified as follows,

according to the covering system mentioned

above:

llmenite type
Lime-titania

type

High cellulose type


High titanium

oxide type

Low hydrogen type


Iron powder-high titanium

oxide type

Iron powder-low

hydrogen type

Iron powder-iron

oxide type
D 43

Special type
Each type
features.

of welding

L Indicates type of covering material.


0 - Special type
1 - llumenite type
3 - Hightitanium oxide type
4 - Iron powder-titanium oxide type
6 - Low hydrogen type
7 - Iron powder-iron oxide type

rod has its own distinctive

As an example,

the types and features of

the covered welding rod for mild steel are shown on


page 19, and the types of covered welding

rod for

high tensile steel, which is often used in construction


machinery,

are shown on page 20.

The JIS symbols (D4301

or D4340)

used in the tables

have the meanings shown in the table at right.

Indicates welding position


0 - Developed in Japan and can be used in any
position
1 - Can be used in any position (Cellulose type,
if followed by 1)
2 - Can be used in flat position and in
horizontal fillet welding
4 - Can be used in any position including
special position (Iron powder-low hydrogen
type, if followed by 6)
Indicates tensile strenght (kg/mm*

18-

Types and features of covered arc welding

For Standard of AWS/BS/DIN,

rods for

Type of welding rods (JIS)

D4301

Type of covering materials

llumenite

44to48

Elongation (%I

y
High titaniurn oxide

High
cellulose

_ime-titania
I

Pi
c

refer to List of Standards

of Welding Rods by Countries.

mild steel (JIS 23211-1967).

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

Impact value (kgm)

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

Main features and usage

-19-

Plain
Excellent

Excellent
I

-t

Slightly deep

Few

Few

Types

of covered

welding

rods for

mild

steel (JIS

For standards of AWS/BS/DIN,

2321 I-1978).

refer to List of Stand-

ards of Welding Rods by Countries.


Mechanical properties of deposited metal

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

High titanium oxide

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

Iron powder titanium


oxide

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

or Horizontal fillet welding

(A)

F: Fiat

(B)

AC: AC current
DC (2): Both polarities of DC current
DC (+): DC electrode positive

DC t-1: DC electrode negative

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-

Mechanical properties of deposited metal


Welding current

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 -

3) Types of wires for COz gas shielded arc welding


The wires for CO2 gas shielded arc welding are classified

roughly

Types

of solid wires are shown in the table below.

as solid

wires and combined

wires.

These wires are generally plated with copper in which


the chemical composition

has been adjusted.

They are most widely used in semiautomatic


(JIS 23312-1977/AWS

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

wires are made of steel hoops and

powdered substances, the sectional areas of which are


shown at right.
a

deoxidizer,

The

table

The powdered
alloys,

below

and

FIUX

substances consist of

slag forming

shows the features

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

not exceeding 0.30%.


Suitable for welding with a current of 230A
horizontal fillet welding.

Amounts of aluminum, titanium,


YCWP

or more (spray transfer range). Generally used for flat position or

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)

4) Types of gas welding rods for mild steel


The

types of welding

carbon

rods used in gas welding

steel and low alloy steel, which

of

are easy to

weld, are shown in the table at right.


The diameters of these welding rods are regulated by
JIS to 1 to 6 mm and the length to 1,000 mm.
addition,

In

the type or brand name is carved on them,

or the ends are colored for distinction.

- 22 -

SR means that stress is removed:


NSR means that stress is not removed.

5) How to select welding rods


It

is fairly

difficult

for

inexperienced

select which covered welding

persons to

rods and COs gas arc

solid wires to use since many factors are involved.


The following
ing rods,
ordinary

tables clearly show how to select weld-

based on the

theory

and experience

of

repair shops.

Steelfor structures
Materials (JIS)

. __
-::.:
*::.
-::.:
,*:.*.
. . . . . . .~.~.~.~.~.~.~.~.~.~.~.~.~.~.~.~
~.~.~.~.~.~.~.~.~.~.~.~.~.~..~.~.-.~
. . . . . . . . . . . . . . . . . . .

Note

When joints
use C.

require a high cycle fatigue limit,

When the static strength of joints must

be equal to that of the base metal, or when high


wear resistance is required, use D.
(A - 2)

D4316

I D4326 I

In each use range, when high durability


deposited

metal

is not especially

of the

required,

use

welding rods whose deposit metal has a strength


B

(~50161

below 50 kg/mm

in order to reduce the cost of

welding rods.
Figure

in

) following

rials indicate
(calculated
component).

- 23 -

percentage

with

upper

the symbols of mateof carbon


limit

equivalent

of each chemical

Steel for machine


structures

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.
*::::.
. .
~:::::::,
~:::::::,
:.:::::::<
_ _._*_*_*_*_..

For joints which may crack.because

of large

in each use range,

when high durability

of

the deposited metal is not especially required,

stress caused in welding, use C.

use welding

rods whose deposit metal

strength

below

of

50

kg/mm

has a

in order

to

reduce the cost of welding rods.

) following the symbols of mate-

* Figure in (

rials indicate percentage of carbon equivalent


(calculated

with upper limit of each chemical

composition).

- 24 -

TYPES OF ARC WELDERS FOR ARC


WELDING WITH COVERED WELDING
RODS AND HOW TO SELECT THEM

5-2

Covered

welding

welding

methods

welders

for

in Komatsus

arc welding

are divided
and DC.

rods are used much more than other

into

two

with

types

The following

service
covered

shops.

The

welding

rods

by the current

used, AC

table shows the types of arc

welders.
Motorgenerator
Rotary type

type

Engine driven tvpe

DC arc welder
Thermal flow tvPe
-c

Static type
i

Discharge tube type

Arc welder
Removable core tVPe
Removable coil type
AC arc welder
Saturable reactor tvpa
Tap changer type

In the early stages of development


welders
have

were widely

replaced

used.

them

of welders,

However,

as the coverd

DC arc

Items

arc welding

rods

have been improved.


At

present,

DC

arc

welders

purposes

such as welding

outdoors

with

AC

welders

The main
pared
are

are used

for

special

thin sheet metal or working

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

engine driven welders.

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

welders are used in the field.

25 -

5 -3
*

WELDING

Various

welding

POSITIONS
positions are possible, as shown in

the figure at right.

These include the overhead posi-

tion,

vertical

flat position,

tion, and combinations

position,

horizontal

Flat position

Vertical

position
$0

Ctd
i\ZO

posi-

of these positions. Since weld-

ing in the flat position provides the best performance


of joints and highest work efficiency,

the materials to

be welded must be set so that they can be welded in


the flat position.

This can be done by arranging the

m
Vertical

order of assembly and using proper jigs.


For the angles of welding

rods, refer to the figure

- Horizontal position

below.

Vertical

Welding in flat position

Horizontal

Welding in vertical position

Welding in horizontal

26 -

fillet welding

position

Overhead position

5-4

METHODS

OF DEPOSITION

* When depositing a welding rod on a base metal, deformation,


In

shrinking,

addition,

and residual stress always occur.

the

heat

affected

zone

may

become

brittle or may crack, depending on the material of the


base metal.
Various

methods

of deposition

have been developed

to prevent these defects.


Classified by direction
forehand
welding,
strain

of weld, these methods include


backhand

and skip welding.

welding,

welding,
layer

welding,

welding,

symmetric

To prevent strain,

restrictive

welding,

heat

and water cooling welding are used.

methods

include

buildup

welding,

pre-

induction
Multicascade

sequence, block sequence, etc.


*

1) Forehand welding
Forehand

welding

used method.

is the simplest

and most widely

However, when welding long lines with

this method,

there

is likely

and residual stress.


hand

welding,

to be a lot of shrinkage

To prevent these defects, back-

symmetric

welding,

or skip welding

can be used.
2) Backhand welding
In backhand

Forehand welding

welding, the direction

site to the direction

Progressof weld

Backhand weld

Symmetric

of beads is oppo-

of the overall weld, as shown in

the figure at right.


This method
tions

is used to prevent corrugated deforma-

(buckling

distortion)

which

occurs on thin

steel sheets.
3) Symmetric

welding

In this welding

method,

welding

is performed

the center of the weld line toward


ities by

depositing

the proper

from

the outer extrem-

length of beads, as

shown in the figure at right.


When welding

X-grooved

or H-grooved joints,

metric welding should be performed


weld

line but also on the front

alternately.

For

a long fillet

welding should be performed

welding

sym-

112211)1~)\)))))))(((((((((((~
-

Progressof weld
--

not only on the

side and back side

weld

on both

alternately

sides,

on the right

side and left side.


*

4) Skip welding
In

this method,

welding

is performed

Skip welding

by skipping

over one or two sections.


This method is used to weld cast iron.
Progressof weld

- 27 -

5) Prestrain welding
In this method,
is predicted.

*
the deformation

The prestrain

Prestrain welding

caused by welding

is given before welding,

as shown in the figure at right.

6) Restrain welding
In this method,
by

force

The

figure

Restrictive welding

Heat induction welding

the materials to be welded are held

to prevent

deformation

of t;ie materials.

at right shows an example

welding where the butt welded joint

of restrictive
is clamped

by

jigs.

7) Heat induction welding


In this method,
operation
heat

the heat produced

is transferred

conductivity

to

in the welding

to a substance with
prevent

deformation

Base metals

good

Jig

caused

by heat.
The
heat

heat is absorbed near the weld line by a good


conductor,

such as copper,

Copper

as shown in the

figure at right.

8) Water cooling welding


In this method,

Water cooling welding

the back side of the weld zone is

cooled with water to prevent deformation

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

to lessen the deformation

Water

the beads are

However,

cascade

sequence is often

used

-I@-

and residual stress.

* Cascade sequence

Sectional drawing at weld center line


*

Forward block sequence

Sectional drawing at weld center line

- 28 -

5 - 5 WELDING
*

To

prevent

defects

always work
tors

in welding,

it is important

under the proper conditions.

affecting

voltage,

CONDITIONS

welding

arc current,

conditions

to

The fac-

include

the

welding speed, atmosphere,

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

in the table below may

occur.
Generally,

the arc length should be about the same as

the diameter of the core wire.


The

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

When arc is unstable

1.

Penetration will be uneven.

2.

If arc is too long, it cannot be concentrated;


short, short circuit is likely to occur.

3.

Undercut and overlapoccur

4.

Width and height of beads are uneven.

5.

Slag is included in beads.

6.

Oxygen and nitrogen from the air get mixed into the
beads, and the weld metal becomes brittle.

if too

1.

Keep arc length constant.

2.

Adjust welding current properly.

3.

Connect welding cables perfectly to reduce


resistance in circuit.

4.

Clean the surfaces to be welded.

easily.

Cautions
Set the
to

grounding

be welded

sparking

cable as near to the surface

as possible.

may occur

(Be careful

in the hydraulic

Remove the grounding

terminal

because

cylinders.)

from the battery

before starting to weld.


Do not start the engine while welding.
Wind

must not blow directly

against the surface

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,

the arc current should be increased when

welding

in the flat

vertical

position,

position.

When welding

in the

the current

should be 20 to 30%

less than in the flat position.

When welding in the

overhead position,

it should be 10 to 20% less than

in the flat position.


If the arc current

is not proper, the follwoing

tend-

encies are likely to occur.

When arc current is too weak

When arc current is too large

Undercuts occur easily.

1.

Overlaps occur easily.

Penetration becomesto deep.

2.

Penetration is insufficient.

Many spatters appear.

3.

Slag is likely to be included in beads.

Slag deos not cover beads completely; surface of beads


become coarse.

4.

Beads become too narrow and too high.

5.

Blow holes occur easily.

6.

Deposition rate of welding rod becomes too low.

Welding rods get red hot.


Deposition rate of welding rod becomes too high.
Blow holes and cracks occur easily.
Flax drops off while welding.

Since the deposition

rate of the welding rods is not

related to the arc voltage but is proportional


arc current,

a large current

to the

is necessary to increase

the welding speed.


For this reason, a large current
full automatic
ing wire.

is used in semi and

welding for the diameter

of the weld-

(The current density is high).

- 30 -

5- 6
*

DEPOSITION

Although

RATE

the deposition

edge preparation,
deposition

rate depends on the types of

welding current,

etc., the average

rate for arc welding with covered welding

rods of 4 mm diameter at 170A is 150 to 200 mm per


minute, for example.
The depth of peneration
welding

current

is determined

to the deposition

by the ratio of

rate.

Therefore,

if the welding current is large, the deposition


be increased

almost

in proportion

rate can

to the welding

current.
The table below shows an example

of conditions

for

butt welding and fillet welding.


1) Welding

conditions

for

butt joints in flat

V-shape

position
loot yp$ing

Method of depositing beads

(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

B indicates one back run. Two or more different

1-B and 2 to 4 in the number of beads column

sizes in the column

means that the first welding and the back run are

(for example,

4.0 mm,

of welding

rod diameters

5.0 mm,

6.0 mm) means

performed

with

welding

rods of 4 mm diameter,

and the second layer through

that all of them are used together.

welding rods of 5 mm diameter.

-31

fourth

layer with

2) Welding condition

for fillet

welded joints in horizon-

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

Size of tack welding


Outer dia. of pipe

osition of tack welding

Dia. of welding rod


Lenght (Q)

,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)

Position to start welding:


position.

Avoid the tack welding

Make the weld so that neither the starting

point nor ending point are near the points of maximum

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 -

When pressure is applied, a bending


force will act as indicated by the
dotted line. (Avoid starting or
ending welds in bending directions.)

(2)

Lapping length at end of weld (L):


length + 10) mm or more.

Must be (crater

(Fig. 3 and 4)

Note:
(1)

Size of tack welding:

If the size of tack welding is

not proper, the penetration

by regular welding will

not be sufficient,

and will

result in cracking and

For strengh,

it is ideal to deposit

oil

leakage.

narrow

and long beads by tack welding,

workability
(2)

&
0

but the

will be low if too narrow.

Position of tack welding:


tack

may crack if the maximum


on it.

in the direction

Fig. 3

Since the area around a

weld may not be sufficiently

concentrated

Crater

penetrated,

stress is applied

Therefore,

it
and

avoid tack welding

in which the maximum

stress is

applied (in the bent direction).


(3)

Position to start regular welding:


tration

Since the pene-

started from the position of the tack weld, do not


start the regular weld from there.
penetration

may not be sufficient

the stress to concentrate

there.

and the beads


Therefore,

end the weld in the same direction


maximum
Lapping

Sectional drawing of bead

In addition, the

may not be even at the end of the weld, causing

(4)

First

may not be sufficient if the regular weld is

never

in which the

stress. is applied (in the best direction).


length at the end of the weld:

If the

lapping length at the end of the weld is too short,


oil may leak.

- 34 -

Fig. 4

layer

5 -8

BACK

When

butt

RUN

AND

welding

may be performed
weld

defects

inclusion

BACKING

thin

sheet steels, the back run

without

back chipping.

such as insufficient

However,

penetration,

slag

and blow holes tend to appear in the first

layer of the general butt welded joints,


chanical properties
rapidly.

and its me-

are not good because it is cooled

Therefore,

the back side of the weld zone

is often

chipped off and welded after depositing the

second

and subsequent
required

The

side can be chipped

back

Back chipping

layers.

especially

if the joint

is

needs to be strong.
Flatten with a grinder

off with machines or

chisels, and can be removed by gas gouging or arc air

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,

not be too thick.

are usually used.


it is.

Strips

The narrower

It is tack welded by spot

and must be tack welded

Spot welding only

so close to the

base metal that no gap remains and so that it can be


fused together with the first layer and the base metal
perfectly.
welding

In addition,
current

for

it is necessary to increase the


the

first

layer

to

penetrate

deeply.

35 -

Backing strips

5-9
.

TACK

WELDING

Tack welding

is an auxiliary

welding

performed

be-

fore the regular welding to keep the assembled parts

G!i%
4i3

in the proper positions.


Since tack welding is short, it is composed of only the
starting

point

insufficient

and a crater.

penetration,

sion often occur.

Thus, such defects as

blow holes, and slag inclu-

Therefore,

tack welding

must be

avoided on places where stress is concentrated


as ends, corners, and important

4!9

such

strong points which

are shown in the figure at right.


Tack

welding

which

later

impossible

must

will
to

not

performed

be welded

avoid

on the

permanently.

such places, the

places
If it is

tack welded

positions must be removed before making the regular


weld.

This must strictly

observed for those strong

parts whose thickness is important.


Gaps are often produced between plates during tack
welding.

To

prevent

this, the following

methods

are used.
1) Just after tack welding (while the slag is dark red):

Hit with hammer to set


the plate as shown by
the dotted line.

Hit the tack welded position with a sledge hammer or


a hand hammer as shown in the figure at right.
When tack welding two plates, reduce the gap to 0.5

Gap: 0 - 0.5 mm

mm or less. If C-clamps are used from the first, the


gap can be minimized

and the regular weld can be

made easily in a short time,

I f

and the weld zone can


Section A - A

be kept strong.
2) Butt tack welding:

* When tack welding new parts


Set the root opening to 0 to 3 mm.

* When gouging for repair (of cracked or bent portions):


Before gouging, measure the thickness of the plate
to be gouged, and leave a root height of 1 to 2
mm.

Do not make the root opening too wide.

t Root

36 -

height

3) Examples of tack welding jigs


Various
tack

jigs are used for temporary


Some

welding.

examples

assembly and

are shown

below.

Tack weld on one side only.

5-10
*

REGULAR

Use for bolts, seats, or when squareness or


tolerance are specified.

WELDING

In regular welding,

the welding rods, their diameter,

and the welding current are selected according to the


thickness
welding

of materials,
position

type and size of joints,

in order to obtain

and increase the efficiency


Note:

The following

and

the best results

of the work.

points must be noted carefully

during regular welding.


(1)

Since the starting and end points of the beads


tend

to be incomplete,

welding
(2)

If

at the

your

end

do not start or end

or corner

can not avoid starting

welding

of

material.

or ending

at the end or corner of a material,

turn back on the beads.


(3)

Round the corners of plates, and do not cross


fillet weld lines.

(4)

Examples
ones

of

good starting

(insufficient

points

penetration),

and bad
and

good

ending points and bad ones (cracks in crater


caused by bad treatment
on the next page.
the welding
starting

method

of crater) are shown

The welders must adjust


in consideration

of the

point, the cause of cracking, and the

concentration

of stress.

37 -

1) Examples of treatment

of starting/ending

positions for various kinds of welding

T-

Examples of good treatment

Explanatory

drawing

Examples of bad treatment

Weld zone

Weld zone

End at 20 to 30 mm from
corner.

Starting from corner and


ending at wrner will
cause cracking.

Connect the beads at 20 to


30 mm from corner.

Do not connect beads at


corner.

Connect beads at center of


reinforcement plate or at
20 to 30 mm from corner.

Do not start or end Welding


at wrners of reinforcement
plate.

Round corners of
reinforcement plate to
30 to 50R.

Do not cut off wrners


of reinforcement plate
squarely.

Design reinforcement
plate so that beads do not
cross each other.

Do not cross beads of


reinforcement plate as
shown in the figure.

lzl
R

- 38 -

5-l 1 BRAZING
The principle of brazing is as follows.

I) Brazing and its features


Brazing

is a method

of joining

metals known

When the brazing filler metal is heated, it melts and

since

becomes liquid.

long ago, and is still used in many electrical, mechanical, and chemical fields.

It is a method of joining two

base metals by letting a metal with

metal

feature

of brazing

is that

property

The

adheres to both of the base metals.

and soaks into them,

metal and base metals.

A filler metal which sticks to certain

base metals may not sitck to others.

Its main

important

features are described below.


Base metals can be joined without
types

flux

being melted.

Metals of different

can be joined.

The strain on the joined zone is very small, and

The

The

Brazed joints can be disconnected

work

can be automated

is used.
brazing

struction

machine work.

04

JIS Symbol

example,

the

Operation
temoerature ranae C

11

A5.8-76)

Table 3 Chemical components of silver solder (JIS 2326%1976/AWS

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

Sum of remaining elements (3)

39 -

always used in con-

pipes and adapters.

for

In this

a filler metal called silver solder is used.

by reheating.

Table 2 Chemical components of brass solder (JIS 23262-1977/AWS

JIS
Symbol

is almost

to join copper and steel -

to join hydraulic

combination,

and rationalized.

method

Brasssolder

Silver solder

When brazing, material called

Flux removes the oxides from

machinery

Table 1

Type

it is

base metals to improve the wetting property.

metals can be joined after

Therefore,

to choose a filler metal which can stick to

the base metals easily.


@

thereby
Wetting

means how easily the filler metal sticks to

the base metals.

the deposited

This melted metal wets the surface

base metals

bonding the filler

a melting point

lower than the base metals flow between them.


distinctive

of the

4) How to braze

2) Flux
Flux

is a material

flowing

which

properties

improves the wetting

of the filler

81

metal.

and

It must have

are many brazing methods

present.

They

used to melt

the following features:


2

There

An ability to dissolve the oxide film.

(flame)

Melt at a lower temperature

induction

than the filler metal,

be able. to prevent oxidization

and be able to improve

of the base metals,

the flow

of the filler

the filler

brazing,

metal.

Among

them,

torch

furnace brazing, and high-frequency

brazing

are most

parts in construction
the filler

in practical use at

are classified by the heating device

widely

machinery.

metal is melted with

used to make
In torch

a torch.

brazing,

This is the

metal.

oldest method,

Have a viscosity low enough to be pushed out by

it is simple and does not require any special devices

the force

other than the torch.

of the filler

metal

from

the gap be-

and is often used to repair parts since


The procedure of torch brazing

tween the base metals.

is described below.

Not deteriorate

(I) Preparation for brazing

Be removed easily after brazing is finished.

until brazing is finished.

Prepare the set of tools, filler metal, base metals,


flux, jig, and heating device.

The flux must be selected according to the operation


temperature

range of the filler metal.

composition
turer,

Although

the

(2) Completely

of the flux differs according to manufac-

the following

the corresponding
Borax-boric

oxidization

two types are generally used for

Fluoride type flux:

while brazing, clean by hand instead

of with flux.

base metals.

acid type flux:

remove the stains, grease, scales, etc.

Since the basic purpose of the flux is to prevent

(3)

Brass solder

When brazing with the torch, pay special attention to the place of application

Silver solder

and the amount

If these factors are not proper,

of the flux used.

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

forms of brazed joints are shown in Fig. 1.

Brazing is most often used in construction


for the joints of hydraulic

pipes and flanges.

(e), (j), and (k) are commonly


machinery,

used.

can be the criterion

Joints

liquidus

In construction

stress may be concentrated

of the joints

makes ahard slag. The active temperature

machinery

at the corners

(4)

line

for

+lOOC

brazing.

range

A range at

or so should be chosen.

The jigs are used for holding, positioning, assem-

because of vibration

and cracks may

bling, and measuring the materials to be brazed.

occur because of fatigue. Therefore,

the form and re-

They

must be given suffi-

torch

inforcement
cient

care.

of these portions

If an enclosed container

is brazed from

(5)

are especially

The

will expand and prevent the filler metal from flowing.

mostly

an air vent is necessary.

in brazing with a

is carried

out

manually.

Preheating and heating

outside as shown in Fig. 2, the air in the container


Therefore,

important

since the work


quality

of

brazing

with

a torch

on the skill of heating.

depends

If heating the

base metals up to the brazing temperature

(liq-

uidus line of filler metal) is defined as preheating,


and heating

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

of heat while brazing

absorb the filler


of the filler

metal),

metal.

In

both processes, it is necessary to heat the surface


to be brazed evenly.
(6)
Fig. 1 Typical

After treatment
The

forms of brazed joints

brazed

joints

Air vent

be

removed

completely

chemical method.

(a) Bad

need to

be cleaned.

The

residual flux, which may weaken the joints, must

(b) Good

Fig. 2 Example of air vent

- 40 -

by

a mechanical

or

5-12
.

ARC AIR

GOUGING

Arc air gouging is a method to gouge metals by melting the

metal

with

the

heat

between a carbon electrode


ing off the molten

produced

by an arc

and the metal and blow-

metal with

an air flow

injected

in parallel with the electrode at a high speed.

The

arc air gouging method

vantages

and

disadvantages

has the following


when

compared

adwith

Sketch of arc air gouging

chipping with a pneumatic chipping hammer.


Advantages
High gouging speed.
Low noise
Weld defects can be found easily since they are
not squeezed.
Easy operation.

Disadvantages
A lot of powder and dust is produced.

In the first stages of development


DC

current

and electrodes

were used.
chipping
boring,

This method

with

of arc air gouging,


rounded

sections

was used mainly

for back

of welded joints, gouging out weld defects,


and for cutting

range of

application

development

stainless steel.

However,

has been extended

with

its
the

of electrodes for AC current.

1) Power source
As one of the features

of arc air gouging, the arc

voltage increases by 10 to 15V, and the arc becomes


unstable because the working point and the electrode
are always cooled by the high speed air flow.
rule, therefore,

As a

DC current is used for arc air gouging.

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

side of the welder

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

at a high pressure, graphitized,

copper.

Its properties

of

mixture

is

and plated

are shown in Table

1.

Table 1 Main properties of carbon electrodes

0.0013 *
0.0002

1.85 *
0.02

60+5

O-=
or less

7 f 2

700 f
100

The sectional shapes of carbon rods are circular, half


circular,

rectangular,

etc.

Electrodes

with

Bead

circular

sections are used for general grooving such as back


chipping, and ones with half circular and rectangular
sections

are

base metal,
circular

used for removing projections


such as beads.

section are hollow,

on the

Some electrodes with

Electrodes

for AC

current

which can gouge a wider


with

agent is mixed

into

in workability
The

Fig. 1 Sectional shapes and application


electrodes

base meta

of carbon

the same sectional


9

and

There is no large difference

11

12

16

13

between these two types.

dimensions

carbon electrodes

Table 2

Half circular and


rectangular

The arc stabilizing

some of these electrodes,

filled as a core in others.

Hollow circular

bottom in the ,groove. (Fig. 1)


shapes are also on the market.

Circular

a standard

gouging current

of the

on the market are shown in Table

Dimensions and standard gouging current of


carbon electrodes

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

Fig. 2 Gouging torch (manual)

1. Support metal

13.

Head

2.

Body

14.

Cable connector
Cable

3.

Spring

15.

The gouging torch shown in Fig. 2 is generally used.

4.

Spring stand

16.

Rubber hose

5.

Valve

17.

Terminal connector

water

spray type

torch

is also used when

it is

necessary to reduce the powder and gas produced by

6.

Packing

18.

Punch band

gouging.

7.

O-ring

19.

Cover of terminal

It is said that

this torch

can reduce the

powder to about 50%, and reduce the gas to 50 to

8.

Valve cap

20.

Air pipe connector

70%.

9.

Cover of support metal

21.

Bolt

gouging torch, which

10.

Cover of body

22.

U-shaped screw driver

detects the arc voltage and current and controls the

11.

Support lever

23.

Swivel joiner

electrode

12.

Handle

24.

Box nut

Another

type

is the automatic

feeder motor.

This is used when gouging

long grooves which have a constant shape.

- 42 -

4) How to gouge
The

brazing

welding
DC

with

current,

method

is simple and is similar to arc

covered

welding

connect

the
the

rods.

When using a

cables with
electrode

the positive

electrode,

and hold

with

the

torch

projecting

150 mm or less. Start the arc and proceed

at a constant speed as shown in Fig. 1. While gouging,

is used, and an intermittent


an AC current

is used.

otherwise

least 5 kg/cm2,
be blown

off

sound will be heard if

The air pressure must be at


the molten

sufficiently,

will decline.

In addition,

metal cannot

and the work

efficiency

the gouged surface will not

be smooth, and carburization

will be deep.

a continuous jet sound will be heard if a DC current

Torch head

(a) Grooving (Back chipping)

(b) Progress of torch

Fig. 1 Example of gouging

Generally,

the base metal can be grooved 1.5 m to

In addition,

3 m with

one carbon electrode

groove.

four
AC

minutes.
current

described
current

(305 mm) in two to

The workability
is worse

before.

than

The

the sectional

of gouging with

an

gouged with

a DC current,

as

wide U shape, which

with

work

a lot of carbon will remain in the gouged

However,

efficiency

of an AC

is also worse and is only about half that of

current

shape of a groove

will

usually

become a

is an advantage when chipping

the back side or a welded joint.


Cast iron can be gouged with an AC current, but not
with

a DC current.

an AC

DC

current,

because the

intermittent

grooves the metal mechanically.


Conditions of arc air gouging (for mild steel)
Size of carbon electrode (mm)
Length

Diameter

Copper
plating

Gouging current (A)

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

To de good welding work,

AND

COUNTERMEASURES

it is necessary to be famil-

iar with the kinds and causes of weld defects and the
countermeasures

against them.

The quality of a weld

depends on the materials used (base metals and welding materials), the plan (design and performance),

and

skill (the actual welding work).


If

these three

conditions,
Weld

factors

weld

defects

are adapted

defects will

often

occur

to the welding

occur less frequently.

because there

are many

other factors in welding which affect each other.


Weld

defects

are roughly

divided

into the welding

strains, defective shapes of beads,_cracks, and internal


defects.

6 - 1 WELDING
When

metals

rapidly,

STRAINS

are welded,

the weld

and then cooled rapidly


This

base metals.

zone is heated

results in a sharp temperature

gradient around the weld zone.


This

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

can be reduced by changing the design

i
I
I

I
I

and method of welding.

I
Joints are deformed

in many ways as shown in the

figure at right.
The

most common

tortion

deformation

is the angular dis-

of butt joints. This is caused by the difference

in contraction

of the weld zone between

the upper

side and lower side of the base metals.


If the beads contract crosswise, transverse contraction
if they

occurs;
contraction

If this deformation
the

contract

lengthwise,

longitudinal

occurs.
is restrained by an outside force,

stress corresponding

remain in the weld zone.

to

the outside

force

will

If this residual stress over-

comes the strength of the material,

the material will

crack.
Since it is usually difficult
mation

and

the

residual

to reduce both the deforstress, try

to

residual stress when strength is important


plates

are used,

and try

to minimize

minimize
and thick

t----,
l!!i!i3
cEYIL
Progress of weld

c -_
*

deformation

when thin plates are used.

Rotative distortion

44 -

---7

/--

Angular distortion
(of butt welded joint)

Various
mize

methods

the

and procedures

strain.

Some

are used to mini-

common

ones are shown

below.

1) Symmetric
Welding

welding

is performed

Order of welding in symmetric welding

Order of welding in backhand welding

by beginning at the center of

the weld line and then progressing towards the outer


extremities

by depositing beads on alternate

sides of

the center, as shown in the figure.

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

by skipping over one or two

Overall progressof weld

Order of welding in skip welding

sections.

00000
----4) Prestrain welding
The

welding

strain

OveralI progressof weld


is predicted

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

easily and produce good results.

- 45 -

6- 2
*

DEFECTIVE

Defective

OF BEADS

shapes of beads not only detract from the

appearance

of

the

cause cracking
concentration
The

SHAPES

welded

because of

structures

but can also

insufficient

strength

or

of stress.

main defects

in shapes of beads are improper

throat depth, overlaps, undercuts, defective treatment


of craters, and bad appearance.

Throat depth is too thick

Throat depth is too thin

Overlap

1) Too thick or too thin throat depth


If the welding current,
welding

diameter

speed is not proper,

of welding rods, or

the throat

depth

may

become too thick or too thin.

2) Overlaps
If the welding speed is too low, the melted metals will
overlap.

Overlaps

can be prevented

proper welding

speed, welding current,

of manipulating

the welding rods.

by using the
and method

Since the overlaps are similar to notches, stress will be


concentrated

on them, resulting in cracking.

3) Undercuts
Undercuts are dents made on the border between the
base metal and weld metal.
welding

Undercuts occur if the

speed is too fast, the welding current

is too

J-l

large, or the arc is too long.


Undercuts

must be prevented

concentration

since they can cause

of stress.

To prevent undercuts,

deposit the droplets

into the

molten pool properly, finish both ends of the grooves


carefully

in the vertical

position, and

be careful about the angle of welding

rods and the

welding

when welding

speed when making horizontal

4) Defective treatment

fillet

welds.

Undercut

Defective treatment

of craters

If the arc is stopped

abruptly,

the craters will

be

dented deeper than the base metal because they are


not filled with the melted metal.
To prevent these dents, stop manipulating
ing rods momentarily

the weld-

or resupply the arc to fill the

dents.

46 -

of crater

6 -3

CRACKS

* Cracks are the most serious and dangerous defects

Therefore,
nated

which occur in the weld zone.


Fortunately,
improved

the quality
recently,

and

of steel products
welding

rods

selected carefully

has been
have

cracks

(preheating,

been

There

developped that do not cause cracking.

can be almost completely

if the base metals

and welding

postheating, etc.) are observed.

Bead cracks (Crater cracks, longitudinal and transverse cracks)


Location

Cracking in heat-affected

Base metal
cracks

zones

Solidification

cracks (Segregation cracks)

Hot cracks
c
Types of cracks

Contraction

cracks (Ductility

Time of cracking

Cold cracks (Delayed cracks)

Stress-relief annealing (SRI cracks


-

Peculiarities
Lameller tear

1) Bead cracks
Beads may be cracked transversely, longitudinally,

Longitudinal

cracks

or

at craters, as shown in the figure at right.


Longitudinal

cracks occur in the direction

of the weld

lines, and are usually caused by the contraction

of

beads in the transverse direction.


Transverse cracks occur
the

bead,

longitudinal
Cracks

in the transverse direction

of

* Transverse cracks

and are caused by a large stress in the


direction of the bead.

occur

cooled rapidly

in the

the

craters are

or when they are dented

craters

when

because of

bad treatment.

47 -

cracks.

they are classified by location, the time of

cracking, and other peculiarities.

are

and the proper welding procedures

are various ways to classify welding

Generally,

elimi-

materials

Crater cracks

reducing cracks)

2) Cracking in heat-affected zones


Cracks in the heat-affected
root cracks, Underbead

Root cracks

Toe cracks (Overlaps)

zones are classified into

cracks, etc., as shown in the

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

by the root opening,

as a notch.

Cracks may also be

Toe cracks (Undercuts)

caused by the hydrogen which gets mixed in the


roots during welding, by the hardening of structures

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

in base metals which

have

been greatly hardened by heat.

Underbead cracks
Underbead

cracks occur

near the fusion line.

in heat-affected

These cracks often

zones
occur

in high tensile steel, high carbon steel, and low

Underbead cracks

alloy steel.
They are dangerous because they cannot be seen

Deposited metal (Bead)

from the surface. These cracks may be caused by

the hydrogen

which penetrates from the melted

metals, the hardening of structures by heat, and


the contraction

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

cannot stand the stress.

The resistance against deformation

will be reduced if

elements with low fusion points are segregated along


the

grain

boundaries

solidified.

when

the

melted

metals are

Cracking may start from the grain bound-

aries by

the contraction

forces which

occur

stress and the restraining

in multi-layer

welding.

In this

case, the elements with low fusion points on the grain


boundaries in the previous beads are remelted by the
heat from

the

beads.

These cracks often

occur in

melted alloys whose elements are segregated easily or


in melted
produce

metals which
alloys with

contain

elements

that

can

low fusion points, such as sul-

phur, phosphorus, etc.

- 48 -

zone

4) Cold cracking
Whereas

hot

cracking

occurs

process or heat treatment


cold cracking

occurs after

Since

cooled.

during

the

The ability

cooling

it occurs

cient.

the weld zone has been


after

welding,

it

is large, and if a lot of structure


which

may

+ 1/4Mo

stress

has been hardened.

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

are shown on page

few alloy elements,

equivalent

is low, whereas

of high tensile steel and low

mild steel does not harden very much


is high, but high tensile steel and

steel are hardened

The hardened

the

a lot and have a low

structure

is also affected

by the cool-

The faster the cooling speed, the more

the weld zone will harden, and vice versa.


Preheating

must be

(or

postheating)

is an effective

way

to

delay cooling.

If it gets into voids such

holes or cracks, or non-ferrous

Preheating

inclu-

weld

sions, it will become molecular hydrogen (Hz).


hydrogen cannot diffuse freely, so it is also

called non-diffusible

hydrogen.

As the temperature

and solubility

can

not only

prevent

hardening

of the

zone, but can also help discharge the residual

hydrogen
Molecular

of the major types of steel

machinery

weldability.

decreases until the hydrogen

free

contains

ing speed.

metal

diffused and be discharged.


as fine

of iron.

+ l/!Xr

The carbon equivalent of mild steel,

0.

In other words,

hydrogen.)

of hydrogen

is set free.

lattice

equivalents

and its weldability

and the atoms of hydrogen can be

the

called diffusible

the solubility

+ 1/40Ni

alloy steel are high.

steel can dissolve a lot of hydro-

When the steel has solidified,

to

the carbon

grooves, in rust and oil, and in the moisture in the air.


Therefore,

carbon

(Ceq), and can be

+ 1/14V

used in construction

metal, can be found in many places such as in organic


covering

of all elements in the

expression.

Ceq = C + 1/6Mn + 1/24!3

if there is a lot of

in the weld zone, if the restraining

Hydrogen,

The sum of the ability

obtained by the following

Cold cracking occurs more often

to harden steel is com-

steel is called the carbon equivalent

is also

called delayed cracking.

hydrogen

of each element

pared with that of carbon and expressed by a coeffi-

process fo the weld zone,

from

the weld zone by retarding the cool-

ing speed.
In other words, the preheating action prevents crack-

hydrogen

is collected

becomes very high.

decreases, a lot of

ing by restraining

in the voids, and its pressure

Finally,

residual

this internal pressure will

time.

overcome the strength of the steel and cause a crack.


In this way,

hydrogen

has the largest effect on cold

enough to follow

caused by the internal


However,

crack.
hardened

the weld zone at the same


as the most effec-

On the other hand, if the weld zone is bound with a

the

because it

structure

has been

pressure, it will
in weld
heated

and does not have the ductility

ing, the

the defor-

The properties

of the hardened structure

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

especially strongly, the possibility of cracking is high.

are related

of steel and the cooling

speed.

internal

overcomes the strength of the material,

not

zones

the deformation.
the

from

it is used widely

strong force to restrain the deformation

If the steel is ductile

abruptly,

Therefore,

the hardening and discharging the

tive method for preventing cracks.

cracking.

mation

hydrogen

49 -

From

the above explanation

of the three factors of

cold cracking, we conclude that the following


are important
@

points

to prevent cracking:

Prevent

hydrogen

from

getting

into

the weld

zone.

- Select welding rods that do not have much hydrogen.


-

Remove

matter

which

contains

hydrogen

(water, oil, rust, etc.) from the surfaces to be


welded.
@

Preheat and postheat the weld zones.


The following
gen that

table shows the amount of hydro-

gets into the deposited

various kinds of welding.

metal

during

The wires for COz gas

shielded arc welding and the low hydrogen type


covered

welding

rods contain

relatively

little

hydrogen.

Diffusible hydrogen
(cc/100 9)

Welding method

Arc welding with ilmenite type covered welding rods (4 mm@)

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

Mia weldina (Ar)

1 to1.2

CO, gasshielded arc welding (solid wire, CO,)

0.5 to 1.2

Submerged arc welding (wire 36, Cr 50)

On the other hand, the preheating


conditions

for

preventing

cracks

and postheating
depends

on the

welding materials, thickness of materials, and welding


conditions.
welding
page.

An example

of these conditions

for arc

with covered welding rods is shown on next


In the table, the preheating temperature

is low

if the carbon equivalent is high, and vice versa.


In addition,

the preheating temperature

the thickness

or diameter

is also law if

of the material

is small,

and vice versa.


This table

is convenient

if used together

Tables for Selecting Welding

with

the

Rods on page 23 to 24.

- 50 -

Remarks

25
2.5

0.2

Note:

For the carbon equivalents of materials,

0.4

on the basis of the carbon equivalent

may not need to be preheated/postheated

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

Necessity shall be determined after consulting the


manufacturing division.

Not required

II

II

50 to 200

III

Remarks:

The
parts

200 or more

above conditions
that

conditions

do not apply to the

have been welded

0.5

0.6

0.7

Carbon equivalent %

page 12 to 15. Materials that must be preheated/


postheated

0.3

refer to

under

lower

and have not had troubles in the

past.

-51

0.8

0.9

Welding conditions

5) Unusual cracking
In addition

to the cracks described so far, there are

Weld the materials


(welding

These are sulphur

Cracking can be effectively

purities with

cracks, which are caused by im-

a low fusion point and which

contain

current,

under the proper conditions

various cracks called unusual cracks.

voltage,

welding

speed, etc).

prevented by welding

at a high speed to reduce the heat input and by

sulphur, SR cracks, which occur when removing stress

making multilayer

from

Make the first bead as large as possible.

high tensile steel of the 80 kg/mm2

lameller

tears which

thickness

occur at a right

of copper

plates and look

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

Treat craters carefully.


cracking

explained

above are summarized below:


Temporary

Connect

the beads carefully.

of a bead when
When welding

assembly and tack welding

starting

Chip off the end

a weld

from

a bead.

materials that crack easily, cover

the weld zone with asbestos to delay its cooling


Never tack weld on portions where stress is concentrated, such as corners, ends, etc.
Keep the tack welding beads long (30 to 50 mm).
Install

end tabs to prevent starting welds from

the end of materials.


Do not set the root opening more than 3 mm
wide.

Preheating

Control

the preheating temperature

with thermal

choke, etc.

Set the

preheating

temperature

a little

than the standard (approximately


pensate for the heat drop.
the temperature

Carefully

higher

5OC) to com-

However,

do not set

too high.

control

the interlayer

temperature

so

that it does not get too high.

Welding materials
When welding materials that crack easily, use low
hydrogen

type welding

rods or weld with

CO2

gas shielded welding.


Dry the welding rods sufficiently.
Remove

rust,

oil,

etc.

from

the

edges to

be

welded.

- 52 -

speed.

6 -4

INTERNAL

DEFECTS

. The following are called internal defects.


Slag inclusion
Insufficient

penetration

Blow holes
Pits
Non-metallic

Slag inclusion
right.

impurities

is shown in the figure

at the upper

Slag inclusion

It often occurs when the skill of the welder is

low.
If a thick

welding

rod is used for the first layer of

butt welding, slag often gets mixed into the deposited


metal

because of

insufficient

penetration.

If slag
Slag inclusion

remains from a former weld, it is likely to get mixed


into the newly deposited metal.
Insufficient

penetration

lower right.

small or the welding


prevented
rods,

rods are too thick.

by using the proper

the

method

is shown in the figure at the

correct
of

welding

current,

manipulating

the appropriate

the welding

rods for the


etc.

They are bubbles created when the rods and

base metals are melted,


metals are solidified.

and remain inside when the

The voids completely

in the metal are called

blow

included

holes, and voids that

open on the surface of the metal are called pits. The


main cause of voids is the gas in the deposited metal,
the hydrogen

in the moisture

of welding

rods, rust

and oil on the steel,the oxygen and nitrogen which get


into the metals when the arc is too long or weaves too
much.
The major countermeasures

against these defects are

shown in the table on next page.


There are various countermeasures
by

starting

low

hydrogen

type

against blow holes

welding

rods at the

point of beads, as shown in the table.

The

cause of these blow holes is that oxygen or nitrogen


gets into the melted metals when the shield gas is not
sufficient

at the beginning

they can be prevented

of welding.

by generating

gas as soon as the arc is started.

Therefore,

a lot of shield

This is realized by

inputting

a lot of heat into the starting points (tip

reworking

rod, hot start, extra pad method),

generating
coating

penetration

of welding

Both blow holes and pits are voids in the deposited

made

Insufficient

It can be

diameter

shape of the edges, the thickness of materials,

metal.

It occurs when the welding current is too

agents, (blow

rod), or rewelding

hole preventing

using gas
agent, tip

the starting point

(back-

hand welding).

- 53 -

Insufficient penetration

1) Countermeasures

against blow holes and pits (manual welding and CO2 gas shielded welding)

Item (Welding methods)

Countermeasures

Arc length (Manual welding and OC, gas


shielded welding).

Shorten arc length (Lower voltage in CO, gas shielded welding).

Weaving width (Manual welding)

Safe width is within three times the diameter of covering material.

Rust of base metals (Manual welding and


CO, gas shielded welding) l *

Remove thick red rust. Rust contains water, which impairs CO, gas
shielded welding.

Oil on base metals (Manual welding and


CO, gas shielded welding) **

Remove oil with a burner or by cleaning with thinner.

Paint on base metals (Manual welding and


CO, gas shielded welding) l *

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.

Anti-spatter compound (Manual welding


and CO, gas shielded welding)

Examine types and amount of application in advance.

Danpen in welding rods (Manual welding


and CO, gas shielded welding) **

Dry the welding rods. They should be dried just before making one
layer filler welds.

Insufficient gas flow (CO, gas shielded


welding) l

Gas flow should usually be kept at 15 literlmin.

Wind (Manual welding and CO, gas


shielded welding) *

Make a wind shield. Wind speed must be less than 2 m/set for CO, gas
shielded welding.

Position of nozzle (CO, gas shielded


welding) l

Nozzle must not be more than 30 mm away when gas flow is


20 liter/min.

Fluctuation of arc length (CO, gas


shielded welding) l

Check circuits.

Starting point with low hydrogen type


welding rods (Manual welding) *

Use backhand welding, extra pad method, tip reworking rod. Use a
hot start welder. Use antiblow hole agent or tip coating rod.

Base metals (Manual welding and CO, gas


shielded welding) t*

When welding materials of bad quality, use low hydrogen type


welding rods or ones which do not make many blow holes.

Welding rods (Manual welding)

Use low hydrogen type welding rods, and redry them.

Use of large welding current (Manual


welding)

Limit welding current to proper range.

* :
** :

Pits may be produced.


Pit are often produced.

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-

. Some simple methods of distinguishing materials are


shown below.
The most practical

and widely

used method

of dis-

tinguishing steel products is the grinder spark test.


it is supplemented

with the powder

pellet test and if special elements


spectroanalysis,

the

steel

If

spark test and

are checked with

products

can

be distin-

guished perfectly.

- Methods of distinguishing materials.


t
No.

Method

Tvpe

Grinder spark test

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.

Powder spark test

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

The powder of a test specimen ground by a grinder is buried in a glass plate.


Judgement is made by observing the size, color, and shape of the buried powder
with a microscope.

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

Test specimen is luminated. A spectrum of this light is analyzed by a spectroscope


to detect the presence and amount of special elements.

Reagent reaction method

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.

Quench hardness test

The amount of carbon in steel products is estimated from the maximum hardness
obtained by water quenching.

Microscopic test

The amount of carbon is estimated by measuring the ratio of ferrite to pearlite


with a microscope.

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

A magnet is used to determine if the specimen is austenite steel, ferrite steel, or


nonmagnetic steel.

12

Magnetism test

The amount of carbon in steel products is estimated from their magnetic


permeability. A carbonanlyser, cerbon-meter, etc. are used.

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

The results of heat treatment,


induced current.

15

Specific gravity test

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

Fusion point test

The fusion point is measured to determine if a specimen is a pure metal or an alloy.


If it is an alloy, its composition can be estimated from its phase diagram.

metal sorter

55 -

strain, and quality are judged from the change in the

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

separate heats of steel, whether

or not it is rimmed steel, the degree of decarburization and nitriding,

whether

the steel is quenched or

not, the degree of forgeability,

etc.

Tools for spark test


A grinder of l/4

to l/3

HP, 3500

to 5000

grain size 36 to 40, and hardness Q.

rpm,

The stand-

ard samples should be 15 mm in diameter

and

150 mm long and have a known chemical composition.


Test method
The test should be performed

under the specified

conditions

in a dark room where the brightness is

constant.

When testing outside,

use a portable

darkroom.
Make sparks horizontally
will

be approximately

so that the streamline

0.5 m, and observe them

visually.
Divide the streamline

and observe each division

carefully.
From the base of the streamline,
C and Ni can be estimated.

the amount of

From the brightness

and shape of the sparks at the middle


streamline,

of the

Ni, Cr, Mn, Si, C, Al, and V, can be

detected.
From

the

streamline,

shape and splits at the end of the


Mn,

MO, and W, can be detected.

- 56 -

How to judge
The quality

of steel products

Percentage of carbon in steel and characteristics of


sparks

can be judged by

the color, shape, and length of the streamline, by


the

form

and number

of flowers,

resistance against your hands.


compared

with

and by the

These factors are

Angleof streamlines

a standard sample in the spark

----

test.
(i) Effect of carbon
Carbon has the most distinctive influence on
the sparks made by the grinder.
caused by carbon

The splits

is the basis of the spark

test.
The relation
bon

between the percentage of car-

in the steel and characteristics

of the

0.2

0.4

spark is shown in the figures at right and the

0.6

0.8
Amount

I.0

1.2

1.4

of carbon

(%)

table below.
The judgement
ber,

size,

is based mainly on the num-

and

brightness

of

the

The percentage of carbon can be determined


accurately
are

to

judge

and

involve

certain

Foz&
K=0.153/0)

since the sparks are affected by

elements,

correction

ThreAth
two branches each

Characteristics of grinder sparks of carbon steel

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%)

Feather type flowers

Kz0.5%)(Mn)

Streamline
Brightness

(C=o.l%)

Se*
(c=o.2%)

Several splits with three


branches each and pollen

0%

Three splits

must be made

for the amount of those elements.

--+

some

degree of error.
In addition,

+
Two s lits
(c=o.&%)

Thorns
(C<O.O5%)

up to 0.5%, but greater quantities

difficult

Sparks made by carbon steel

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 -

(ii) Effects of special elements

The effects of special elements on the char-

Characteristics of sparks produced by special

ele-

ments

acteristics of sparks are shown in the figure


at right and in the table below.
(iii) Essential

points

for

identifying

special ele-

Spears with tuft

Spears with white

ments Si restrains the explosions of carbon.


Significant

differences

in the amount

can be easily detected


steel as follows:

in various kinds of

for structural

(WI

of Si

steel, 0.1%

Foxtail
(W)

Small drip
(WI

*Z

cf 0.3% cf 0.5%, for spring steel, 1% ++ 1.5%.


and for heat
Mn

resistant

in amounts

steel makes

steel, 1.5% ++ 2.5%.

of up to

no distinct

1% in structural
difference

in the

spark.

+
White ball
(Si)

(09

_------.--___..

However,

in high carbon steel, a 1% content

___

Broken
streamline
(WI

Corrugated

of Mn will reduce the number of sparks and

Spearhead
(MO)

streamline
(WI

enlarge the angles of the branches of sparks,

It is difficult

to make the sparks look like twigs.

1% and 3% Ni in structural steel because the

If structural

steel contains about 1% Cr. the

Cr can be detected by sparks which look like


chrysanthemums,

thin streamlines,

and pol-

influence

to detect a difference

between

of C and Si on the sparks will ob-

seure the influence of the Ni.


However,

this difference

can be detected by

the resistance aginst hands and the thinner

len.
However,

a lot of skill is required.

Cr

the

steel,

fewer

streamlines

in number,

In high

are shorter

and

and each line is thicker.

streamlines.

Thinner

MO can be detected

The base of streamlines becomes reddish,and

heads. However,

there is a lot of resistance against hands.

form

low carbon steel, the significant


in the
follows:

amount

of

In

differences

Cr can be detected

as

1% + 3% ++ 5% ++8% ++ 10% cf 13%.

Ni can be detected by swelling flashes. Since

streamlines

indicate

less Ni.

if there

most easily by spear-

the spearheads are hard to

is a lot of carbon.

Therefore

detect the MO by grinding the decarburized


layer.
If there

is more than 0.5% W, spears with

tufts and foxtails will appear, and the stream-

Ni in low carbon steel can be detected most

lines

easily, it should be determined

structural steel contains 0.1 to 0.2% W,swell-

the decarburized

by grinding

will

be corrugated

ing sparks will

layer.

and broken.

appear, which

If

are similar to

the sparks produced by Ni.


If the steel contains V, large flowers tend to

* Effect of special elements on characteristics of spark

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.

How to distinguish materials


(i) First, determine

the amount of carbon in the

material

and classify

(Carbon:

0.5% or less) or tool steel (Carbon:

it as structural

steel

more than 0.5%).


Then,

classify the structural

hardening
high

steel (Carbon:

strength

steel

steel into case

0.25%

(Carbon:

or less) or
more

than

0.25%).
(ii) Determine

the

amount

of other

elements,

and compare the results with standard types


of steel.

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-

mining the amount of Co in high speed steel.


Although

the presence of each element can be deter-

mined easily with this method,


determine
The

it is not so easy to

the amount.

percentages

can be estimated

at the following

levels if compared with standard samples.


(For Spectrometer

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

Hilger Co., Ltd.)

0.1%-l%

59 -

20%

7-2

HOW TO CHECK

WELDED

AREAS
3) Supersonic inspection

Welded areas can be checked for internal and external


defects without
destructive

being destroyed.

inspection,

and

This is called non-

includes

the

If supersonic waves of 0.5 to 1.5 MHz are applied to

following

the welded areas, they will be reflected

methods:

by the inter-

nal defects.
The

1. Visual inspection

existence

detected
2. Radiant-ray
3. Magnaflux

inspection

of the defects can be

strength of waves reflected by the bottom of the weld


can be applied to larger materials,

4. Supersonic inspection

time
inspection

6. Magnetic-analysis

location

with the waves reflected by the defects.

inspection

5. Penetration

and

by using a cathode ray tube to compare the

and expense and simpler

radiant ray nondestructive

test.

This method

and requires less

equipment
Another

than the

merit of this

method is that the devices only need to be placed on

inspection

one side of the material to be checked.


However,

to apply this method

most important

to an

shapes, and a lot of

skill is needed to judge the results of this test.

Visual checks are the basis of all inspections and the


Almost

it is difficult

uneven surface or complicated

1) Visual check

kind of inspection.

all external

defects can be discovered by ob4) Penetration

serving the appearance of welds carefully.

inspection (Color check)

Cracks and holes on the surface of the welded area


can be detected easily by this method,
2) Magnaflux
Lines

of

welded

magnetic

force

are

passed through

The penetrating

the

welded

areas. Defects on or near the surface can be

detected

Usually,
and

magnetic

magnifies

powder

small

the

The penetrating

by visual inspection.

cent material.

magnetic

powder

is usually

iron powder

or a

magnetic iron oxide powder, which is colored white,


red,

or

black

to

contrast

with

the

magnaflux

detection

method,

oil and scale from

material

to be checked.
liquid

is mixed into

Then soak the material

in

or spray the liquid over the

Wipe the penetrating

Do not spray the


mable.

cracks, the

liquid from the surliquid.

The defects

liquids

because they

can be detected.

60 -

are inflam-

Never inhale the cleaning liquid or penetrating

liquid because they are poisonous.

inclusion of slag just under the surface and blow holes

completely

the surface of the

will appear red on the white developer liquid.

light oil and splashed on the weld.


the

the

face, and spray on the developer

In the dry method, dry powder is spread on the sur-

With

remove

material.

the powder

liquid contains a red dye or fluoresBefore using this method,

the penetrating

surface to be

checked.
face. In the wet method,

liquid is

liquid remain-

and size of the defects.

welded

areas can be checked more precisely and easily than


The

into the defects,

Then a developer

ing in the defects to the surface to show the location

is used. Since it

defects,

to penetrate

applied, which attracts the penetrating

coil to measure the magnaflux which leaks from those


attracts

liquid is applied on the surface of the

area, allowed

and is then washed out.

by using magnetic powder or an inspection

defects.

which is used

widely because of its simplicity.

inspection

5) Magnetic-analysis

The

inspection

This is also called the eddy current test.


crepancies

in

thickness

material

quality,

of surface layer

electromagnetic

induction

Flaws, dis-

dimensions,

passes between the

metals to be checked and a coil through


current

flows.

Materials

which AC

with simple shapes such as

wires, pipes, and bars can be quickly


If the magnetic

this method.

and

are checked by using an


which

inspected with

pictures

below

show examples

specting devices, which

0
@

inexpensive

Can detect flaws up to 15 mm deep


Inspections can be made from directly above the
beads

flux generated in the

coil passes through the metal and changes over time,

Can inspect fillet welded areas

an electromotive

Can detect flaws in any direction

force will occur and a current will

flow in the metal.


This current

0
of the materials,

change in magnetic
the

frequency,

and flaws.
directly,

flux

over time,

Since this current

cannot

the secondary external

rent, that is, its reaction,


the condition

in other words
of materials

using any contact medium.

There is no

need to remove rust and paint.

but also by the

shape and dimensions

Materials can be checked by contact of the probe


without

is not only affected by the conductivity

and permeability

Cnm
,_...e

uses of this device are shown below.

be measured

effects of this cur-

are analyzed to determine

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

devices are available for this purpose.

Inspection of weld zone and base


metal of pipes

Inspection of fillet weld zones


of steel frames

- lnpsection of butt weld zones


of steel plates

-61-

in-

features:

Portable
Relatively

of common

have the following

Inspection of weld zones of


flanges

8.

HOW

TO READ WELDING

SYMBOLS

Some people think that welders dont need to be able


to read drawings.

In fact, however, their skills will

never improve as long as they depend on the foreman


without

being able to read the drawings for them-

selves.
This

section

describes

the

welding

symbols

which

indicate the portion to be welded.

8 - 1 WELDING

SYMBOLS

a The basic and supplementary

symbols used in draw-

ings are shown in the table below.


Type of welding

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

For Double J-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.

65

For Double U-Groove welding, this symbol is entered symmetrically


on both sides of the reference line.

66

For Double Flare, V-Groove welding, this symbol is entered


symmetrically on both sides of the reference line.

66

If

For Double Flare Bevel-Groove welding, this symbols is entered


svmemtrically on both sides of the reference line.

66

11

The vertical lines of symbols must be on the left side.


For parallel welding, this symbol is entered symmetrically on both
sides of the reference line. However, for staggered intemittent
Fillet welding, the symbol at right may be used.
l+

v
Bevel weld,
Double Bevel-Groove weld

Fillet weld

66,67

67

Plug or slot weld

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

Convex line in relation to reference line.


Concave line in relation to reference line.

68

C
G

If finish method is not specified, F is used,

If all around welding is obviously necessary, this symbol .may be


omitted.
0

62 -

68

B- 2

HOW TO ENTER

Except

WELD

for bead deposition

the welding

SYMBOLS

and build-up

welding,

Reference line

symbols are as a rule used to indicate

the types of welding for joining two materials.


The

welding

symbols

should by entered

Reference line
F=r

line
Arrow

on refer-

ence lines together with dimensions.


The reference

lines are made of straight base lines

and leader lines which

indicate

the portions

to be

horizontal.

Tails

connected.
The

reference

lines are usually

may be added to the base lines if necessary.

(See

figures at right).
Draw the leader lines straight at 60 to the reference

The

welding

symbols

lines if possible (bent lines will do), and add arrows

entered

to the end of the

ence lines shown below.

leader lines.

However,

if it is

necessary to indicate the surfaces to be grooved for


V,

Double

reference

flare or flare-bevel

welding,

should

be

1) When opposite side of arrow or far side is to be

bevel, J, or Double J-welding, or flare

surfaces for

and dimensions

at the standard positions around the refer-

welded:

place the

lines at the side to be grooved or flared,

bend the leader lines, and direct the arrows toward


the surface to be grooved or flared.
The

symbols

under the

and dimensions

reference

should

be entered

lines when the arrow side or

near side are to be welded,

and on the reference

lines when the opposite side of the arrow, or the far


side are to be welded.

They

should contact

the

reference lines.
The

supplementary

Number of spot weldings or Proiectio


weldings (may be entered above bare line)

symbols

for field

welding,

all

around welding, and all around field welding should


be entered

at intersecting

2) When arrow side or near side is to be welded:

points of the reference

lines and leader lines.

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

of how to enter the welding

symbols are

* shown below.
are groove welding

gymbol

II II

Draw parallel lines at a


right angle to reference
line.

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

Enter bevel groove weld


symbol symmetrically on
both sides of reference line.

Both sides

Arrow side or
near side

Arrow sideGroove depth:


16 mm, Groove
angle: 45,
Opposite side of
arrow - Groove
depth: 9 mm,
Groove angle: 45.
Root opening:2mm

Opposite side of
arrow or far side

opening:

Svmbcl
Y

Draw a half circle. Leg


length must be aout half
of the radius.
Drawing

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

Draw a quarter circle.


Leg length must be
about half the radius.

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

Groove angle: 25.


root radius: 6 mm,

- 65 -

Drawing

Actual shape

Opposite side of
arrow or far side

Enter J-groove weld symbol


symmetrically on both
sides of reference line.

&

Double U-groove
(H-groove) welding

Enter U-groove welding


symbol symmetrically on
both sides of reference lint1.

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

If leg lengths are


not same, enter
dimension of shorter
one first, then Iongelr
one in brackets.
If sectional drawing
is possible, indicate
which leg is to be
lengthened.

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 -

Draw an equilateral right


angle triangle.
Drawing

lug or slot welding


Fillet weld
(intermittent)

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

Staggered intermittent fillet


welding.
Leg length: 6 mm
at near side, 9 mm
at far side, length
of weld: 50 mm,
Pitch: 300 mm

Staggered intermittent fillet


welding. Leg
length of both
sides: 6 mm,
length of weld:
50 mm, pitch:
300 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

Height of arc must be


about 112 of radius.

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

Chip this area.

Opposite side of
arrow or far side

Grind this area.

~~__

?
Building up

Fillet weld zone


with different leg
lengths must be
grind 2 mm deep.

Portion to be welded

Thickness of built
up metal: 6 mm,
width: 50 mm,
length: 100 mm

Flush

Contour of portion
to be welded.

All around weld

All around field weld

Actual shape

Portion to be welded

Portion to be welded

Drawing

Field fillet weld

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

is designed so that welders

can control

GAS

flame

WELDERS

WELDERS

Gas regulators

pre-

cisely.
The

equipment

cetylene

welding

required

for

oxya-

is simple and inex-

pensive. The simplest set consists of


an oxygen tank,

an

acetylene tank

or acetylene generator

(plus a safety

device, in case of low pressure acetylene generator),

two pressure regula\!$Gxvgen

tors, two hoses, and a welding torch,


cutting

tank

torch or welding torch with

metal fittings for a cutting nozzle.

Fuel gas tank

sources
of

gas

Pressureregulator
Torch and mixer
t

Oxygen

I
Fuel gas

With these devices, all metallic materials for industrial


use can be welded;

any steel, wrought iron, and cast

iron that can be cut by a manual cutting torch can


also be cut; and materials can be heated partially

and

effectively.
The oxyacetylene

torch is a device that mixes oxygen

and acetylene in equal volumes, sends it to the nozzle,


and burns it.
The nozzle on the torch can be replaced according to
the type and thickness of the materials to be welded
or cut so that the size or characteristics

of the flame

can be adjusted properly.

70 -

9 -2
*

STRUCTURE

AND

USE OF WELDING

TORCHES
Low pressure type

Each welding torch has a handle with inlet connectors

(Injector type)

Valves are

at one end of the passages for gases.

35

installed to each outlet to control the flow of oxygen


and acetylene.

Oxygen

and acetylene

27

are mixed to

the specified ratio and sent through the torch to the


nozzle by means of these valves.
Various

nozzles with

different

gas mixing

chambers

and gas holes can be installed to each torch, and the


size or characteristics
in a remarkably

of the flame can be adjusted

wide range with only one torch body

and its valves.

1. Torch head

2.

Body

3.

Holding pipe

4. Gas pipe

5.

Internal pipe

6.

Valve

8.

Hoseconnector

9.

Nozzle tip

7.

Needle valve

Medium pressure type

Torch head

2. Valve

3.

Armor pipe

5.

Internal pipe

6. Adjustment valve

Hose connector

8.

Nozzle body

9.

Holding pipe

Nozzle tip

Classification of welding torches


Oxyacetylene
types

In

torches are generally classified into two

according

to the pressure used, the

injector

below

0.07

type

with

and the medium

kg/cm

uses acetylene
higher.

uses acetylene

with

kg/cm*

The medium

or

and

type torch is most appropriate

pressure gas generator

with

medium

pressure type

a medium

or high pressure

torch

works effectively

pressure gas generator

pressure acetylene,

but cannot

or a high

be used with

a low

pressure gas generator.


In

the

torch

acetylene

into

the injector

of

the

itself

nozzle.

injector

type,

oxygen

sucks

when passing the small hole in


One advantage of this is that the

volume of acetylene sucked by oxygen changes as the


volume of oxygen changes, thereby
of oxygen

and

acetylene

constant

keeping the ratio


throughout

the

operation.

-71

acetylene

oxygen

and

pressure into the


greatly accord-

pressure type torches which use oxygen


of the same pressure are called the

same pressure type.

acetylene.
The

torch,

ing to manufacture.

for low pressure gas generators, but can be used with


a medium

pressure type

are sent by independent

The structures of these torches differ

a pressure

pressure type

a pressure of 0.07

The injector

medium

mixing nozzle.

type and the medium pressure type.


The

the

acetylene

injector

1) Low pressure type (Injector

type, French type)

The figure at in the below is a sectional drawing of

Therefore,

the nozzle of an injector type torch which is installed

completely,

on the handle.

* Oxygen flows out of the injector tip at a remark-

The passage of oxygen is at the center of the injector

flow out of the nozzle, then burn.

ably high speed, and draws out a proper volume of

nozzle.

acetylene within

When

oxygen

injector

passes through

nozzle,

the small hole of the

completely

it increases in speed and develops

- Acetylene

sucking force which draws out the acetylene.


The

the oxygen and acetylene expand and mix

passage for the mixed

gas beyond

itself.

Oxygen and acetylene mix

before flowing out of the torch nozzle.


of less than 0.07

kg/cm2

pressure can

be used with this torch.

the injector

gets gradually wider near the nozzle tip.

Acetylene

,,-,

0.0 7 kg/cd

5 kg/cd

I
Mixed gas

2) Medium pressure type (German type)


In the medium pressure type torch which uses acety

The passage of this type of torch is also widened

lene of higher pressure, a mixing nozzle of a different

that the gases can expand and mix completely.

shape is used in place of the injector.

* The hole for acetylene is several times larger than

has holes at and around itscenter,


through

the

center

hole

in

This torch also

but oxygen passes

the one for oxygen.

some manufacturers

the

models and acetylene in others.


Each

manufacturer

inlet

and

The two gases are mixed at

sent to

the

nozzle

through

the

mixing chamber, as shown by arrows.

recommends

the

pressure

of

oxygen

and acetylene

volume

of gases and mix them at the specified ratio

- The torch can use acetylene at a pressure of 0.07

needed to supply the proper

to 1.3 kg/m2.

in the torch nozzle.

Mixer

Oxygen
\

Acet ylene

so

Torch head

72 -

Nozzle

3) How to adjust the flame


When the mixing ratio of the gases flowing out of the
nozzle is approximately
tained.

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

The shapes of each kind of flame are shown in Fig. 1.


After

opening the acetylene valve a little and igniting

the acetylene, opening the oxygen valve will gradually


increase the volume
reducing flame.
will

first become

dizing flame.
either

an

of oxygen

and produce a blue

Fig. 1 Shapes of flame

If more oxygen is supplied, the flame


neutral, and then become and oxi-

To obtain the best results, do not use

oxidizing

or reducing flame, unless doing

special purpose welding.

4) Welding methods
Gas welding methods are divided into forehand welding and backhand welding.

In forehand welding, the

welder holds the torch in his right hand, the welding


rod in his left hand,

and welds from

right to left.

In backhand welding, the holds the torch and welding


rod in the same way,
These two
method,

methods

the

tip

but welds from


are shown

in Fig. 2.

of the welding

extend beyond the flame.

Progressof weld

///

left to right.
In any

rod must not be

The rod is added by keep-

ing its tip in the molten pool.

Backhand welding

Since metals can be welded rapidly without


the forehand welding method,

strain by

it is suitable for weld.

ing plates of 3.2 mm thickness or less. An example of

Fig. 2 Gas welding

how to hold the welding rod is shown in Fig. 3. When


welding

thick

melted

metal

plates with this method,


is pushed toward

however, the

the metals not yet

melted, and that may cause defects.


On the other hand, backhand welding is suitable for
welding

plates thicker

roots with this method,

than

3 mm.

When welding

direct the nozzle toward the

roots and move the nozzle straight along the progress


of the weld.

If the welding rod is added while main-

taining a small hole as shown in Fig. 4(a).


welding

can be carried out.

URANAMI

The method of holding

welding rods for the second layer and after is shown


(a)

in Fig. 4(b).

E-type

(b)

Fig. 4 Backhand welding


Handling the nozzle

- If the internal flame ocurrs easily, clean the nozzle.


If

the

fluctuate

hole

is blocked

and make

or stained,

heating difficult.

slag sticks to the outside


difficult

the flame

of the nozzle,

to operate the nozzle.

will

If too much

Therefore,

it will be
clean the

nozzle often,

- 73 -

-3

STRUCTURE

AND

USE OF CUTTING

TORCH

If a part of iron or steel is heated to the fusion point


with the preheating flame, and pure oxygen is blown
onto

it, it will burn violently,

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

steel in the preliminary

Gas cutting

as the equipment

has

is used widely to cut

stage of welding.

The heating flame of oxyacetylene

blows out of the

set of holes around a large hole through which pure


cutting oxygen flows.
used,

the

cutting

If many preheating flames are

direction

can be changed

freely

while preheating the metal in a stable manner.


Nowadays,

a concentric

flame over the cutting oxy-

gen hole is used instead of several flames.

Low pressure type (Injector


The

gas mixer

pressure type
the

low

gas cutter

pressure

propane

type)

for the preheating


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,

did not require


but

the

any basic

diameter

has been enlarged

of the

to supply

more

oxygen for preheating than the nozzle for acetylene.


Therefore,

the nozzle of the low pressure type cutting

torch must be changed according to the fuel.

2) Medium pressure type


In the medium
and acetylene
medium
oxygen
the

pressure type

torch,

oxygen

in the same way as in the

welding

torch.

The cutting

is blown out from the hole at the center of

cutting

mixture

pressure type cutting


are mixed

nozzle,

is blown

and the oxygen

out from

and acetylene

the small holes around

the center hole.

74 -

Acetylene

Replaceable nozzles

Torches for special works

Plates of various thickness can be cut with one torch

In addition

by replacing

almost

general

are even and straight,

torches

the cutting

all holes for cutting

nozzles.

oxygen

Although

to the welding

use,
for

each

and cutting

manufacturer

torches for

produces

many

special use, such as for airplanes,

thin

the hole of the divergent nozzle gets gradually wider

plates, piping, and wiring, and special torches for gas

toward the nozzle tip.

welding machines, gas cutting machines, etc.

Many types and thicknesses of plates can be practically

and economically

cut with

the various forms


3) Cutting method

and sizes of cutting nozzles now available.


To cut a thin

plate with a clean surface that can be

To

cut easily, use a nozzle with few small holes.


To cut a thick
large preheating

rusty dirty,
flame

or

or painted

ignite the torch,

keep the valve closed for high

pressure cutting oxygen, slightly open for preheating

plate, use a

increase the number

oxygen,

of

After

flames because more preheating is required.

heating

When grooving, removing flaws, or cutting rivets, use

open wide

igniting

the

oxygen

for acetylene,
torch,

until

open

a neutral

and then

the

ignite.

valve for

flame

pre-

is obtained.

Bring the nozzle near the steel plate to preheat the

specially designed nozzles.

starting point.
When the starting point becomes a shiny red, gradually open the valve for high pressure cutting
After

confirming

bottom

of the plate, move the nozzle along the cut

line.
Table 7.3-l

Table for manual cutting (mild steel)

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

6.7 to1 1.0

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.

that the cutting reaction reaches the

9 -4

PRESSURE

REGULATOR

1) Types of pressure regulators


Although

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

1 atm. or less is used in weld-

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

(also called a reducing

by an oxygen

regulator

An acetylene

regulator

valve).

is used for the same purpose.

The so-called
regulators

French

type regulator
The pictures
regulator,

type

are most

All

at right

show

a French

of them

type

and the other indicates


tank

The German
type

acetylene

regulator,

and

regulator.

are equipped

the

a French
oxygen
with

One gauge indicates

Therefore,

type pressure

used.

is used only to regulate oxygen.

German type oxygen


each.

and German

commonly

two

pressure

gauges

the pressure in the tank,

the pressure of use.

gauge indicating

the pressure

in the

has a high pressure range, and the one indicating

the use pressure has a low pressure range. Some low


pressure gauges indicate
can

be welded

or

cut

the thickness
instead

of

of plates which
the

pressure

of

oxygen.

* German type pressure regulator

76 -

2) Structure

of pressure regulators

French type pressure

regulator

The pressure regulators for oxygen and acetylene


are different.
A

sectional

drawing

of a pressure regulator

is

High pressure

Low

pressure

shown at right.
Diaphragm
by

the

A, made of a rubber sheet, is pressed

adjustment

It

spring.

moves valve C

according to the pressure required to adjust the


volume of gas flowing from high pressure cham

ber D to low pressure chamber E and adjusts the


pressure of gas flowing

into the torch.

for hose

While

valve C is closed, pressure gauge G indicates the


pressure in the tank.
If

the

pressure adjustment

press the adjustment

screw is turned

spring, diaphragm

to

A will

bend upward to open valve C, which is connected


with the diaphragm.
Oxygen

in high pressure chamber

low pressure chamber

D flows into

E through valve C, and its

pressure presses the diaphragm

as shown by the

arrows.
Then,

spring

B shortens

Consequently,

slightly.
pressure

chamber

words,

the

closes valve
pressure

becomes

phragm is bent upward,


In other

and

lower,

in

low

the

dia-

and valve C opens again.

the adjustment

spring tires to

open valve C, but the pressure of oxygen tries to


close it.
When

these two

forces are in balance, oxygen

flows at a constant pressure.


From the above, it is clear that
adjustment

screw is turned

higher pressure of oxygen

if the pressure

to press spring B, a
can be obtained,

and

oxygen can be sent to the torch at the desired


pressure.
spring

Therefore,

diaphragm

A, valve C, and

B are the most important

pressure regulator,
will determine

and the quality

parts in the
of these parts

the quality of the whole regulator.

- 77 -

A.

Diaphragm

E.

Low pressure chamber

B.

Spring

F.

Pressure gauge at low


pressure side

C.

Valve
G.

D.

High pressure chamber

Pressure gauge at high


pressure side

German type pressure regulator


Although

the operation of the German type pres-

sure gauge does not differ

greatly from that of

the French type, it can adjust the pressure finely


since the pressure of the adjustment
the diaphragm
Therefore,

spring on

opens the valve through the lever.

the German type is not suitable for a

large volume

of oxygen.

On the scales of the

secondary pressure gauges of some German type


regulators, the thickness of plate that can be cut
at the given pressure is indicated.

tank valve

A. Primary pressure gauge

D. Sat nut

B. Secondary pressure gauge

E. Sat screw for pressure gauge

C. Safety valve

F. Set screw for flowmeter

- 78 -

9- 5

HOW TO HANDLE

OXYACETYLENE

WELDERS
Troubles of this kind often occur in high pressure

1) General cautions

Never use oil.

gauges when the tank valve is opened abruptly,

Since oil and grease burn violently

or in low pressure gauges when the tank valve is

in high pressure oxygen, never allow oil or grease


to contact the devices used in oxyacetylen

opened

weld-

ing (including oxygen and the hoses).

Inspect the equipment

often.

Replace parts only

repair

or replace parts not specified

instruction

manuals, have the equipment

by a shop authorized

which

in the

value.

repaired

replace it immedilowers the

it to the normal

It is installed on most regulators.

Always

keep

the

connection

regulator airtight.

needs repair or im-

proper devices for oxyacetylene

pressure adjust-

The safety valve automatically

excess pressure and restores

by the manufacturer.

Do not use a torch

loosening the

If the safety valve is broken,


ately.

with genuine parts supplied by the manufacturer.


To

without

ment screw.

of the tank

and

Before installing the regulators,

open the tank valve a little to remove all dust, as

welding.

it may scratch the seats of the nipples at the inlets of the regulators, and prevent the regulators
and tank

2) How to handle torches

from

after tightening
Work with
tip.

care when replacing the nozzle or nozzle

Although

which

the torch is sturdy, the seat surface on


if handled

roughly.

If the nut is tightened

a cleaning

recommended
confirm

drill

of the proper

by the

torch

If the valve cannot

the regulator.

to repair

between the regulator and

the tank.

be closed completely,

clean

the gas still leaks, close the valve tightly

If the regulator is not to be used for a long time,


release the pressure applied on the valve seat of

Remove the valve and wipe the seats of

If it does not work,

may

Close the tank valve before tight-

ening the connection

and

the valve stem and valve body with a cloth.


times.

the seat or

If this happens, ask the manufacturer

size,

Use the packings


manufacturer

much,

and the regulator

not be able to be installed to other tanks.

that they are free front oil.

the seat.

too

screw may be damaged,

If the holes of the nozzle tip are clogged, clean


with

close

and clean

at the inlet of the regulator.

and seat periodically.

them

If gas leaks

the seat of the tank valve, the nipple and the seat

Inspect the valve

soft brass wire, or steel wire.

airtight,

the tank valve, remove the regulator,

the head or nozzle contacts the handle may

break easily,

becoming

the nut for the connector,

the low pressure gauge.

If

When leaving the regulator installed to the tank

several

for a long time,

replace the valve or

justment

valve body.

confirm

that the pressure ad-

screw can be turned freely, then tighten

it one or two turns after it contacts the spring.


When

If

the

regulator

creeps, repair

it immediately.

relatively

creeps, the pressure will fall a

rise again gradually.

If the regulator creeps, reIf the needle of the

pressure gauge does not go back to its original


position when the pressure goes down, repair the
pressure gauge.

If pressure is applied to the pres-

sure gauge, it may break and the needle may not


return.
In this case, ask the manufacturer

to make the

repair.

soft material,

sure applied on it.

little rapidly after the torch valve is closed, then


place the valve seat or stem.

again, turn the presuntil it

To extend the life of the seat, which is made of

the torch valve has been closed.


regulator

regulator

screw counterclockwise

can be turned freely.

Creeping is defined as a rise in use pressure after


If the

using that

sure adjustment

3) How to handle regulators

79 -

always release the pres-

9-6

OTHER

TOOLS

FOR WELDING

AND

CUTTING

1) Hoses and connectors


The

hoses used in oxyacetylene

are specially
strength

made.

to withstand

flexibility

equipment

the internal

pressure, enough
of the torch, and

The hoses for oxygen are usually balck

green,

and equipped

with

screw coupling and cap nut.


are usually
equipped

welding

hoses must have enough

to follow the movement

be airtight.
or

The

a special right hand

The hoses for acetylene

red and have grooved surfaces, and are

with

a special left hand screw connector.

These hoses are the passages for gases, and are connected to the equipment

by using couplings.

Do not use the hoses for oxygen


other

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.

supply centers, the oxygen tanks can be


to

type collecting
connected

each

There

other

by

means

of collecting

are both installed type and portable


devices.

More than 30 tanks can be

by an installed type device, and about 5

tanks with the portable type.


When

a great volume

an acetylene
available,

the

of acetylene

generator
acetylene

of

the

tanks

is required

proper
can

and

size is not

be connected.

The collecting devices for oxygen and acetylene must


be purchased from and installed by a welding equipment manufacturer.

80 -

9- 7

ASSEMBLY

OF EQUIPMENT

* Sequence of assembly
Install

Install the hoses to the torches.

the acetylene

regulator

Connect

to the acetylene

the

tank.

torch

the black hose to the oxygen valve of


and the

red hoses to the acetylene

valve.
Install the oxygen regulator to the oxygen tank.
Adjust the nozzle.
Connect

the hoses to the regulators

Adjust

the

working

pressure

of

and torch.

oxygen

Slide the nozzle nut to the outlet of the mixing


chamber

and

and set the nozzle to the proper angle,

then turn the screw to fix the nozzle to the torch

acetylene.

handle.

Ignite the torch and adjust the flame.

Adjust the working pressure of acetylene.


Since the method of adjusting the working

Open the acetylene

pressure,

torch

valve and adjust the

the method of igniting the torch, and the method of

regulator to the specified working

adjusting the flame depend on the type of pressure

close the valve.

gauges, torch,

oxygen in the same way.

directions

and manufacturer,

of the manufacturer.

to the tanks

always follow

the

This applies not only

but also to the oxygen

pressure, then

Adjust the working

pressure of

Ignite the acetylene.

and acetylene

Open the acetylene valve of the torch and ignite

supplying devices.

with a lighter.
Adjust the flame until it is neutral.
Adjust the oxygen valve to make a neutral flame.

How to assemble the devices


The safety of workers and devices can be guaranteed
Open the tank valves slightly for a short time to

by following the above assembly method.

clean the inside of the adapters.

Study

Open each tank valve for a short time to blow


the dust off the adapter,

and wipe the seats of

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

the black hose to the oxygen

regulator,

then install the red hose to the acetylene

regu-

lator.
Open the tank valves.
Loosen the screws of the regulators, then slowly
open
before

the

tank

loosening

valves.

Never open the valves

the screws of the

regulators.

Clean the inside of the hoses.


To clean the inside of the hoses, open each regulator with its screw, then loosen the screw.

-81

the safety rules on page 85 before assembling

the devices.

9-8
*

REMOVAL

When

removing

OF EQUIPMENT
the

devices,

follow

the procedure

described below.
@

Close the acetylene valve of the torch.

Close the oxygen valve of the torch.

Close the valve of the acetylene tank.

Close the valve of the oxygen tank.

With the oxygen valve of the torch closed, open


the acetylene valve of the torch to release acetylene from the acetylene pipe.
Loosen
regulator,

the

adjustment

and

screw of the

immediately

close

oxygen

the

oxygen

valve of torch.
@

Open the oxygen valve to release the gas in the


oxygen

pipe

while

torch is closed.

the acetylene

valve of the

Loosen the adjustment screw of

the oxygen adjuster, then immediately

close the

oxygen valve of torch.


@

A flash-back

will occur when the two gases are

mixed in the oxygen or acetylene hose.


If the nozzle tip is in good condition,
of the torch is adjusted properly,
sure is correct,
acetylene

oxygen

will

pipe and acetylene

if the flame

and if the pres-

not flow

into the

will not flow into

the oxygen pipe when starting or stopping.


@

Remove the regulators before moving the tanks.


If the tank is empty,

write Empty

on the cap

of the tank valve.

82 -

9-9
.

SAFETY

Starting

RULES

work

dangerous

without

both

Understand

first

confirming

to the woker

safety

is

and to other people.

the safety rules which cover all aspects of

welding and cutting.

Do not set the valve adapter of tank toward the


oxygen tank.
When opening the tank,

turn the wrench about

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

the valve can be closed immediately

so

if an

accident occurs.

Do not store the oxygen and acetylene tanks in

Do not use the acetylene regulator, hose, etc. for

the same place.

the oxygen tank.

Do not use oxygen

near combustible

materials,

especially oil and grease.


Oxygen

itself

does

but

promotes

not

burn,

Do not let oil and other combustible

materilas

combustion.

contact

Do not move acetylene from one tank to another.


Do not fill other tanks with acetylene,
mix

a different

kind

Do not

of gas into the acetylene

tank.

the oxygen tank,

valve, regulator,

hose,

etc.

When

returning

tightly

to prevent the remaining gas from flowing

an empty

tank,

close the valve

out.

Do not handle the oxygen tank with oil-stained


If acetylene

hands or gloves.

outdoors,
Do not use the oxygen

regulator,

hose, etc. for

leaks from the tank,

place

it far from

fire,

take the tank


and call the

manufacturer.

gases other than oxygen.


Do not use acetylene
Open the valve of oxygen tank fully when start-

atmospheric

at a pressure higher than

pressure.

ing work.
Do not mix a different

kind of gas in the oxygen

tank.

Collecting devices and piping

Before handling the tank, ensure that the valve is

When

closed tightly.

nected to a collecting device or generator,

Do

not take out oxygen

directly

without

the

Do not play with the tank or try to repair it.

Acetylene
Always

use the correct word

Acetylene.

Do

not call it gas.


Acetylene
used

in

is completely
home

and

different

in furnaces,

from the gases


and

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

through the proper regulator.

- 83 -

for oxygen

and acetylene

is con-

the instal-

ler must explain the safety rules for these devices to


the workers.

regulator.

the piping

10.

PREVENTING

10-l PREVENTING
1)

ACCIDENTS

ACCIDENTS

IN WELDING

WORK
2)

Accidents caused by electrical shocks

caused by harmfull

radiation

The degree of danger of an electrical shock depends

In arc welding,

on the level of current

rises to about 6,OOOC. and a strong light is radi-

man body.

that flows through the hu-

ated.

If the current flows through heart, the

injury may be fatal.

In addition

Strong

The arc voltage is 60 to 9OV when not welding, and

it tired.

20 to 40V

during welding.

electricity

Although

in the home,

down

this is lower

it can still

the temperature

of the weld zone

to the visible rays, this light also

contains ultraviolet

The fatal level of current varies

with the person, but it is around 100 mA.

than

rays and infrared rays.

light stimulates
Ultraviolet

the optic nerve and makes

rays have the power to break

tissue, so if they

enter

the eyes, they will

cause a sharp pain to the conjunctiva

be very

Strong

dangerous if the hands or feet are wet with perspi-

infrared

and corea.

rays can reach the retina through

ration, etc.

the cornea and crystalline

Some tips for preventing electrical shock in welding

of eyesight.

work are given below.

plates must be used to shut off the arc. To prevent

0
@

Radiation

Use an insulated holder.

Do not use a welding cable whose core wire


is projecting.

gets shocked,

lowers voltage when

do not touch

Immediately

administer

Therefore,

leg guards made of leather.

turn

artificial

him

with

off the power,

make him lie down, and call a doctor.


consciousness,

sunlight.

If he has lost

respiration

until

the doctor arrives.

do not roll up your


To prevent

burns caused by spatters, wear gloves, an apron, and

If an electrical accident occurs


If someone

to a shield glass.

If bare skin is exposed

sleeves, or wear an open neck shirt.

device to avoid electrical

welding is stopped.)

your bare hands.

also causes burns.

a screen or shield

to the arc, it will be burnt as if it were exposed to


strong

shock (a device which

in diagonally,

sheet must be installed in addition

Wear shoes with rubber soles.

Use a preventive

lens, and may cause a loss

To prevent injuries to the eyes, shied

light from coming

Wear leather glooves.

Ailments

84 -

3)

Ailments
Almost

caused by the smoke produced in welding

ture of the arc is extremely

of weld

-Progress

all smoke produced in arc welding consists

of solid particles, called fumes.

Since the tempera-

high, metals and com-

ponents of slag are vaporized and blown off by the


arc, cool rapidly and become particles of 1 micron
diameter
formed

or less. These are the fumes.

Fumes are

as shown in the figure at right.

component

of fumes is iron

The main

Other

oxide.

com-

ponents differ depending on the kind of welding rod


used.

An example

of the components

shown in the graph at right.

Base metal

of fumes is

Major ailments caused


*

by fumes are described below.

Chemical composition

(1) Metal fume fever


When

materials

of fumes

Chemical composition of illmenite type


plated with

zinc or cadmium,

materials painted with paint containing


lead, or nonferrous

zinc or

metals containing

a lot of

copper or tin are welded, the fumes will contain


fumes,

he may get metal

fume

fever

languor,
ing.

will

fume

cause recurring

welding

produced,

and the worker

fume

However,

IO,

Al,O,

CaO

MRO N&O

KLI

Chemical composition of low hidrogen type


20.

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

may feel as if he has

fever even after welding

steel plates.

will

MnO

30.

of

If low hydrogen

rods are used, fluorine

50,

Metal

last for several hours be-

fore disappearing temporarily.

metal

fever.

symptoms

pains in the joints, chills, and sweat-

These symptoms

type

Fez03

If a worker inhales these

these heavy metals.

relatively

ordinary

harmless low

hydrogen type welding rods have been developed recently.

(2) Pneumoconiosis
Pneumoconiosis

is one of the major

caused by fumes.
insoluble

diseases

Pneumoconiosis occurs when

particles of the fumes accumulate

the lungs.

Although

in

not as serious as silicosis

(caused by non-bonding silicon such as quartz),


damage to the lungs is inevitable.
(3)

4)

Gas poisoning
When

arc welding

carbon
fluorine,
though
they

with covered welding

monoxide,

nitrogen

and other
the

amount

of

When

welding

in a poorly

for

gas, there

is danger

of

can be prevented by the following


(1)

long a

caused by the

Install a fume

measures.

restoring device.

Ventilate

various sections and overall factory

the

with fans.

ventilated

room and using carbon dioxide or argon as the


shied

ailments

* Diseases caused by the smoke produced in welding

Al-

these gases is small,


if inhaled

against

smoke produced in welding

rods,
ozone,

gases are produced.

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

The most serious accidents caused by gas in welding


and cutting
welding

or cutting

limit (combustible
In

addition,

materials

The

are explosions.

fuel gas used for

has a relatively

wide explosion

2)

Cautions when handling tanks

* Cautions when moving and transporting tanks


When

limit) and a large exploding power.

there

are

often

other

in the work area, which can multiply

seriousness of the accident.

moving or transporting

tanks, close the

main valves and install the caps.

combustible
the

Do not place oxygen and fuel gas tanks with

Some cautions for weld-

their adapters facing each other.

ing work are described below.


Load the tanks onto vehicles so that they do
I)

not project

Cautions in work operation

from

the sides.

Secure them with

ropes.
Wear proper clothes,

including

goggles, gloves,
Always

apron, leg guards, safety shoes, etc.

keep the handle for opening and clos-

ing the
Use a detector

or soapy water to inspect the

welding equipment,

cutting

pressure

regulators,

hoses, etc. for gas leaks.

Confirm

that

is no oil on places which

there

adapter

of

the

valve of

the

bombs with

you

devices, gas tanks,


Cautions on storing tanks
@)

come into direct contact with oxygen, such as


the

main

for emergency use.

oxygen

tank,

Store the tanks


ventilated

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.

Do not expose tanks to direct sunlight.


their temperature

When working

in an enclosed container,

ine the working


not work

method

gases and oxygen

in separate places.
Keep

below 4OC.

exam-

and procedure.

Do

Cautions on use

alone, since leaking gases may cause


Open and close the main valves slowly with the

explosions or shortage of oxygen.

special

handles.

Leave the handles installed

while welding.
*

Always

If an accident occurs
If

the

oxygen

hose catches fire,

do not touch

keep acetylene

tanks

upright

during

use.

it.

Do not use acetylene at a pressure above 1 kg/

Close the main valve immediately.

cm.
Do not consume all the gas in the bomb.
minimum
@

If the acetylene tank becomes too hot, cool it


with water.

- 86 -

Keep

gas pressure at 0.1 kg/cm2.

11.

COST OF WELDING

CONSUMABLES

11-l
COST OF PREPARATION
* Gas consumption
-

Steels are cut with


are prepared.

machines or gas, and their edges

The most general costs of gas cutting

are shown below.

Table 1 Cutting conditions for mild steel

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

of the cut surface), the cutting

The standard

3.30

conditions

are shown in Table 1.


the conditions

for

gas cutting

mild steel

quality

The cutting speed varies with

of the cutting

hole,

the volume

speed must be slow.

of

On the other

is not especially important,

hand, if quality

the cutting speed can be

oxygen and fuel gas, etc. The required quality of the

raised up to 130 to 150% of the upper limits shown

cut surface

in Table 1.

is another

cutting condition.

factor

which determines

the

To obtain a cutting result of high

87 -

11-2
1j

EXPENDITURES

Consumption
The major
welding

ON WELDING

of weld metal

part of the welding cost is the cost of

rods, so the calculation

amount

for the consump-

of back gouging, the reinforcement

weld, etc.

of the

The deposition rates for plates of various

tion of welding rods forms the basis for estimating

groove are shown in Fig. 1 (1) and (2) by thickness.

the total cost of welding materials.

These rates are calculated

The consump-

tion of welding rods depends on the thickness of the

the

material

reinforced

to be welded,

the welding

position,

the

plates

are grooved

on the assumption

as shown

in

Fig.

that

2 and

properly.

shape of the grooved edge, the depositing rate, the

Thickness

Thickness

(mm)

Fig. 1

(mm)

(2)

(1)

Weight of deposited metal

(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

This rate is around 90% for covered welding

rods if calculated

(1)

is the ratio of the weight

to the weight

on the

basis of the total

rods including the covering mate-

rials, it is around 60%.

on the basis of the weight of the

(2)

Both sides V-

(3)

groove butt welded

U-groove butt

(4)

welded joint

Double-U-groove

(5)

butt welded joint

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"

Fig. 2 Welding rod preparation

88 -

r'

(mm)

2/3t
13.5O

2)

Consumption

of covered arc welding rods

- The weight of welding rods consumed to weld 1 m is


shown in kg.

Thickness

(mm)

Thickness

(1) V-groove butt welded joint

(2)

lmm)

Double V-groove butt welded joint

30
Thickness

(3)

40

0
5 6 7 8 9 IO II I2 13 14 ,5 16

60

(mm)

Thickness

U and double U-groove butt welded joints

Fig. 3
The

weight

of consumed

10% depending
positions.
welding

welding

rods varies about

on the welding current

and welding

Fig. 3 shows the consumption


rods

under

various

conditions

rates of
which

are

calculated to include the above factors.

89 -

(4)

(mm)

Fillet welding

3)

Time required for arc welding with covered welding


rods.

- The time required to weld 1 m is shown in minutes.

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

V-groove butt welded joint

(2)

I
24

26

I
26

27

28

29

(mm)

and back welding of double


V-groove butt joint

Surface

70
60
60
40
30
20
IO

I
4

Thickness

IO

15

Thickness

(mm)

(3) U and double U-groovebutt welded joint

20

(mm)

(4) Fillet welding

90 -

I
25

I
30

4)

Power consumption
The

electric

power

for arc welding


required

for

melting

power

a given

consumption

is shown

in

Fig.

1.

Power

amount of the welding rods varies greatly depending

consumption

on the type of welding

and thickness of base metal is shown in Fig. 2.

the type

of current

Diameter

An outline

of the

I
60

I
50

I
40

rods used, their diameter,

used, etc.

by types of edges, welding positions,

of welding

rod (n?m)

Fig. 1 Relation between welding rods


and power consumption
(Arc time is assumed to be 40%.)
16

I7

18 19 20 21

Thickness of base metal (mm)

(1)

Thickness

(3)

Fig. 2

(4)

Double Vgroove

butt joint

Fillet welding

curve (Power required for 1 m weld is shown in KWh)

Relation between power consumption

25 26 27

Thickness of base metal (mm)

U and double V-groove joint

Power consumption

(2)

V-groove butt welded joint

of base metal (mm)

22 23 24

Thickness of base metal (mm)

and type of edge, welding position, thickness of base metal

Arc time ratio


The ratio of the work time consumed in welding to

continuous

the actual time consumed to generate the arc.

when the operation

ratio is 25 to 30% when the operation


35

to 48%

when the circumstances

This

be performed

rate is poor,
are good and

-91

welding

can

be carried

out,

and

50%

rate is high and the welding can

on a conveyer.

12.

EXAMPLES OF TROUBLES
AND COUNTERMEASURES

When repairing or reinforcing

welded structures, the

value and direction

of load, and the type

which the structure

receives must be considered.

addition,

the repair

be designed to
ability
of

or reinforcement

simplify

IN WELDED

operation

of stress

method
and

In
must

machining

and to minimize the costs. The characteristics

welded

joints

coefficient

(residual

stress, joint

efficiency,

of notches, etc.) must also be examined

to achieve both economy

and strength of the struc-

tures.
To attain

the above, it is important

experience.
occurred

Actual

in welded structures

ures taken will


the

examples

be described

countermeasures

stress is concentrated
the figures)

Stress after treatment


direction,

cated

type,

by symbols

to study past
trouble

which

and the countermeasbelow.

the

The effects of

positions

where

the

(measuring points are shown in

are measured with

shown as follows:
The

for

of

a strain meter, and

Stress under trouble

(kg/cm)

--f

(kg/cm*).
and location
or arrows

of load are indi-

in the figures.

The

meaning of those symbols are as follows:


Mt:

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

Large shearing force


is applied.
w

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.

_-

----

Weld places sufficientlv where


shearing force is
large.

Use thick side plate,


and remcwe reinforcement plate from inB _ S side. Bevel (or Igroove) edge of
back plates, pass
them continuously,
and weld sufficiently.

WELDED

STRUCTURES
Countermeasure

Cause

Crack

Pass back slate


continuously.

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

At welded connections between heavy


and large parts, dimensions of back
plate and frame are
dispersed widely and
precision of edge
preparation is low,
resulting in weld
defects.
(1) Make butt welds

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

Frame is bent, and


pressing stress is
concentrated on
front and rear ends
of bracket.

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

Weld boss inside.

is welded outside where


stress is high.
Boss

Remarks

D5016
E7016

Frame is bent, and


stress is concentrated on welded
area of ends of
seats.

Stress at portion A
t13,-19*+6,-4

Use single seat.

Support

D5016
E7016

Support receives
load from above.
If side plate are
thin, stress is highly concentrated.

Y /

Length& ribs up to the places


where base metal is thick and
stress is low.

w
Crack

Stress concentrates
on bracket causes
cracking.

Remove

D5016
E7016

end of

Bracket of this type


cannot be ured
since stress concentrates on rib
%3re&

Make bracket round to prevent


concentration of stress and remove end of weld zone where
stress is concentrated.
M

Straighten the
corners.
Smooth the
shape of and
of bracket.

SUPP~

Stress is concentrated on weld zon


of bracket because
of shape (R) of
base metal, resulting in cracks.

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

Do not install additional materials on upper and lower surface.


(!~!s;ot weld front and rear

94 -

Do not weld at right


angle to direction of
main stress.

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.

Make projected portion on cast


iron to butt weld.
As loads applied
to left and right
frame are different,
connector is twisted and stress is
concentrated on
connecting part
with frame.

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

Use cast steel as material for


frame connectors at both sides,
and finish both ends into
trumpet-shape.

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

iden box (8) m much


possible so that ends
rib and box are the
minimum that can be
welded.

D5016
E7016

Bending load is
applied to frame,
and tensile stress
is applied to its
base.

Stress at portion A
+42++15

install rib to prevent con-

12-6
-

Nc

HOW TO PLACE

REINFORCEMENT

PATCHES

D5016
E7016

Total frame is bent


and twisted, and
stress is concentrated around
bracket.

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.

Bending stress and


load are applied to
frame, and stress is
concentrated
around it.

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.

Place seat plate


/and weld leg.

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

Use prepared edge


with back
plate.

B -8
weld line

Cracks start especially from cornen.

Section 6 - B

As straight portion is welded to


corner, weld zone is cracked.

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

Prepare edges of cast steel as


shown above to prevent weld
defects caused by one-sided
thickness or offset centers.

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

Pipe is bent, and


comers where
stress is concentrated are welded.

Prepare edges of cast iron,


and weld at stright portion.

Machine until black


skin is removed.

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

Frame is bent, and


stress is concentrated on root of
additional materials.
Do not
at end.

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.

Enlarge this dimension


as much as possible.

As installation end:
of additional matGals are at the sami
level, stress is concentrated because
of difference in
rigidity.

Nelding rod

Lengthen end toward front as


much as possible, and stop welding at point where stress is low.

&ck

Stress is concentrated because of


difference in
rigidity between
thin plate and
block.

Place a large pad which


is thinner and larger than
the base metal.

Stress at portion A
MO. -23 + +18, -10

Place picture frame type plate to


reduce concentration of stress by
smoothing the change in rigidity.

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

each other exactly.

OF WELDING

backgrounds.

rods of various

below

RODS BY

standards

do not correspond

with

This table should be used only

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

High titanium oxide

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

RODS JIS, AWS, BS, DIN.

Classification of welding rods based on JIS

JIS Z 3211-1978

JIS Z 3212-1978

Covered arc welding rod for


mild steel

Covered arc welding rod for


high tensile steel

Japan

Method of classification
Example:

D p-p-j

D4301

D 4327

D 5016

D5326,

etc.

Meaning of classification symbols


D:
(1)

Covered arc welding rod

Tensile strength and yield point of deposited metal

Classification

Symbol

Min. tensile
strength kgf/mm

Min. yield point


kgflmm

(N/mm)

(N/mm)

NOTE:
The yield point and tensile strength of D4327
may

be reduced

by 1 kgf/mm*

(9.8 N/mm*

for each increase in elongation of 2%.


However,
33

the

kgf/mm*

yield

point

(323 N/mm*),

strength at least 41 kgf/mm


(2)

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

of welding rods based on AWS

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.

Meaning of classification symbols


E: Covered arc welding rod
@

Tensile strength and yield point of deposited metal

REMARKS:
1.

Unit of figures in

2.

Yield

point

reduce by 1,000
elongation
mum

is SI.

and tensile strength

be

of 1% from the specified mini-

value.

However,

tensile

strength

48,000

must

PSI and 60,000

yield
not

PSI in the 70,000

be

point

and

less than

PSI in the 60,000

PSI series, or less than


70,000

may

PSI for each increase in

58,000

PSI and

PSI series.

Welding positions and type of covering materials (including elongation and impact value of deposited metal,
efficiency,

power source, etc.)

:/zgm
Sym- M:a;;An,
tion

bol

2%

10

22

11

22

Impact value QV Charpy)


5 tlb (kgfm)
Tern eratSe
Jl
-20 F
(-29C)

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)

Classification of welding rods based on BS


BS 639-l 976
England

Covered arc welding rod for carbon steel and carbonmanganese steel

Method of classification
xamples:

E43

21

R13

E51

33

B160

20(H)

Meaning of classification symbols


E: Covered arc welding rod
@

Tensile

Elongation and impact value of

strength and yield point

/
Elongation and impact value of deoosited metal (No. I)

E43

Efficiency

Symbol

Efficiency %

None

Below 105

0
@

deposited metal (No. 2)

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

All positions (except downwat


welding in vertical position)

Flat, flat fillet, and horizontal


fillet welding

Flat position

Flat, downward i? vertical pas


;;xI~ horizontal fillet, and flat

All positions, and any combination of those positions

Power source

Symbol

21
3

Amount

AC no-load
voltage

DC polarity

Detail

07

Type of covering materials

Symbol

47

All values marked * must be at least 2OJ.

Svmbol 1

-50

50

of hydrogen

(HI is entered if diffusible


NOTE:
+: Electrode positive, -: Electrode
negative, t: Electrode positive or
negative

-102-

Classification of welding rods based on DIN

4)

DIN 1913-1976
Germany

Covered arc welding rod for normal steel


and low alloy steel

Method of classification
E

p]

pi

DIN1913

mlml

Exampes:

;5;;;;;

;D,l;;;;;_,g,3

Meaning of classification symbol


E: Covered arc welding rod
0

Tensile strength and yield point


of deposited metal
Tensile strength Min. yield point
Symbol
N/mm
N/mm*

Impact value of deposited


metal (47J)

Efficiency

Min. impact value


(2 V Charpy)
0

No regulation

Elongation and impact value of


deposited metal (28J)

Remarks:

Each value must be at


least 28J.
Detail of symbols of welding position.

Applied to rods of
Remarks:
RRII,
ARII,
B12, B(4112.
the efficiency of which is
135% or above.

Power source

Type.of weld mg rods (including type of covering materials, welding


posmon, power source, amount of hydrogen, etc.)

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

Acidic rutile (thick)

RR(B)7

Basic rutile (thick)

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

~,

Type of covering materials

Rutile (thick)
Basic rutile (thick)

B9

Basic (thick)

B(R)9

1Basic*(thick)

Acidic rutile (Efficrency

1
1

O(6)

1Oorless

Remarks:
Figures in ( ) are
thickness of cover and
efficiency.

2105%)
NOTE:

-103-

*:

Includes non-basic materials

14.

LIST OF STANDARDS
COUNTRIES

OF METAL

MATERIALS

Although

the standards of metal materials of various

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,

use one whose

and tensile strength corre-

spond.

of various standards

shown in the table below do not correspond

equivalent

BY

Carbon

to each

+I/40

Equivalent
Ni + l/6

(Ceq)

= C + l/6

Mn + l/24

Cr + l/4 MO + 1/14V

This table should be used only for

reference.

1)

Rolled steel for general structures (JIS G3101-1977)

Type

Tvpe 1

2)

Symbol
(JIS)

Tensile
strength
(kg/mm)

ss34

34 to 41

Rolled steel for welded

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

structures (JIS G3106-1977)

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)

Cold rolled steel (JIS G3141-1977)


Symbol
(JIS)

Tensile
strength
(kg/mm*

TVP~ 1

SPCC

(228)

Type 2

SPCD

Type 3

SPCE

Type

Corresponding standards
Ceq

KES

ASTM

228

4)

Carbon steel for machine structural use (JIS G4051-1965)

5)

Carbon steel forgings for general use (JIS G3201-1964)

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)

Carbon steel tubes for general structural purposes (JIS G34441977)

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

Carbon steel tubes for machine structural purposes (JIS 634451977)

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

A51 9-l 040

A519-64
A519-1050

245

-106-

3602-l 962

1629(St55)

8)

High tension rolled steel plates for welded structures (SHT)

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

Yield strength - Tensile strength


kg/mm*

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

Stresses (yield strength - tensile strength)


Previous unit:

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

AWS * ABS - MIL

Germany

DIN - GL

France

NF

Norway

NV

Italy

UNI - RlNa

ABBREVIATION
Abbreviation

I so:

AND

LEGAL

- BV

NAME

Legal name or name of institution


International

Organization

which established standards (Standard book)

for Standardization

J I S:

Japanese Industrial Standard

J RS:

Japan National

(Architects)

Architectural

N K:

Marine Association of Japan (Rules for registration and structural

A WS:

American

Welding Standard

A B S:

American

Bureau of Shipping (Rules for Building and Classing Steel Vessels)

I L:

B S:
L R:

Military

Railways
Institute of Japan (Rules of welding work)

Specifications

tests of ships)

and Standards

British Standards Institution


Lloyds Register of Shipping (Rules and Regulation for the Construction

and Classification

of

Steel Ships)
GOST:

Gosudarstbennie

D I N:

Deutsche lndustrie Normen

G L:

Germanifcher

B V:

Bureau Veritas (Rules and Regulation for the Construction

N F:

Norme Francaise

N V:

Norske Veritas (Rules for the Construction

U N I:

Unificazione

I Na:

Standart

Lloyd

ltaliana

Registro Italians Navale

ASTM:

American

Society for Testing and Materials

K ES:

Komatsu Engineering Standard

-114-

and Classification of Steel Vessels)

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

for generating acetylene

gas by the reaction of water with

calcium carbide (CaCs 1.

Actual

Actual throat

throat

of fillet

weld to the face.

weld:

Shortest

distance from

Actual throat of butt weld:

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

Method of scraping a groove on a metal surface by continuously

Arc air gouging

blow-

ing the metal fused by the heat of the arc with compressed air.

Arc cutting

Cutting by using the heat of an arc.

Arc length

Distance between the two ends of an arc.

Arc spot welding

Spot welding

wherein

plates are heated from

one side with the heat

of an arc and fusion welded.

Arc voltage

Voltage at both ends of an arc.

Arc welding

Welding by using the heat of an arc.

Atomic-hydrogen

welding

Arc

welding

produced

carried

out

by using the heat of reaction

when the arc is bridged

in hydrogen current.

-115-

between

of hydrogen

two tungsten electrodes

Automatic

arc welding

Arc welding carried out by employing a device which can automatically


feed the electrode

Axis of a weld

and continue

the weld without

A line through the length of a weld, perpendicular

manual operation.

to the cross-section,

at its center of gravity.

Back chipping

In butt welding,

chipping

off the insufficient

penetration

or the first

layer from the back of the metal.

Back fire

See flash back.

Backhand welding

Welding

technique

whereby

the welding torch

or gun is directed

op-

posite to the progress of the weld.

Backing

Application

of a metal,

asbestos or other material

to the back of a

joint during welding.

Backing strip

Backing weld

Metal used for backing.

In arc welding, weld previously deposited on the back of the metal to


prevent molten metal from dropping off.

Back run

In welding single groove welding carried

out from

the back after the

face has been welded first.

Bare electrode

An electrode without coating and used for arc welding.

Base metal

The metal to be welded or cut.

-116-

Bead

The weld metal deposited in one pass.

Bevel angle

The angle formed


perpendicular

Blowhole/Gas

pocket

between the prepared edge of a member and a plane

to the surface of the member.

A cavity in the weld metal caused by gas.

A device which controls the mixing ratio of gas and its flow; the por-

Blowpipe/torch

tion of a holder used for inert gas arc welding.

Welding wherein the edges of metals to be welded are prepared as they

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

metal, copper alloys such as Torbin

fusion points of 640 to l,OOOC are used.


those metals is as follows;

Copper:

bronze, etc. which have

The typical composition

of

59 to 62%. zinc: 37 to 40%. tin:

0.5 to 1 .O%, lead: below 0.1%. iron: below 0.2%.

Method of joining base metals without

Brazing

Brazing filler metal/hard

solder

fusing them.

A filler metal for brazing with a liquidus above 450C.

Buttering

(See surfacing)

Butt joint

Joint

between

two

metal

members

welded

on approximately

the

same plane.

Butt resistance welding

Resistance welding carried out by butting surfaces of two metal members against each other while applying

pressure, as in upset or flash

welding.

Butt seam 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

bers, and continuously


manufacture

welding

of pipe material.

-117-

by applying
along

passed through the

pressure to the metal memthe

joint.

Used mainly

for

Welding used for butt joints.

Butt welding

C
Carburizing flame

Covered electrode

See reducing flame.

A filler

metal

core wire

with

electrode,
a thick

used in arc welding,


covering.

metal from the atmosphere,

consisting

of a metal

The covering protects the molten

improves the properties of the weld metal,

and stabilizes the arc.

CO,-gas arc shielded welding

Arc welding carried out in an atmosphere of CO2 gas.

Continuous fillet weld

A weld

which extends continuously

from

one end of a joint

to the

other.

Cone/flame

core

The white conical

portion

of a gas flame at the mouth of the nozzle.

Concave fillet weld

A fillet weld with a concave face.

Convex fillet weld

A fillet weld with a convex face.

Core wire

The metal wire used as filler metal for shield arc welding.

-118-

Corner joint

Joint with corners of two base metals welded at a right angle.

Cover glass

A clear glass used in goggles, hand shields and helmets to protect the
filter glass from spattering material.

Crater

A depression at the end of a bead on an arc weld.

Cutting torch (cutting blowpipe)

device

used in oxygen

cutting

for controlling

and directing

the

gases.

Cutting shoulder

The top edge of a gas cut section.

Cutting tip

The part of an oxygen cutting torch from which the gasses come out.

DC arc welding

Welding carried out with a DC arc.

Deposited metal

Metal deposited onto a base metal during a welding operation.

Deposition efficiency

The ratio of the weight of deposited metal to the net weight of electrodes

consumed,

excluding

the stubs.

Usually,

but not always, the

weight of coating on a covered electrode is added.

Deposition

rate

Die-burn

The weight of metal deposited in a unit of time.

In butt resistance welding, a surface defect occurring on the surface


of the base metal or adjacent thereto due to inappropriate

transmitting

welding current.

Dissolved acetylene

Acetylene

dissolved in acetone and absorbed by a porous material in a

container.

-119-

Drag

In a gas cutting

plane, the horizontal

distance between

the inlet and

outlet points of the gas cutting current.

Kerf

Double groove joint

A weld made in a groove between

two members to be joined.

The

standard types of groove welds are as follows.

Square Groove weld

Double - Bevel -

Double -

-120-

V-

Groove weld

Groove weld

E
Edge joint

A joint between the edges of two or more parallel members.

Edge preparation

Working the edge of a base metal to a suitable bevel for welding.

Effective length of weld

The length of weld through which the correctly

proportioned

cross-section exists.

Electrode holder

A device used for mechanically

holding the electrode and conducting

current to it.

Electrode tip

In spot welding,

a bar electrode

which

directly

contacts

the metal

members to transmit welding current and welding pressure.

Electron beam welding (EBW)

A welding

process wherein

tained from a concentrated

coalescence is produced

by the heat ob-

beam composed primarily

of high velocity

electrons impinging upon the surfaces to be joined.

Electroslag welding (EW)

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

by its resistance to electric current passing between

the electrode and the work.


Consumable
welding

Guide

wherein

Electroslag

filler

metal

Welding

is supplied

A method

of electroslag

by an electrode

and its

guiding member.

End tab; Runoff-tab

Reinforcing

plates attached

-121-

to the starting

point

and end of beads.

Exposed core

A part of a covered electrode lacking a cover for the purpose of holding


with a holder.

Expulsion and surface flash

Scattering
itself.

of metals in lap resistance welding or the scattering metal

The cause of this phenomenon

excessive current,

insufficient

is the excessive heat caused by

pressing force, too little end surface area

of the electrodes, dust or scale on the metals, etc.


outer surface which contacts the electrode

This occurs on the

as well as surfaces of metals

which contact each other.

F
Face-bond specimen

Test specimen bent so that the face of the butt welded joint is tensile.

Filler metal

The metal added in welding, brazing, or soldering to form joint.

Fillet weld

A weld of approximately
. approximately

triangular

cross-section joining two surfaces

at right angles to each other in a lap joint, tee joint or

corner joint.

Fillet welding joint

A joint welded by fillet welding.

Fillet weld in normal shear/

Fillet welding where the weld line forms an approximate

Front fillet weld

the direction of stress.

Fillet weld in parallel

Fillet

shear/Side fillet weld

direction

of stress.

A filter,

usually colored,

Filter lens

weld where the weld line is approximately

shield harmful

Fire cracker welding

Welding

right angle to

in parallel with the

used in goggles, helmets, and hand shields to

beams produced during welding.

carried out automatically

by keeping a covered electrode

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,

silver white, which appears on the broken surface

of a welded metal.

Flare groove weld

A weld at the flared portion between two metal members.

-122-

Flash back (back fire)

Flash burr

Phenomenon

where the flame suddenly

In resistance butt welding,

flashes back into the nozzle.

metal solidified

after fused metal has been

pushed out by the action of pressure around weld.

Flash welding (FW)

A resistance-welding

process wherein coalescence is produced simulta-

neously over the entire area of abutting surfaces, by the heat obtained
.from

resistance to electric current

the application

of pressure after

between the two surfaces, and by


heating

Flashing and up-setting are accompanied

is substantially
by expulsion

completed.

of metal from

the joint.

Flat position

The position of welding wherein welding is performed

from the upper

side of the joint and the face of the weld is approximately

Flux

Material

used to prevent,

dissolve or facilitate

horizontal.

removal of oxides and

other undesirable substances.

Forehand welding

A welding technique

wherein

the welding torch or gun is directed to-

ward the progress of welding.

Forge welding

Welding

carried

Furnace brazing

Brazing carried out by heating the base metal in furnace.

Fusion welding

Welding carried out without


ing impact

out

to metal

by applying

applying

members

welding, arc welding, thermit

blows or pressure to heated metal.

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

Grooving carried out by using a gas flame and oxygen.

-123-

Gas pressure welding

Pressure welding carried out by using the heat of a gas flame.

Gas welding

Welding carried out by using the heat of a gas flame.

Gravity type arc .welding

A kind of automatic

arc welding, in which the holder is lowered by the

gravity along a support made of metal which stands at a certain angle to


the base metal, and the welding rod held by the holder is also lowered
slowly while welding the base metal and keeping the angle to the base
metal constant.

This method can be applied to horizontal

and flat butt joint welding.


worker

fillet welding

Since the device is easy to handle and one

can weld evenly and securely using many devices at the same

time, the efficiency

is very high.

bridge construction,

building construction,

This method is used in ship building,


etc. The length of the weld-

ing rods is 500 to 700 mm usually.

Goggles with

Goggles

which

tinted

protect

lenses, used during

the eyes from

harmful

welding
radiation

or oxygen
and flying

cutting,
particles.

The opening provided between two metal members for a groove weld.

Groove

Includes the following forms:

)g

fg

"J'g"b'p """
RDouble
""ii--g

Square

Bevel

Fillet

Groove angle

The

total

Double bevel

angle of the groove between

groove weld.

Groove angle
Groove angle

52

-124-

Double U

two parts to be joined

by a

Groove depth

The depth of the groove between two parts to be joined by a groove


weld.

Groove weld

A weld made in the groove between two members to be joined.

The

standard types of groove welds are as follows:


Square-Groove

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

of the welding machine

frame

to the earth

for safety.

Guide-bend welding test

Bending test wherein

a member

is bent along male and female

jigs.

H
Hand shield/face shield

In arc welding,

a hand held protective

device with a peep window

to

shield the face and neck.

Hard facing

Depositing
hardness.

-125-

a metal of high hardness on a metal surface to increase its

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

heat of welding, brazing, soldering or cutting.

A protective

Helmet

neck.

device, used in arc welding,

for shielding the face and

A helmet is equipped with a suitable filter

glass and is designed

to be worn on the head.

High frequency

induction

welding

Butt or seam welding carried out by using high frequency

induction

heat while applying pressure to the portion to be welded.

High frequency

resistance welding

Resistance heat welding carried out by flowing


high frequency

directly,

through

an electric current

the base metal while applying

of

pres-

sure to the portion to be welded.

Horizontal

position

Fillet weld -

The position of welding wherein welding is performed

the upper side of an approximately


,approximately

vertical surface.

horizontal

Groove weld -The

position of welding

wherein the axis of the weld lies in an approximately


and the face of the weld lies in an approximately

on

surface and against an


horizontal

plane

vertical plane.

I
Ice-flower-like

structure

A structure seen in the fracture of weld, wherein fine columnar crystals


are in line in the form
microscopic

of ice columns,

non-metallic

inclusions

among which there remain

and blow holes.

Fractures with

such a structure are called linear fractures.

In lap

Indentation

resistance

welding,

depression

on the surface of base metal

caused by the electrode tip.

Induction

brazing

Brazing

carried

current.

126-

out

by using the heat obtained

from

an induction

Inert-gas arc welding

Arc welding carried out in an atmosphere

of inert gas (argon, helium,

etc.) with a small amount of active gas.

Inert gas metal arc welding

An

arc-welding

process wherein

coalescence

is produced

with an electric arc between a filler metal (consumable)


the work.

Shielding is obtained from a gas, a gas mixture

contain an inert gas) or a mixture

of a gas and a flux.

by heating

electrode

and

(which may

(This process has

sometimes been called Mig welding.)

Intermittent

fillet weld

A weld wherein the continuity

of the weld is broken by recurring un-

welded spaces.

J
Joggled lap joint

Lap joint wherein one member is stepped so that both members are on
approximately

the same level.

L
Layer

Layer of weld metal made by one or more beads.

Leg length

Distance from root of joint to toe of fillet weld.

-127-

A joint between two overlapping members.

Lap joint

Resistance welding carried out by applying

Lap resistance welding

an overlapped

joint,

pressure from both sides of

includes spot welding,

projection

welding,

and

seam welding.

The

Liquidus

lowest temperature

at which

a metal or an alloy is completely

liquid.

M
Phenomenon

Magnetic blow

wherein

the arc is biased by the magnetic

action of an

electric current.

Manual welding/hand

welding

Welding performed

by hand.

Melting rate

The weight or length of electrode melted in a unit of time.

Metal arc welding

A generic term for arc welding performed

using bare or covered metal

welding rods.

Mixing chamber

The part of a torch wherein the combustion gas and oxygen are mixed.

Multiple electrode spot welding machine

A spot welding machine with multiple electrodes.

Multiple-impulse

The making of welds by more than one impulse of current.

welding

Multiple operator welding machine

Welding

machine

which

operators at the same time.

-128-

can

be operated

by two

or more welding

N
Neutral flame

A flame which is neither oxidizing nor reducing.

Notch brittleness

Brittleness

of a metal member.

Ductility

is satisfactory

when there is

no notch, it is brittle when there is a notch.

An attachment

Nozzle/tip

to the tip of a welding or cutting torch.

A flame comes

out if its opening.

In lap resistance welding,

Nugget

the metal which has fused and solidified

at

the weld zone.

0
Overhead position

The position of welding wherein welding is performed

from the under-

side of the joint.

Protrusion of weld metal beyond the toe or root of the weld.

Overlap

Overlap

Overlap

Oxidizing

falme

Oxygen-arc cutting (AOC)

A gas flame

containing

An oxygen-cutting
means

Overlap

more

oxygen

than

that

elevated temperatures,

reaction

of oxygen

129-

with

the necessary temperature

means of an arc between a consumable tubular

of a neutral

frame.

process wherein the severing of metals is effected by

of the chemical

metal.

Overlap

the

base metal

being maintained
electrode

at
by

and the base

Oxyacetylene

welding

Welding carried out by using the combustion

heat of acetylene

with

heat of hydrogen

with

oxygen.

Oxyhydrogen

welding

Welding

carried out by using the combustion

oxygen.

P
A single welding operation

Pass/run

along a joint or weld deposit.

The result of

a pass is a bead.

The mechanical working of metals by means of impact blows.

Peening

Penetration
The minimum

(Joint penetration)

depth a groove or flange weld extending

from the face

into a joint, exclusive of reinforcement.


The depth a groove weld extending

(Root penetration)

into the root of a joint measured

on the centerline of the root cross-section.

Penetration/weld

penetration

Distance

between vertex of the fused portion

of a base metal and the

surface to be welded.

Penetration

Percussion welding

Welding

wherein

discharging

a joint

electric

is heated with the arc produced by suddenly

energy

previously

metal, and welding by applying

stored

through

butt

faces of

impact pressure during of immediately

after the electric discharge.

Pit

Small depression on the outside surface of a weld due to blowholes,


chills, etc.

Platen

Component
surface
mounted,

on

parts of a resistance welding machine which have an even


which

electrode

and which

upsetting force.

-130-

dies,

transmits

locating

welding

equipment,

etc. can be

pressure of an electrode

or

Plug weld

Welding carried out by boring holes in one metal member,

and joining

with the other member by welding.

Porosity

Gas pockets or voids in metal.

Postheating

The application

of heat to an assemble after a welding, brazing, solder-

ing or cutting operation.

Preheating

The application

of heat to the base metal immediately

before a welding

or cutting operation.

Pressure thermit welding

Method of welding whereby the heat of a thermit


in addition to the application

Projection welding (RPW)

A resistance-welding

process wherein

heat obtained *from

resistance to electric

parts held together


are localized

coalescence is produced
current

under pressure by electrodes.

at predetermined

reaction is employed

of pressure.

through

by the

the work

The resulting welds

points by projections,

embossments or

intersections.

Pulsation welding

See Multiple-impulse

welding.

R
Rate of deposition

See deposition rate.

Reducing flame

A gas flame having a reducing property

-131-

(excess of fuel gas over oxygen).

Reinforcement

of weld

Weld metal on the face of a weld in excess of the metal required for the
specified weld size.

Residual stress

Residual stress left in a structure or metal member.

Resistance welding

Welding

carried out by transmitting

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

of DC arc welding whereby

a metal member is connected to

the negative pole of an electric power source and an electrode to the


positive pole.

Roller bend test

Bend test made by supporting a weld on rollers as shown in drawing.

Direction of force

Rollers

Roller electrode

Roller spot welding

round

electrode

used in seam welding,

Spot welding carried out continuously

roller spot welding,

etc.

by using a roller electrode at a

fixed distance.

Root face

That

portion

of the groove face adjacent

Root face

Root of joint

Root of butt welded joint:


welding,

-132-

root of the joint.

l-l

In butt welding, portion

metal members closest to each other.


fillet

to the

line of intersection

Root of fillet

of a joint of two
welded joint:

In

of surfaces of two metal members.

The separation between the members at the root of the joint.

Root opening

Root opening

C!5
Root opening

The radius of a J- or U-Groove.

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

carried out continuously

along a joint

electric current through a roller electrode

being rotated

and applying pressure.

Semiautomatic

arc welding

Arc welding carried out by using equipment

capable of automatically

feeding an electrode and manually moving the welding head.

Series spot welding

Resistance

welding

wherein

welded by transmitting

Sheet separation

two

or more joints

are simultaneously

an electric current in series.

In resistance lap welding, the gap of a plate produced around a nugget


as a result of welding.

-133-

Submerged arc welding

Arc welding carried out while shielding the arc and deposit metal from
the atmosphere with a protecting medium.

Shrinkage stress

See residual stress.

Side-bend specimen

A test specimen to be bent on the side of a weld.

Seal weld

Any weld used primarily

Single groove joint

Joint

to obtain tightness.

with a groove scraped out on one side only of two metal mem-

bers. Includes the following

basic forms:

Square
J
U

Single operator welding machine

Welding machine made to be used by one welding operator.

Size of fillet weld

Size used for design to specify the size of fillet weld.


For equal leg fillet

welds, the leg length

right-triangle

can be inscribed

which

of the largest isosceles

within

the fillet-weld

cross-

section.
For

unequal

triangle

leg fillet

welds, the leg length

which can be inscribed within

Skip weld

See wandering sequence.

Slag

Non-metallic

Slag hammer

Hammer used for removing slag.

Slag inclusion

Non-metallic

-134-

of the largest right-

the fillet-weld

substance produced during welding.

solid material entrapped in weld zone.

cross-section.

A weld made in an elongated hole in one member of a lap or tee joint

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

The hole may be open at one end

or completely

filled with weld metal.

welded slot should not be construed as conforming

A group of joining processes wherein coalescence is produced

Soldering

ing to a suitable temperature


uidus not exceeding 800F

(A fillet-

to this definition.)

by heat-

and by using a filler metal having a liq-

(427C)

and below the solidus of the base

metals.

In arc and gas welding, the metal particles expelled during welding and

Spatter

which do not form a part of the weld.

Spatter loss

Metal lost due to spatters.

Spot weld

A weld made between

or upon overlapping

members

wherein coales-

cence may start and occur on the laying surfaces or may have proceeded

from

the

surface

(plan view) is approximately

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

in one line are staggered with respect to those in the

other line.

Straight polarity

A connecting
welded

method

is connected

in DC arc welding,

whereby

the metal to be

to the positive pole of the power source and the

electrode to negative pole.

Strapped joint

Joint

with the surface of base metal fillet

doubling plate.

-135-

welded

to the face of the

Welding carried out in a flux

Submerged arc welding

with the heat produced

by the arc be-

tween a bare electrode and the base metal.

Depositing

Surfacing

a filler

metal

onto the surface

of a metal to obtain

the

desired properties or dimensions.

T
A weld made to hold parts of a weldment

Tack weld

in proper alignment

until

the final welds are made.

Tee joint

A joint

between two member located at about a right angle in a T

formed

by placing the end face of one plate on the surface of the

other.

Theoretical

A weld of approximately

throat

approximately

triangular

cross-section joining two surfaces

at right angles to each other in a lap joint, tee joint or

corner joint.

Actual throat

Theoretical

and actual throat

Theoretical

throat

Legs

Thermit

mixture

Mixture

of metallic

for thermit

reaction.

-136-

oxide,

aluminum

powder

and other alloys used

Thermit

welding

Method of welding carried out by using the heat of a thermit

reaction.

The fused metal thus obtained is deposited as filler metal as it is.

Throat of a fillet weld

See a theoretical

Tig welding, tungsten-arc welding

A kind

throat

and actual throat.

of insert-gas arc welding

wherein

tungsten

or another

non-

consumable metal is used as the electrode.

Tip holder

In resistance welding, the holder for the electrode tip.

Toe of weld

The junction

Groove weld

Tpe of weld

Fillt weld

between the face of a weld and the base metal.

Toe of weld

Toe of weld

Toe weld

Torch head

The portion

to which the nozzle of a welding or cutting torch is at-

tached.

Transition

temoerature

The

temperature

at which

the

breaking

form

of a metal drastically

changes.

U
Ultrasonic welding

A solid state welding process wherein coalescence is produced


local

application

of

high frequency

vibratory

energy

as the

by the
work

parts are held together under pressure.

Underbead crack

A kind of crack occurring at the heat affected


but not reaching the surface of the base metal.

-137-

zone close to the bead,

Undercut

Portion

of groove left unfilled

by weld metal after the base metal has

been scrapped out along the toe of weld.

R
_

Underlaying

Undercut

Undercut

Undercut

In build up welding, depositing a non-fragile

metal onto the surface of

the base metal to prevent it from being broken or blisterred.

Uranami welding electrode

A covered electrode

made to easily obtain even beads on the back of a

metal by starting the weld from the face of a bevel.

Upset butt welding

Welding by means of joining butt faces of metal under heat while applying pressure.

Vertical position

The position of welding wherein the axis of the weld is approximately


vertical.

Wandering sequence

longitudinal

sequence wherein

the weld

bead increments

are de-

posited at random.

Weaving

A method of moving the electrode

alternately

crosswise in the welding

direction.

Weldability

The capacity of a metal to be welded under the fabrication


imposed

into a specific,

satisfactorily

suitably

designed structure

in the intended service.

-138-

conditions

and to perform

Weld bead

Weld length

See bead.

Length of portion

of uninterrupted

weld, excluding starting point and

crater.

Weld line

Line showing direction

of bead, filler or butt welding.

Weld line

Weld metal

That portion of a weld which has been melted during welding.

Heat-Affected

PA

zone

Weld metal area

Base metal + Deposit metal

Weld metal test specimen

Test specimen of weld metal excluding the base metal.

Weld time

The time that welding current

Weld zone

The

is applied to the work in making a weld.

area of the weld, including

the part of the base metal which is

melted and the deposited metal.

Welding current

The

electric

current

transmitted

welding.

Welding force

The pressure applied to the weld.

-139-

to

generate the heat required

for

Welding position

Position of welding operator


flat, horizontal,

and the work

during welding.

vertical and overhead positions.

Welding rod

Filler metal in the form of line a bar.

Welding symbol

Symbol in a drawing which describes the weld to be made.

Welding transformer

A transformer

140-

used to supply welding current.

Includes

APPLIED INSTRUCTIONS
11 BASIC

WELDING

. q
I!!!!3

Items required for welding repairs ........


Procedure for checking for cracks ........
Preparation of edges by gouging .........
Welding procedure .....................
Finishing procedure with a grinder ........
Peer-ringprocedure .......................
Weldability of steel materials .............
Sections to be repaired by welding and
selection of welding rods ...............
List of major materials of bulldozers ......
Points for ensuring quality after welding ...

. ll-

II. II. ll11-23


1 i-25
. 11-26

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.

To facilitate understanding, this manual gives examples of typical

welded structures and major parts which are often repaired by welding.
t

JIS (Japanese Industrial Standard) and KES (Komatsu Engineering Standard)


symbols are used in this manual.
AWS/ASTM symbols are also used in some tables. For standards used in other
major countries (BS and DIN) which are not shown in the tables, see 13. LIST
OF

STANDARDS

OF STANDARDS
ERAL

WELDING

OF

WELDING

OF METAL

RODS

MATERIALS

BY

COUNTRIES

and 14. LIST

BY COUNTRIESin

GEN-

INSTRUCTIONS.

11 -1

cc

APPLIED

BASIC WELDING

INSTRUCTION

ITEMS

REQUIRED

The following

FOR WELDING

items are required

REPAIRS
j.

in order to make re-

Hammers

(sledge hammer, hand hammer, chipping

hammer)

pairs by welding.

k. Wire brush
a. Chemicals required for dye penetrant checks

I. Tape measured, steel measures, straight edges

b. Torch for arc air gouging

m.Set

C.

d. Arc welder (Rated current:

n. C-clamp
o. Centering punch, scriber

Covered welding rods

p. Centeralized

g- Welding rod drier


h. Disc grinder
i.

piping system for compressor or com-

pressed air
q. Other items

Pneumatic hammer

PROCEDURE

(Leg covers, arm covers, apron,


safety goggles for welding, safety

goggles for gas cutting, safety goggles for grinding)

500 A min.)

e. Gas cutting machine


f.

of protectors

dust respirator,

Carbon rods for arc air gouging ($4 to @I mm)

FOR CHECKING

FOR CRACKS

Before removing cracks which are found in a periodic or

trant checks (color check) is the most appropriate

other

od to rapidly and easily detect fine cracks on the welded

inspection,

it is necessary to know

positions and lengths of the cracks.


spection,
magnaflux
eddy

(1) dye

inspection,

current

destructive

penetrant

flaw

(3)

supersonic

tests may be used.

or (5)

correct

check),

inspection,
radioactive

meth-

structures in the field.

To make this in-

checks (color

detection,

the

(2)
The procedure and cautions for the dye penetrant check

(4)

are shown below.

non-

However, the dye pene-

1. PROCEDURE
Description

Step

Key points and remarks

Prepare the chemicals for the dye penetrant check


(detergent,

penetrant and developer),

wire brush,

and some cloth.


Use a wire brush to wipe off all the soil and rust

* If the surface is painted, remove the paint film.

from the surface to be checked.

Wash the cracked surface with the detergent to

* Remove grease with thinner.

remove the oil, then dry it well.

- The chemicals used for the dye penetrant

temperature
40C

Confirm that the

of the surface to be checked is 15 to

(it should not feel hot or cold when touched

and thinner are flammable.

check

Do not use them

while welding work is being performed

with your hand).

or when the temperature

If it is cold, heat it with a gas burner; if it is hot,

is still hot because of welding.

nearby

of the nearby surface

wait until it cools.

11-2
0

After the surface is dry, spray the penetrant,

and

wait 5 to 20 minutes.

WELDING

APPLIED

Description

Step

BASIC

INSTRUCTION

Key points and remarks

Spray the detergent again, and wipe the penetrant

If the surface to be checked is wide or long, wipe

from the surface with a cloth.

it in advance to simplify the work.


Use as little detergent as possible so that the penetrant in the crack will,not

Just after wiping off the penetrant,


%

WELIDNG

developer.

spray on the

The developer must be applied thinly

and evenly so that the texture

of the surface to

be checked can be seen through the developer.

flow out.

* Shake the bottle of the developer before spraying it.


- Spray the developer from a distance of 25 to
30 cm.

After 15 to 20 minutes, check the location and

Check the surface after it becomes white (after

length of the crack visually.

the solvent evaporates).

The whole length of

the crack must have been dyed.


If there is a paint film which may confuse the inspection, remove it again, then perform the dye
penetrant check.
Confirm the location of both ends of the crack,
and mark them if necessary.

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

beyond the ends to stop the crack from extending.

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)

Spray the chemicals while swinging the can horizontally (Fig. 2)

horizontally

Fig. 2
4)

After

spraying

the developer,

turn the can upside

down and spray lightly (to prevent clogging).

Fig. 3
5)

After

spraying the chemicals,

put the cap back on

the can.
6)

Before

disposing

the

used (empty)

cans, make

hole in them with a screwdriver or chisel.

WELDING

1 l-5

APPLIED

PREPARATION
After

BASIC WELDiNG

INSTRUCTION

confirming

OF EDGES BY GOUGING

the location

edges.

and length of the crack,

1.

TYPES

of gouging are explain-

OF GOUGING

There are three types of gouging.


is the best method

No.

The types and procedure

ed below.

remove the cracked section by gouging to prepare the

Method

not have a bad effect

Arc air gouging (No.11

because it is highly efficient,

perform,

it does

on the base metals, it is easy to

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:

Gouging torch, carbon rod,


Compressed air of 5 kg/cm2 to 7 kg/cm2

Heat the base metal with a gas cutter, and blow it off with
Gas gouging

All positions

oxygen.
(Tools:

Gas cutter, gouging nozzle)

Melt and drop the base metal with a gouging rod.


Arc gouging

Overhead

This can be done with a welder (AC or DC), but a lot of

and vertical

smoke is produced.

positions

or less. Gouge a depth of 3 mm or less in each pass.

Lean the gouging rod to 15 degrees

Use gouging rods of 4 to 5 mm diameter.

Table 1.

1 l-6

Types of gouging

WELDING

APPLIED

2.

ARC

BASIC

INSTRUCTION

AIR

GOUGING

WELDING

PROCEDURE

Remarks

Description

Step

Prepare a DC welder (rated current to be 500 A

As a characteristic of arc air gouging, the arc is

or so) as the power source.

not stable since the gouging voltage is 10 to 15

Protect electrical wiring and piping from the

V higher than for arc welding with covered


electrodes, and the working point and electrode

spatters.

are always cooled down by the high-speed air

flow.

_I

As a rule, therefore,

use a DC welder.

If welding rods for DC current are not


available, use carbon rods to which an arc
stabilizer is added.

Base metals which need to be preheated for

For the necessity of preheating and the pre-

welding must also be preheated for gouging.

heating temperature,

Connect the carbon rod to the positive (+)

[When the crack is not extended through the plate]

terminal.

Hold the rod at a 45 degree angle

(1)

to the surface of the base metal, and move it

see page 11-l 0.

Gouging dimension for cracks shorter


1 to 1.5 times of
gouging depth

than 20 mm

from right to left.


Moving direction of gouging rod

Carbon

Splashing direction
of melted metal

(2)

Gouging dimension for cracks longer


than 20 mm

1 to 1.5 times of
gouging depth
Length of crack:

Angle of gouging rod for arc air gouging

Dimension of carbon rod and standard current

\
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)

Gouging dimension applied when a back


plate can be inserted.
1 to 1.5 times of thickness

40 to 50

/=essx
15
Length of crack

(2)

Back plate

Gouging dimension applied when a back


plate cannot be inserted.
Crack

-u--

Flat position: 2 mm
Vertical position: 2 to 3 mm

WELDING

7-jRemove the crack ccmpletely


by
gouging as shown in the figure at
leh, then weld so that the mm can
be melted sufficiently.

1 1-7
0

APPLIED

INSTRUCTION

BASIC

Remarks

Description

Step

WELDING

After preparing the edges by gouging, use the


dye penetrant checks to groove surface, especially its two ends, for cracks.
If a crack is found, remove it by gouging again.
4

\\\\\\\\\\\\\

-v

Check both ends carefully.


If any slag sticks, remove it.

Use a grinder to remove the slag sticking to the

Example of gouged surface:

gouged surface.
Finish the worked surface smoothly.

Table 2. Arc air gouging procedure

Dimension of
carbon rod (mm)
Diameter

Length

Steel cover

Current
(A)

Gouging speed
(mm/min)

Shape of groove (mm)


Width

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,

of arc air gouging (for mild steel)

a groove of 1.5 to 3 m can be made with one carbon rod (305 mm long).

Two to four minutes is required to

make this groove.

11-8
0

WELDING

APPLIED

INSTRUCTION

WELDING

BASIC.

WELIDNG

PROCEDURE

1. PREPARATION

FOR WELDING

Prepare the arc welder, gas cutter,

covered welding

rods, welding

(sledge hammer,

rod drier, hammers

hand hammer

and chipping

hammer),

wire brush,

set of protectors, and a C-clamp.


*

Cover the oil, wiring, and vinyl piping to protect


them.

WELDING

2.

RODS AND

PRECAUTIONS

Before using the welding rods, dry them under the


condition

shown in Table 1.

Since the low hydro-

gen type welding rods are made to reduce the moisture in the coating, they

must be dried at 300 to

35OC for about one hour before use.


*

If

moist

welding

dried, the following

rods are used without


symptoms,

being

which are causes

of defects, will appear.


- The coating can be removed easily, and the arc
is not stable.

* Blow holes are made, and the deposited metal is


made brittle by hydrogen.

- The mechanical properties of the welded metals


decline.

- The beads have a bad appearance.

Type of welding rod

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

Flux for submerged


arc welding

150 to 300

Table 1. Drying condition

for various welding rods

Notes:

- Available time means the time in which the dried

* If the coating of the welding

welding rods can be used after they are taken out of

(cracked,

discolored,

the drier.

out using them.

rods

is abnormal

etc.), throw them away with-

- The welding rods must not be dried more than three


times.

WELDING

1 l-9
0

APPLIED

3.

INSTRUCTION

PRECAUTIONS

1)

BASIC WELDING

BEFORE

WELDING

If paint, oil, rust, or chemicals for the dye penetrant


check stick to the surface to be welded,

burn that

surface with a gas cutter, then brush it with a wire


brush or grind it with a grinder.

2)

It is necessary to determine the preheating and postheating conditions


heating

to prevent

and postheating

cracking.

conditions

The pre-

will vary with

the welding materials, thickness and welding conditions.


Install

3)

the

the grounding

cable for welding

place to be welded

installed to the main frame.


and oil from

as near to
It must be

as possible.

Remove all paint, soil,

the place where the grounding

cable

will be installed.
Although

4)

the preheating and postheating conditions

should be determined
bon equivalent)

1 200Cand

III

up

590to

68OC

according to the types (car-

and thickness of the materials, the

following table can be used as the standard.


*

Carbon equivalent:
lated

to

following

the

A very important

weldability,

figure re-

obtained

from

the

expression.

Carbon equivalent

(Ceq) = C + Mn/6 + Si/24 +


NiPlO + Cr/5 + MO/~
+ VI14

Weldability:

If Ceq is less than 0.4, good.


If Ceq is 0.4 to 0.5, some caution
must be taken.
If Ceq is above 0.5,

GENERAL

WELDING

1) Welding condition:
proper

arc

voltage,

Arc voltage:

current,

to weld with
welding

0.6

0.7

0.8

0.i-

%()

of preheating and postheating

speed,

Generally,

covered welding rod 3 to 6 mm in diameter


the flat position.

the length of the arc


of the core

a little and the voltage should be lowered by 2


to 5 v.

There should be 20 to 30 V when using a


To stabilize the arc:

If the arc is not stable:


1. The penetration

1. Keep the length of the arc at the correct length.

will not be even.

2. If the arc is long, it cannot be concentrated.

If it is

too short, the rod tends to short-circuit.


3. Undercuts and overlaps occur easily.
4. The width and height of the beads are not even.

2. Adjust the welding current correctly.


3. Connect all the conductive cables securely to
reduce the resistance in the circuit.
4. Clean the surface to be welded.

5. Slag is included in the weld zone.


6. The oxygen and hydrogen in the air are included in
the weld zone, making the weld zone brittle.

11-10
0

in

When welding in the overhead

position, the length of arc should be shortened

should be the same as the diameter


wire.

equivalent

METHOD

atmosphere and position.


(a)

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

the arc current

to the

The

melting

speed of welding

WELiDNG

rods is not re-

proper range according to the welding position

lated to the arc voltage, but it is proportional

and the type and thickness

the arc current.

Generally,

the arc current

of the base metal.


should be higher in

the flat position than in other positions.


vertical

position

should

a large current

to
is

necessary to increase the welding speed.

The

be 20 to 30%

than the flat position,


tion

Therefore,

lower

and the overhead posi-

should be 10 to 20% lower than the flat

position.
*
r

If the arc current

is not proper, the follow-

ing symptoms are likely to occur.


If the arc current is too weak:

If the arc current is too strong:


1. Undercuts are likely to be made.

1. Overlaps are easily made.

2. Penetration

2. Penetration

becomes large.

is not sufficient.

3. Many spatters are made.

3. Slag is often included in the weld zone.

4. Slag does not cover the bead, and the appearance of

4. The beads are narrow and raised.


5. Blow holes are easily made.

the bead is bad.

5. The welding rod gets red hot.

6. The welding speed decreases.

6. The melting speed of the welding rod increases.


7. Blow holes are easily made, and the weld zone can
be cracked easily.
8. The flux of the welding rod flakes while welding.
(cl

Welding

speed:

Although

the welding

speed

depends on the shape of the groove and value


of arc current,
welding

it is generally accpeted that the

speed should be 150 to 200 mm/min.

when welding a 4-mm welding rod with


of arc current.
mined

Since the penetration

by the ratio of the welding

welding

speed, the welding

creased almost in proportion

current

to

speed can be into the current

the power source can supply sufficient


2)

170 A
is deter-

if

current.

The bead must be at least 50 mm long. (If the bead


is short, the heat input will be insufficient
weld zone will cool rapidly,

and the

and may cause crack-

ing.)
3)

For the first

layer, use a welding

rod 3.2 mm or

4.0 mm in diameter.
4)

When welding the first layer, defects such as residual


root which

lower the fatigue

zone are likely

to occur.

strength of the weld

Therefore,

use caution

when welding the first layer.


[Welding the first layer]
(a)

When the root opening is less than 3 mm:

Take

care during welding to ensure that the root is


melted sufficiently

(Fig. 1).

3z
I I

-I--

Oto3mm

Fig. 1

WELDING

11-11
0

APPLIED

BASIC WELDING

INSTRUCTION

Fill in two passes.

(b)

When the root opening is 3 to 6 mm:


root

opening

by depositing

Fill the

beads twice,

then

build up (Fig. 2).

Fig. 2
(c)

When the root opening is larger than 6 mm:


stall

backing

procedure

strips

for

the

according
sections

to
to

the
be

In-

repair

repaired

(Fig. 3).
*

Do not place a welding rod or steel strip on the


root (Fig. 4).

Backing strip
I

4!F
targer than 6 mm

Fig. 3

Welding rod

Fig. 4
5)

Be sure to remove the slag after

depositing

each

layer.
6)

If

necessary,

fatigue

peen the weld

strength.

zone to increase its

For the peening procedure,

see

page 11-25.
7)

After

welding,

nearby

check the surface of the beads and

surface

penetrant

for

check

cracks

method.

by

means of the

dye

If any crack is found,

gouge it again.
8)

Other precautions
(a)

Starting an arc
Start

the

dummy

arc at the joint

part.

to be welded

or a

Do not start the arc at any other

place on the frame.


(b)

How to start an arc


To make repairs by welding, low hydrogen type
welding

rods are used.

These rods often make

blow holes and cannot penetrate sufficiently


the starting

points of the beads.

these troubles,

at

To prevent

start the arc by the backward

start method.

11-12
0

WELDING

APPLIED

INSTRUCTION

BASIC

In this method, the arc is started 10 to 20 mm


forward
ing.

WELDING

Permanent wel

from the starting point of actual weld-

Then, bring the welding rod backward

generate sufficient

gas from

rials, and deposit


point of welding.

to

the coating mate-

the bead from

the starting

When starting the welding by

mm

this method, the beads of the backward welding

,n

@ Starting point

must be small so that they will be melted comOtherwise,

of arc

0Lg

pletely by the beads of permanent welding.


the blow holes made by the back-

permanent welding

ward bead may remain.

Fig. 5

(cl Connecting beads


It is difficult

Welding direction

to connect new and old beads, and

notches are often made or the beads will overlap as shown

in Fig. 6 if they

are connected

carelessly.

(I) Attach a new welding rod to the rod holder.


(2) Remove the slag on the crater by hitting
it with a hammer.
(3)

Start the arc in front of the crater, then immediately

move the arc to the crater (back-

ward start) (Fig. 7).


(4)

Lengthen

the arc a little

to preheat

the

crater.
(5)

While

(b)

preheating,

just before

metal of the welding

the

Defective (build up too high)

molten

rod transfers to the

base metal, shake the welding rod to separate the molten metal of the rod, then immediately

move the

rod forward

a little
(c)

from the center of the crater.


(6)

Adjust the length of the arc properly


a little
welding
type

shorter

than

the diameter

(to be

Defective (dented)
Fig. 6

of the

rod in the case of low hydrogen

rods), fill the crater up to the same

width and height as the old bead, then proceed with


the welding

welding.

The manipulation

rod during the

of

above proce-

dure is shown in Fig. 7.

Fig. 7

WELDING

Backward start method

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

With root face

Without

-.-_

root face

General upper layers

Upper layers of
butt welding

WELDING

/WI

When tilted transversely

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

In case of V-groove (with backing strip)

(1) For the first layer, weave in the same width


as the root opening.

(2)

For the second and after

layers, weave in

the same width as the previous bead.


For the second layer from the last, build it

(3)

up to 1 to 2 mm under the surface of the


plates.
For the last layer, melt 2 mm or so on both

(4)

edges of the base metals.

Precautions
If the width of weaving is too large:
0
The bead becomes concave and the root may

If the width of weaving is too small:


II
The bead becomes convex and both sides of
the bead may not melt when depositing the
next bead.

not melt.

\
Not melted.

11-14
0

Not melted

WELDING

APPLIED

b)

INSTRUCTION

BASIC ,WELDING

For V-groove (without


Apply

backing strip)

the first layer according to the following

procedure.

Apply

the second and after layers

in the same way as for a V-groove.


(1)

When the root opening is less than 2 mm:


2mm

Arc point.
Straight

(2)

When the root

opening

is approximately

3 mm:

Start the arc on the crater.

,
I
Arc point.
Semi-weaving (4 to 5 mm wide)

Precautions
If weaving more narrowly

than the root

opening, the base metal will melt down.


(3)

When the root opening is 3 mm to 6 mm:

Connect the beads by weaving with a width of 4 to 5 mm.

WELDING

11-15
a

APPLIED

INSTRUCTION

BASIC

WELIDNG

(cl In case of bevel groove (with backing strip)


Position aimed at and manipulation

of welding

rod for the first layer

[Root opening: 5 mm max.]

[Root opening:

5 mm min.]

Welding direction

*Y

0.
>
*

a-

Penetration is often
insufficient.

Precautions for the second and after layers

Do not weave more wide1


than the root opening.
Do not bring the welding rod
to the side face of the base
Deposit the bead flatly.
Build the second layer from the
last up to 1 to 2 mm under the
surface of the base metal.

11-16
0

WELDING

APPLIED

INSTRUCTION

HORIZONTAL

FILLET

[Knack of manipulating
(a)

BASIC

WELDING

WELDING
welding rods]

Angle of welding rod

from the vertical

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.

(Stop for a little while at mark 0.)

(3)

Multi-layer

building up (Straight method)

Suitable for a leg longer than 7 mm.

Aim at 1 to 2 mm
from the vertical
plate.

WELDING

Aim at the toe of the


weld of the first layer.

Aim at the center


between the upper
toe of the weld of
the second layer and
the vertical plate.

Completion drawing

11-17
E'

APPLIED

3)

BUTT

INSTRUCTION

WELDING

BASIC

IN VERTICAL

[Knack of manipulating

POSITION

(UPWARD

WELDING)

welding rods]

(a)

Angle of welding rod

(b)

HOW to hold the holder

Correct method of
holding the holder
in vertical position.

(c)

Manipulation

WELDING

Incorrect method of
holding the holder
in vertical position.

of welding rod and point aimed at

k?kaving width

Pitch is large.

Pitch is small.

melted by the
next pass.

Note:

If the weaving width

is to be 20 mm or

30 ..jm
m max.
__
Weaving width

more, complete the welding by depositing beads twice.


bead is deposited

If all the

necessary

at one time,

such as slug inclusion may occur.

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]

Angle of welding rod

Knack

of

manipulating

the welding

rod and

point aimed at
(0 mark:
(I

Stop for a while)

) Short leg
Melt corners

(3)

Middle leg

Long leg (Multi-layer

Note:

(2)

building up)

If the weaving width is to be 20 mm or


more, complete the welding by depositing beads twice.

WELDING

11-19
CD

APPLIED

5)

BASIC

INSTRUCTION

BUTT

WELDING

IN

HORIZONTAL

[Knack of manipulating
(a)

WELDING

POSITION

the welding rod1

Angle of welding rod

Welding direction

(b)

Manipulation
(1)

Straight

of welding rod for the first layer


method

(Root

opening:

3 mm max.)

Root opening

(2)

Weaving

method

(Root opening:

3 to 5 mm)

Stop (for approximately

L-Stop

The

straight

method

should

be used for

(for approximately

0.5 seconds)

0.3 seconds)

the

second and after layers.

Arrows indicate the


points to be aimed at.
6 mm min.

11-20
0

WELDING

APPLIED

(c)

INSTRUCTION

BASIC.

WELDING

In the case of bevel groove (35)


(1)

Building

up method

and points aimed at

for each layer


*

For the upper passes (Nos. 1, 3, 6 and 10


passes), reduce the angle of the aim a little.

(2)

Points aimed at for each layer


- First layer
[Root opening:

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

Aim at a little lower part of the upper side


of the groove.

WELDING

11-21
0

APPLIED

BASIC

INSTRUCTION

* Next-to-last

WELIDNG

layer

Leave3mm
or so.

Id) In case of Vgroove


Building

up method

and points

aimed at for

Angle of aim
80 or so for pass Nos. I,3

each layer

and 7.

70 or so for pass Nos. 2,4,

5 and 6.

than the center.

6)

BUTT

WELDING

IN

[Knack of manipulating
(a)

OVERHEAD
welding rods1

Angle of welding rod


[Good example]

r
90"

1 l-22
0

POSITION

[Bad example]

/ i\\
If the angle of the welding

rod is reduced to 85

less, the molten pool precedes the rod.

or

Thus the arc is

not stabilized and many spatters occur.

WELDING

APPLIED

BASIC

INSTRUCTION

FINISHING

PROCEDURE

If necessary, finish the welded


according to the following

1.

surface with

WITH

WELDING

A GRINDER

a grinder

procedure.

PREPARATION
Cover the wiring
to

protect

and vinyl piping in the work area

them

from

the

sparks made

by the

grinder.

i.

WORK

PROCEDURE

The purpose of finishing with a grinder is to prevent


the concentration

of stress (especially at the toe of

weld) by smoothing out the unevenness.

I)

Finishing the toe of the weld


At first, finish the toe of the weld with a grinder as
shown in the figure at right.
undercuts, eliminate
(a)

If there are overlaps or

mm

max.

Finish smoothly

all of them.

Finish smoothly to eliminate

notches.

0.5 mm max.*

Fig. 1

(b)

If there

is an overlap,

notch is eliminated

cut the bead until the

as shown

right.

0.5 mm max.I

(c)

Fig. 2

If there is a shallow undercut, cut the bead and


base metal until it is eliminated
(However,

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

Finishing surface of bead


Finish

the surface of the bead with a grinder until

the grooves shown right disappear.


(a)

Finish smoothly to eliminate

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

If necessary, peen the welded


following

1.

WELIDNG

surface according to the

procedure.

PREPARATION
For the peening, a high speed pneumatic
can be an effective tool.
and

specification

of

hammer

An example of the model

the

high

speed

pneumatic

hammer is shown below.


High speed neumatic hammer
(An example of a Japanese product)

Item

Model
Number of hits

Specification
AA-9
3200 BPM

Diameter of piston

16.0 mm

Stroke

75.0 mm

Shape of chisel bushing

Round

Overall length

245 mm

Weight

2.0 kg

Air consumption

0.35 m3 /min.

Inside diameter of hose

9.5 mm

Before using the pneumatic

hammer,

shape its end

as shown right with a grinder.

2.

WORK

PROCEDURE

Peening the last layer is an effective


crease the

fatigue

strength

measure to in-

of the welded

joints,

Pee

because the surface of the bead and toe of the weld


are smoothed and hardened, and the concentration
of stress is prevented by peening the last layer.

Just

after welding, peen the bead approximately

10 mm

on both its sides until hit marks are made.

The toe

of the weld must be peened until the notches disappear.

After peening, paint the peened surface.

Bead for repair

WELDING

11-25
G

WELDABILITY
Classification

OF STEEL MATERIALS
Preheating/Postheating
Thickness -

Mated materials and welding rods

Major parts to be made

of materials

@@@0000

Rolled steel for welded


structures

High tensile rolled steels

High tensile rolled steels,


110 kg/mm* class

El--k

Caststeel
for welded
@
structures
0

07

High tensile cast steel for


welded structures
Low alloy cast steel for
structures

135mm

70

35

18
Cast iron

Diameter

( C)

Welding rod
Step
*

For the comparison

between KES symbols of materials and the standards of major

countries, see 01 GENERAL


Mark

JIS

INSTRUCTION.

indicates very low weldability,

where welding should not be performed.

AWS

D4316
D4326

E7016
E7028

D5016

E7016

D5816

E9016

Preheating

Postheating

Parts which must not be repaired by welding

I
Parts which must not be repaired by welding

Group
Power line parts

Shaft, gear, clutch disc, bearing

Engine parts

All parts except for the oil pan and other parts made of sheet metal

Reason for prohibition

of repair

If repaired by welding, the strength of these parts will decrease


and they will be subject to strain.

This will cause additional

breakage, then other sections will be subject to serious trouble.


Hydraulic

Pump, valve, hydraulic cylinder

parts

The strength of the weld zone is lowered greatly, and the parts are
broken easily again.

Spring, floating seal

Other parts

Cast iron:

How to distinguish cast steel from cast iron by a spark test


Form of spark:

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

SECTIONS TO BE REPAIRED BY WELDING


SELECTION OF WELDING
RODS

AND

Examples taken from issued Service News

[Reference)

JIS D4316

WELDING

(AWS E7016)

Track frame (D45S, PC300)

Bucket (PClOO, 120)

Fuel tank (HD1200)

Circle support (G D600,605)

Rear axle tube (HD1200)


Front frame (GD605,655A)
\

Boom and arm (PCO4, PC200,220,

PC400)

Rib of dump body (HD180)


C-frame (D60A,

JIS D5016

D65A)

(AWS E7016)

Main frame (HD320.325,

HD460,

HD680, HD780.785,

Tractor frame (WS23S)

HD1200)
L-frame of work equipment

(WF22A)

Diagonal brace (D455A)


Front frame and rear frame (WF22A)

Shaft of apron trunnion

(WS23S)

Upper rib of axle housing (HDI 200)


Dump body mount bracket (HD320,325)

Ripper adapter shank (D80A

thru D455A)

Dump body wear plate (HD1200)


Ripper holder (D80A,

JIS D5816

D85A)

(AWS E9016)

Main frame (D455A)


Track frame (D455A)

Ripper holder (D50A

Lift arm (D95S)

Ripper adapter shank (D80A

Blade (D155,

D355,

WELDING

Bucket (D75S.

D455A)

Straight frame of work equipment

(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)

Selecting the proper welding rods


Select

the

welding

rods according

WELDING

If the mounting

position

of the grounding

cable

of the welder sparks during welding, smooth out the

to the tensile

strength of the materials to be welded.


repairs by welding,

AFTER

WELDING

spark marks with a grinder.

For general

select one of the rods shown


12) Peening the weld zone

below:

After
the
JIS D5816

welding
weld

a place where stress is applied,


to

reduce the

residual

In the case of multi-layer

strain.

(AWS E9016)

zone

peen

stress and

welding,

peen

each iayer.
2)

Drying covered welding rods


13)
The

welding

rods, especially

low hydrogen

type,

After

repairing by welding,

finish smoothly

with a

grinder.

must be dried before use.


Drying temperature

14)

for low hydrogen type:


300 to 350c

Drying time:
3)

After

repairing

by welding,

check the weld

zone

again by means of the dye penetrant check.

30 to 60 minutes

Preventing cracks from extending


Drill

holes 6 to 8 mm in diameter

at 5 to 10 mm

from the ends of the cracks.


4)

Removing slag
After

arc air gouging, remove all the slag. Carefully

remove the slag before starting

an arc to connect

beads or before depositing beads on an earlier bead.


5)

Cleaning surface to be welded


Remove all the water,

rust, paint, and oil from the

surface to be welded.

Burning the surface with a gas

burner is an effective measure.


6)

While

welding

a part,

do not let any wind

blow

against its surface directly.


7)

Preheating/postheating

materials

Preheat

the

and postheat

materials

according to their properties,

to be welded

thickness and welding

conditions.
8)

Weld with proper current, use welding rods with the


proper diameter,

9)

and manipulate

the rod properly.

Take care when starting and finishing an arc


Do not start or finish an arc at an end or corner of
materials.
Avoid
the

Round

the

corners of plates a little.

crossing the lines of fillet

line of welding

on the

welding.

Extend

places where stress is

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.

General precautions for build-up welding

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

(3) Track link (submerged arc welding)

. 12-20

(2) Track link (manual welding)


(4) Precautions when building up

track link tread of oil-sealed track


(6) Roller (submerged arc welding)
(7) Correcting distortion

....

12-28

.....

12-38

..........

(5) Roller (manual welding)

12-29

of roller inside

diameter after build-up welding


(8) Track shoe lug welding

.....

...........

12-47
12-49

(9) Welding lug on rock type


track shoe

...................

12-52

(IO) Welding shoe lug on


oil-sealed track

................

12-54

(11) Welding repair of ripper teeth


(12)

WELDING

Rebuilding conical nose

..........

......

12-55
12-59

12-1
0

APPLIED

HARD

FACING

TYPES OF METAL

WEAR

INSTRUCTION

HARD-FACING

2.

uses arc welding or gas welding to weld

a special alloy to the base metal. Therefore,


rebuilding

the

PARTS

PROCEDURE

1. HARD-FACING
Hard-facing

OF WEAR

worn

mechanical

parts

when

and when

Wear is caused by contact between two objects, and


results in loss of parts of the objects. However, this
definition

is rather too simple.

In actual situations,

making a special alloy surface at the desired place

wear consists of various types of wear occurring at

only,

the same time.

this method

method,

while

presents a comparatively

at the same time

cheap

giving excellent

For example,

wear resistance.

such as soil quality,

With advantages like this, this method is used widely

process. This

over a large field,

more complex.

construction

work.

including

civil engineering

The causes of metal wear are

usualhy the result of a combination


tions and conditions,
plex. Therefore,

and

so they

of various situa-

are extremely

com-

with wear caused by

soil, the wear is caused by a variety of conditions,

Therefore,

if

viscosity, wet process, or dry

makes
we

the

consider

wear
the

phenomenon
wear

phenomena

which are actually seen, we can divide them into the


following categories.

when carrying out hard-facing, it is

vital to do the following.


(1)

Carry out a detailed survey of the wear environ-

(2)

Select

ment affecting the object to be welded.


a suitable

welding

rod

for

the

wear

environment.
(3)
If

Carry out the welding in a suitable way.


any

of these points are neglected,

we cannot

expect the welding to be effective.

12-2
0

even

WELDING

APPLIED

HARD

INSTRUCTION

FACING

OF WEAR

PARTS

Types of metal wear

Adhesion
Wear between

wear (sliding wear)

two pieces of metal


Surface fatigue

(rolling

wear)

Erosion

Wear caused by abrasion


or rock

Wear

from

Scratch wear

sand
t

Abrasion

wear

Gouge wear
Wear caused by gringing

during

impact
I

Impact wear

Wear caused by high speed fluids


Wear caused by heat shock or heat fatigue

(1)

Adhesion

Wear which

wear

ther.

Abrasion
(a)

when two

occurs

pieces of metal

in both

surface, and the softer

Wear which

is caused

occurs between

by

rub toge-

pieces of metal at a very

small contact
which
(2)

occurs

Adhesion

the

metal is torn.

rubbing

between

shafts and bearing,

metal,

etc.

wear
Wear caused by fine particles

Erosion

in fluids

moving

at high

speed; wear of the casing in sand pumps, etc.


(b)

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

wear caused by fine sand,

etc.
(c)

Abrasion

wear

Wear caused by catching


high

or medium

protruding

hard

or cutting

of a metal surface by

stress caused by non-metal


objects;

wear

caused

by

particles

or

hard

soil or

of a metal surface

due to

rock, etc.
(d)

Gouge wear

Wear caused by deep gouging


high stress (mainly

(3)

Impact

wear

shearing force)

caused by impact.

Wear caused by cracks in the metal surface caused by


high impact.

WELDING

12-3
0

APPLIED

3.

HARD

INSTRUCCTION

BUILD-UP

WELDING

The most important

point when carrying out build-

damage

to

putting

the

Failure to check the quality

damage to be repaired.

of the base metal may

of the built-up

used, despite accurate welding


out with
turn

an expensive

lead

to

the

Table of comparative

( @ Extremelygood,

performances

(1)
Abrasive
wear

(2)
Erosion

part when it is

having been carried

welding

separated

@ Good,

OF WEAR

PARTS

PROCEDURE

up welding is to check the quality of the base metal.


result in separation

FACING

rod, This may

metal

in

piece causing

other

parts of the

machine

out

machine,

of action

thereby

for the new

Therefore,

when carrying out build-up welding, it is

impactant

to check the quantity

and to use suitable

preheating

of the base metal


before carrying out

the welding itself.

of covered electrodes for hard-facing

Average,
(3)
Impact
wear

A Fair, X

Poor)

Crack
Heat
c orrosion
resistance resistance resistance

Ease of
cutting

Ease of
operation

Hardness
(I+)

Remarks

Crack resistance and ease


of cutting becomes worse as
the hardness becomes
higher.

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

dry at 300 to 350C

for 30

PREHEATING

AND

TEMPERATURE

CONTROL

DURING

OF

WELDING

The rollers of the undercarriage are usually made of


medium-carbon
welding,

steel, so when carrying out build-up

if the base metal is heated and expanded,

minutes to one hour.

the base metal will contract together with the build-

If you neglect to dry the rod, there will be many

up weld

holes and this will cause cracking.

and deformation

When drying,

use a heater-type

dryer as shown in

the photograph.

as it cools. This will

In addition,

prevent contraction

of the inside diameter.

the deposition

of the base metal and

build-up weld is carried out smoothly,


Part No.

Capacity of dryer

and cracking

or separation after cooling is prevented.

50 kg

7AO-125-0010

As a basic condition

5 kg

7AO-125-0020

metal should be kept at a minimum


2OC.

but for

carrying

for general welding,

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

only on the surface but also inside the base metal.


To

achieve

furnace

this,

at 200

place the
to 3OOC

parts in a preheating
for at least 30 minutes

before starting welding operations.


In addition,
not

the temperature

be allowed

to

point during welding.


where low temperature
With
(2)

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

the surface of the

base metal all oil, grease, rust, water, paint, or other


foreign material. To do this, use a hot water cleaner,
shot chisel, or shot blasting, grinder, etc.
Such foreign

material

will

decompose

heat during welding, and will generate gas. This gas


or cracking.
interfere

with the welding,

carry out welding

repairs first before carrying out build-up welding.


When welding high-manganese steel, such as on rock
machine

hardening

phenomenon

makes

a hard layer of 2 to 3 mm from the surface, so if


welding

machine

is troublesome,

where

so the trend

build-up welding continuously


case, it becomes important

an automatic

is used,

replacing

the

is to continue

on one roller. In this

to maintain the tempera-

ture.
On the D80/85

class and above, if more than two

levels of build-up welding are carried out in succesof the flange outside

diameter and base metal will occur.


In the D75 class and below, after welding one level,
stop the welding.

Never try to carry out build-up

welding of several layers continuously.

If there are splits or cracks in the base metal which

shoes, the

annealing takes place.

arc welding

welding

the metamorphosis

It must be kept below 45OC

sion, softening and contraction


due to the

will mix with the melted metal and cause blowholes

will

submerged

of the base metal must

go above

is carried out on that surface, there is the

danger that it will cause cracks, etc. For this reason,


carry out gas cutting to remove the hardened layer
before carrying out lug welding.

Wait

for

IOOC,
consider

the

roller

temperature

to

drop

below

then go on to the next stage of welding,


using a chuck which

or

enables the roller to

be installed and removed easily.


The limit for the internal temperature

during build-

up welding is 3OOC for small rollers and 350C

for

large rollers. Usually, building up one level will not


raise the temperature
if the surrounding

to this point, but in summer,

temperature

no wind, the temperature

is high and there is

may exceed 3OOC. so use

a fan to blow air when welding.

Never stop in the

middle of welding.

WELDING

12-5
a

APPLIED

HARD

INSTRUCTION

If for some reason the welding operation


stopped,

always carry out preheating

has to be

again before

Even with

during welding also affects the

large rollers, if a current

welding

during
paint

of more than

for the D80/85

and thick

efficiency

of welding.

rebuilding

of the

this

of the

base metal, so a welding machine with a capacity of


500A
(4)

is ample.

If

the

white

momentarily

parts reach that

are covered with a

glow, so it can be judged that they have

intervals of 3 - 6C.

at that time.

is divided into 86 stages, with


so for build-up

welding,

204C.

Thermal crayon
In the same way as above, 22 types from 40C
The

range

of

temperature

difference

is slightly

larger, but this is good enough when checking the

wear at the

place for

build-up

welding

is

temperature

of build-up welding.

necessary, if a hard-facing welding rod is used for all


three layers, this will cause cracking inside the buildup weld. To keep the hard-facing

to less than three

layers, first carry out underlaying.


if build-up welding is carried out with-

out preheating
underlaying

the base metal, it is best to carry out

with a low-hydrogen

If this is neglected,

type welding rod.

cracks will occur in the hard-

facing.
In cases where

there

metal, underlaying

is uneven wear of the base

is also necessary.

If the surface is extremely


carried out without

rough, and hard-facing is

repairing

the surface first, the

finished surface will also be uneven.


To carry out a uniform
facing,

first

two or three layers of hard-

remove the unevenness and make the

surface smooth by carrying out underlaying.


In this case also, use a low-hydrogen

12-6
0

to

are available.

excessive, and three or more layers of build-up are

In particular,

it is

343C,

and 399C.

530C

UNDERLAYING

when

condition

flange and inside in the

enough to prepare four of 149C,

leads not to

but to destruction

they

From 38 to 1204C

rod increases the

However,

roller

roller

direction;

of the base metal

parts in a crayon

reached the temperature

to think that using a

welding

For

lines on the

transparent

class, the limit is 350 to

there is a tendency

high current

welding.

temperature,

375A.
Therefore,

PARTS

melt

diametric

is used, there will be a large increase in

heat, so for the D50 class, the limit is 300

to 350A;

Therm0

This is to check the temperature

generation of heat.
400 to 450A

OF WEAR

Memo

continuing the build-up welding operations.


The electric current

FACING

welding rod.

WELDING

APPLIED

(5)

HARD

INSTRUCTION

FACING

OF WEAR

PARTS

HARD-FACING
I)

Electric current

3)

The current used for the arc has a big effect


the

melting

fusion
If

speed of the welding

For manual

welding,

rod and the

much effect

on the fusion.

of the weld into the base metal.

the

arc

increases,

current

is increased,

so the deposited

merged

the

metal

Polarity of welding rod

on

fushion

is diluted

effect

in

arc

the polarity

welding,

the

current

rod

The correct

reversed and the amount

object

must be selected to suit the

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

of the base metal to fuse. For this

submerged

fushion

arc welding,

is greater than

the distortion

with

the

amount

manual welding,

sub-

(DC), if the welding

positive,

the

of deposit

rod (electrode)

polarity

polarity

is

is smaller;

if

is negative,

and the amount

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

70% is at the negative


Therefore,

if the

the

positive

welding

fusion

speed

higher,

so

the base metal (positive

rod

of the

and the generation

reduced,

pole, and about

pole.

of

of the base metal is larger.

with

has a big

greater.

pole,

reason, it is better to use a low current.


With

is

When using alternating

of

but

is hard and has the

so

normal

[generally

has a high

is comparatively

(hard-facing)

large amount

for the properties

base

base metal

weld

(electrode)

the welding

For hard-facing,

polarity

on the fusion.

When using direct

the base metal and there is excessive distortion.


current

does not have

However,

is the negative
welding

rod

is

of heat is lower

at

pole) end. The fusion

is

and the deposit

rate becomes

larger.

(20% higher than for reverse polarity).


2)

Voltage

For

The arc voltage


deposited

by the arc voltage

higher

electrode

the fusion

part, but the bead width

determined
The

used affects

the

voltage

is from

the arc contact


area of fused

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

increase the deposit

rate, so generally

the

is used (the welding

normal

polarity

hardand

speaking,
rod is

the negative terminal).

As a result,

wider

and the

is larger, so the bead width

becomes flatter.
On the other
narrower

hand, the lower the voltage

the width

The same amount

of arced contact
of fuse metal

a smaller area, so a bulging

is, the

becomes.

is deposited

bead is formed.

in

_
Opposite polarity

IP

Electrode

Normal polarity

WELDING

12-7
a

APPLIED

4)

INSTRUCTION

Welding

HARD

speed (speed at which

welding

rod is

5)

moved)
affects the amount

deposit and bead width

PARTS

of the wire used governs the

melting speed.

of deposit and the bead width.

The

If the welding speed is doubled,

OF WEAR

Melting speed
The size (diameter)

The welding speed (cm/min)

FACING

the amount of

each become approxi-

melting

speed is decided

by the electric

current density

(current per unit area), so if the

current

is increased, the arc jumps to

density

mately half of their previous value.

a smaller space, the heat is concentrated,

The amount

heat is produced

of deposit is reduced because the

heating is shorter
reduced.

The

and the amount

bead

because the

melted

fusion)

unit

per

width

welding

time

of fusion is

becomes
rod

adheres

to

of fusion with the base metal is increased.

narrower

(amount
a

and

in a small area, so the amount

On the other hand, if a small size wire is used,

of

even a small current

longer

will enable welding to be

carried out with the same melting speed.

distance of base metal (speed is higher).

With a constant current and speed, if we compare the


4 mm

build-up

wire,

the

using a 3.2 mm wire and a


deposit

rate

is about

20%

greater for the 3.2 mm wire because the melting


speed is higher.

6) Lead
(Off-set

between

rotation

center and electrode

when welding is carried out by rotating a roller)


4

&

APProx. 25 mm (compared with diameter 200 - 230 mm)

Suitable bead
Too far from top dead center

Speed which makes irregular edge


With flat beads a thin crack or
hollow may be formed in the center

1-00 close to top dead center


Build up bead with small base area
High eggshaped bear
Bead with lumps

12-8
0

WELDING

APPLIED

HARD

INSTRUCTION

(8)
10)Movement

it is impor-

a.

To

transmit

the

electric

current

To cover the melted

base metal and wire,

Rather than building up a straight bead, build-

thereby

ing up using a weaving motion

and preventing oxidization.

of about 12 -

produce a smooth surface, and will

C.

make one bead overlap the next bead by about


l/2

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

and to remove dirt

from the surface of the base

to

maintain

the

temperature

by

preventing sudden cooling.

COOLING

than high manganese, gradual

postheating

base metal

air

To cover the surface of the deposited bead,


and

GRADUAL

the

metal.
e.

POSTHEATING,

melted

with

the time that the base metal

and wire

from

contact

wire, and to aid the formation

To prevent the start and finish of the bead and


crater

and to

assist the welding operation.


b.

carefully.

8 mm will

PARTS

FLUX

tant to keep the arc short and to move the rod

(6)

OF WEAR

Function of flux

of welding rod (manual welding)

When carrying out manual welding,

FACING

f.

To add the alloy element


adhered

after

needed by the

bead from the flux to the melted

metal (bead).

in preventing

cracking, and does not reduce the wear resistance.


Depending

on the amount

metal,

the

cooling

differs

markedly.

and shape of the base

speed of the deposited


Even if the same welding

Thickness of flux

metal

The thickness of the flux has a great influence

rod is

on such points as the external

used, the cooling speed can cause various differences

quality of the finished welded.

in the hardness or internal structure.

which is greater than the hardness indicated

If the flux is too thick,


a.

Air cooling (leaving to cool) often creates a hardness

The bead is rough and forms a ropelike finish.

on the
b.

welding rod.

It

is difficult

formed
(7)

repair

of undercarriage

very hard hard-facing,

parts produces a

so machining

a.

with lathes or

The welded portion

the

gas

and the sur-

when

carrying

out

hard-facing,

it

is

flies

off.

necessary to avoid any unevenness in the finished


is extreme

is not completely

covered, and the melted material


b.

The finish of the external

surface of the build-up weld.


If there

discharge

welding,

If the flux is too thin,

other machines is difficult.


Therefore,

to

during

face of the bead becomes irregular.

FINISHING
Welding

appearance and

appearance

is poor, and holes are easily formed.

unevenness in the build-up,

the

c.

The cooling

so it is necessary to grind off the protruding

parts

suitable

following

with a grinder.

speed is high, so cracks

are easily formed in the surface.

speed of wear is increased when the part is reused,

flux

thickness

should

fulfil

the

conditions.

The flux should not spray over the welded parts


and surrounding

area. The welded part should

be well covered, and the area around the elec-

trode
1,

should rise up and be slightly

the gas generated.


*
Thickness of

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

Removal of 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

Using a wire brush, remove all the mud and rust

mud from sprocket

from

teeth

burrs, remove them with a grinder.

Measurement

the surface of the teeth.

If there are any

Use a sprocket wear gauge and scale to measure


the

wear

welding

of the

teeth.

Decide

the

build-up

process according to the results of the

measurement.

3.

Build-up welding

a.

Preheating
Before

starting the build-up

heat the

tooth

surface

to

welding,
about

pre-

150C

with a burner.

b.

Underlaying
If the measurements
more
welding

than

5 mm,

show that the wear is


use

an

underlaying

rod to carry out underlaying.

underlaying

should

be

one

layer,

The
and

enough to form the shape.

12-12
0

WELDING

PARTS

APPLIED

HARD

INSTRUCTION

FACING

OF WEAR

PARTS

Content of operation

Operation

c.

Hard facing build-up welding


1)

Building up of tooth tip


First decide a tooth tip which will give
the standard

surface of the sprocket

wear gauge.

2)

Build-up of side of tooth


If the

width

of the

tooth

is worn,

build up the side face of the tooth.

3)

Build-up of tooth face


When

building

up the tooth

surface,

carry out edging for each layer, keep


the

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

face, to prevent cracks and peeling from being


caused

by distortion

of the weld,

carry

out

postheating at 1 50C to allow the weld to cool


gradually.

WELDING

12-13
a

APPLIED

HARD

INSTRUCTION

OF WEAR

Content of operation

Operation

5.

FACING

Inspection,

Using a sprocket

measurement

the shape of the teeth.


Check visually

wear gauge and scale, check

or use a magnetic flaw detector

to check that there is no crack in the build-up


weld.

Welding rods
Welding rod

Welding
current (A)

Dia. of rod (mm)

Step

140 -

D5016

Not needed
190-240

05316

Note.

Martensite

12-14
0

180
Min. 15OC

4 or 5
190 -240

Example of chemical composition

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

Cleaning track assembly

Trackassembly

Removal of rust and mud


I

Inspection, measurement

Preheating
I

Build-up welding
[

I
Inspection
[
i
r

WELDING

Painting

12-15
0

APPLIED

HARD

INSTRUCTION

OF WEAR

Setting track

When there is little wear of the pin and bushing,

assembly in

and build-up

position

link tread,

work

If the

is carried out only on the

spread out the track assembly on a

flat surface without

work

removing the shoes.

is carried

out

outside,

build

shelter to prevent the wind from blowing and


forcibly

cooling

the

welded

portion.

At the

same time, also prevent sudden cooling by preventing the heat from

escaping to the ground

surface.

Remove

mud

rust

and

Remove all rust from

the link tread (build-up

weld area) with a hand grinder.


If the rust is not completely

removed, this will

cause blow-holes in the adhesion surface.

Inspection,
measurement

PARTS

Content of operation

Operation

1.

FACING

a.

Inspection
Before carrying

out any build-up welding,

always check visually for any cracks in the


link.

If a crack

is suspected, carry out a

color check or use a magnetic flaw detector.


If the

link

is cracked,

it cannot

be used

again, so mark it to show that it does not


need build-up welding.

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

there is a problem that the pin may come out. Therefore,

an

oversize

Pin,

consider this point when

carrying out build-up welding.


If the distance between the outside diameter of the pin and the top face of the link
boss is less than 2 mm, there will be a big drop in press-fitting force.

ndard boss thickness


top face of boss
ear limit for top face of boss: 2 mm
Top surface of link bo

4.

Preheating

Preheat

the link tread with a gas burner to a

temperature

of

200 - 3OOC

to

residual stress and to improve

remove

the

the deposit of

the build-up metal.


In particular,
without

when

carrying

any underlaying,

out

there

hard-facing

is a danger of

problems such as cracking and separation of the


bead, so preheating must always be carried out.

5.

Build-up welding

When

carrying

out welding,

connect

the

ground directly to the link being welded.

a.

Edging, primary build-up


Using a 4 - 54 low-hydrogen,
steel welding

high-tensile

rod, edge the whole edge of

the link tread. Carry out the edging about


5 mm from the edge of the link tread, and
make

a straight

bead

using a low value

current within the current range.


If there
tread

is excessive stepped wear of the

surface, use an underlaying

welding

rod and carry out underlaying to make the


tread surface level.

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

parts at both ends of the link.


Use a wide weaving method for the welding, move in the direction of the side of the
link, and move from one edge to the other
edge in one weaving motion.
When all of the narrow part at one end is
completed,

carry out the build-up welding

in the same way for the narrow part at the


opposite end.
When

the

pleted,

welding

at both

ends is com-

use the same weaving

method

to

carry out the first layer of welding at the


wide part in the middle.
When welding the central bead, if the welding is carried out from the left and right
edges towards
heat

will

to the center, the welding

be distributed

evenly,

so this

reduces the risk of cracking.


When the first layer of welding is finished, remove all the slag from the welded part,
and carry out the build-up welding for the second layer for the edging, end welding,
and center welding in the same order as given above.
When carrying out the second layer welding, if the temperature

rises too high, carry

out the end welding of the next link first, and wait for the overheated part to cool
down gradually

to a suitable temperature.

the same way as above. Normally,

three

Carry out the third layer of welding in


layers (2 - 8 mm)

is desirable for hard-

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.

Build-up welding of link side face


If there is excessive wear of the idler link
guide (side face of protruding
the

track

flange,

roller

flange

the wear of the

contact

with

Therefore,
build-up

that

it

part) or in

or carrier

roller

andard

width

orn width

link side face in

part will also progress.

is necessary

welding

to

carry

out

of the link side face to

restore the link width.


When carrying out build-up welding of the
link

side face,

welding
prevent
roller

rod with
contact
flange

it

is necessary to

use a

good wear resistance to


(slipping)

during

wear with

steering

to

the

prevent

snaking of the track.

12-18
0

WELDING

APPLIED

HARD

INSTRUCTION

FACING

OF WEAR

PARTS

Content of operation

Operation

When carrying out welding of the side face,


use a comparatively

hard welding rod such

as JIS

DF2B-B

or equivalent.

current

in the current range, start from the

Use a low

bottom

of the link, and weld so that the

Welding direction

beads.pile up.

d.

Build-up of top surface of link pin boss


If there is excessive

wear of the link pin boss top surface, the press-fitting force of

the pin will drop, so build-up welding must be carried out.


Use a hard welding rod at a low current.
If there is a large amount of wear, a round bar of about 5o can be welded to the top
face of the link boss.

uilding

up top face

Welding round bar

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)

HARD FACING OF WEAR PARTS

INSTRUCTION

LINK BUILD-UP WELDING (SUBMERGED ARC WELDING)

t
1

Shipping rpection

Transportation
from repair shop

Cleaning machine

I
installation of
track assembly

t
Installation of
track shoes

Removal 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

Lay the track

assembly on top of a bed with

the shoes facing up, then loosen the shoe bolts


with an impact wrench.

2.

Removing rust

Remove

all the

rust from

the link tread and

shoe mounting surface with a hand grinder.


In particular,

the shoe mounting surface acts as

the ground when carrying out build-up welding,


so be particularly

careful to remove all the rust.

Rust on the welding

surface

(tread face) also

causes blow holes, so remove it.


Using sandpaper, remove the rust from the head
in contact

with the shoe mounting

surface. If

this is not done completely,

it will be impossi-

ble to ground the equipment

properly, and this

may cause defects in welding.

3.

Inspection,
measurement

Inspection
Before carrying

out any build-up welding,

always check visually for any cracks in the


link.

If a crack

is suspected, carry out a

color check or use a magnetic flaw detector.


If the

link

is cracked,

again, so mark

it cannot

it show that

be used

it does not

need build-up welding.

Measurement
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, there is a

problem that the pin may come out, so do


not

carry

out

build-up

welding

on such

parts.
If the distance
meter

between

the outside

dia-

of the pin and the top face of the

link boss is less than 2 mm, there is danger


that

the

problem

given above occur,

so

consider this point when reusing.

WELDING

12-21
0

APPLIED

HARD

INSTRUCTION

5.

OF WEAR

PARTS

Content of operation

Operation

3.

FACING

Setting link assembl)

Using a special lifting tool,

on bed

mounting face at the bottom.

Insert spacer in link

The welding is carried out automatically,

contact surface

out properly,

raise the link assembly and set on the bed with the shoe

so if the alignment

the build-up weld will be misaligned.

of the link is not carried

Insert spacers in the contact face to

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

Install a scribing block to the welding

position

alignment

machine,

move on top of the bed, and set the

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.

Set the pattern

FACING

OF WEAR

PARTS

Content of operation

A photoelectric

conductor

is used to cut the welding at the joint between link and link,

but set a rubber pattern to block the photoelectric

conductor.

a.

Align the scribing block with the position of the welding machine wire.

b.

Align the scribing block with the link shoulder.

C.

Set the

center

photoelectric

of the

allow an adjustment
d.

pattern

conductor

pulled

at a position
in fully.

10 mm from the position with

clearance for the cutting position of the photo electric tube.

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

The reason for pulling out 10 mm is to

Next,

6
_

;02

;j

.-6
.E
:
0.

.-6
C

conductor.

Position of scribing block

move the welding

machine,

and set the pattern

at the position

where the

scribing block contacts the end face of the pin.

1
WELDING

12-23
a

APPLIED

HARD

INSTRUCTION

Operation

1B.

Filling with flux

FACING

OF WEAR

PARTS

Content of operation

Fill with flux to cut off any contact with impurities


temperature

in the air and to help maintain the

of the deposited metal.

Add enough flux to fill the empty

part of the link, but to reduce the amount

of flux

used, it is also possible to put blocks between the links.

Blocks

,3.

Removing spacers

Using

pliers,

remove

the

spacers inserted

to

maintain the clearance between the links.


After

removing

the spacers, the welding

heat

may cause the links to be pulled and moved out


of alignment,

IO. Preheating

After

so fill the link gap with flux.

filling with flux so that the level is equal

with the link tread face, use two burners, and


move

the

welding

machine

to

preheat

both

link tread surfaces at the same time.

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

through the flux as shown in the photograph.

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

If the build-up for each layer is 1.5 - 2 mm, a


good surface can be obtained

for the deposited

metal.
When feeding the bead width, aligning with the
end face of the first layer of deposited

metal

will provide a good bead with no unevenness.

4
b.

I-

Welding cut

Stepped wear of the link end face is caused by contact with the idler tread and
difference

in surface pressure of the contact

surface.

If there is extreme

stepped

wear (over 1 mm), the part must be formed with underlaying.

C.

Set

the wire

holder

about

30 mm above the link tread,

and cover the welding

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.

Remove the slag while proceeding with the


welding.

If you proceed to the next stage of welding


with slag still stuck to the deposited metal
surface,

defects

will

be

caused

in

the

welding.
After

removing the slag from the link sur-

face, always cover the surface with flux to


prevent

direct

maintain

contact

with

the temperature

air and to

for the gradual

cooling.

When carrying

out build-up welding of the link tread with the oil-seald track still

as a link assembly, the heat will be transmitted


cause deterioration

to the built-in

dust seals, and will

of the dust seal.

After building up the tread, disassemble, and replace the dust seals.

Wire flux (hard facing)


Maker
KOBE SEIKO

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

for deposited metal (s/o).


Hardness
Rockwell

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

Example of chemical composition

Wire/Flux

Voltage
(V)

1.45

WELDING

APPLIED

HARD

INSTRUCTION

OF WEAR

PARTS

Content of operation

Operation

12. Gradual cooling

FACING

After

completing

build-up

welding

of the link

assembly, cool it gradually inside the flux.


If it is removed from the flux immediately
welding,

there will be a difference

after

in structure

between the deposited metal and the base metal


(link)

which

will cause distortion,

resulting in

cracking or separation of the deposited metal.


The longer the cooling time, the better, but the
ideal time is one night (12 hours). The welding
part must be left in the flux for at least three
hours to cool gradually.

13.

Removing link

After

assembly from bed

lifting tool to remove the link assembly from

completion

of

gradual

cooling,

use a

the welding machine bed.

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

inside the pins.

If it is necessary to build-up

the link tread and also to turn the bushing, choose one of the following

two methods

according to the situation.


1.

After

carrying out build-up welding of the tread surface with the track as an assembly, disassemble, and replace all

the seals when turning the bushing.


2.

After

disassembling the link, remove the seals, then carry out build-up welding of the link alone. In this case, the

seals can be reused when the bushing is turned.

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.

1 Cleaning roller assembly

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

Clean roller assembly

FACING

Before disassembling the roller assembly, clean it with a steam cleaner.

disassemble the roller assembly to

Completely

part.

make the roller an individual


(For

details

of

of

disassembly

assembly, see DISASSEMBLY

AND

the

roller

ASSEMB-

LY.)

Cleaning parts

Clean all the disassembled parts


(For

details,

see

DISASSEMBLY

AND

AS-

SEMBLY.)

Inspection,

Inspection

measurement

Before carrying

(for judgement

always check visually for any cracks in the

out any build-up welding,

standard values, see

tread

values table)

carry out a color check or use a magnetic

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

welding rod, then carry out

hard-facing.

Measurement
Using calipers, vernier

calipers, and a scale, measure the outside diameter

tread and the thickness of the flange to determine

12-30
0

of the

the amount of build-up.

WELDING

APPLIED

HARD

INSTRUCTION

Removing rust

OF WEAR

PARTS

Content of operation

Operation

5.

FACING

Using a wire brush, remove all the rust from the


roller tread and flange.
If the rust is not completely

removed, it may

cause blow-holes in the deposit metal surface.

5.

Set roller in position

To

as individual part

roller on a rotating stand like the one shown in

make the

build-up

welding

easier, set the

the photograph.

7.

Preheating

a.

Preheating with burner


Set the burner to both tread surfaces of the
roller, and rotate the roller to preheat to
about 130 -

b.

150C.

Preheating with preheating furnace


If preheating

is carried out with a burner,

it is common

for the area near the roller

surface to become very hot while the temperature of the internal parts does not rise.
Therefore,

it

is important

to

bring

whole roller to a uniform temperature,

the
and

the best way to do that is to use a preheating furnace.


Leave for about one hour at a temperature
of 150 - 200C to raise the temperature
the whole roller to 130 -

15OC.

When

furnace,

using a preheating

of

preheat

the roller before setting it in position.

WELDING

12-31
a

APPLIED

HARD

INSTRUCTION

Build-up welding

OF WEAR

PARTS

Content of operation

Operation

3.

FACING

a.

Preparations before welding

For idler
In the box-type

idler, there is a 5 mm@ air hole in the side of the idler body. This

Prevents distortion

or water spurting out due to internal stress caused by expansion

of the air inside the idler occurring because of the heat of


On the spoke-type

ribs to prevent distortion

during build-up welding.

Expansion of internal air

b.

welding.

idler, iron rods are welded at about a 20 mm square between the

Iron rods to prevent distortion

Underlaying
If there is extreme

uneven wear, and shaping is needed, or if the amount of wear is

over 8 mm and more than three


laying with a low-hydrogen,

layers of build-up

are needed, carry out under-

high-tensile steel welding rod.

If the wear is less than 8 mm, and only two layers of build-up are needed, making
one layer of underlaying

and one layer of build-up welding will cause dilution

the top layer of build-up

with

facing

from

being obtained.

the base metal, and will prevent sufficiently

In such cases, omit the underlaying

of

hard

and make two

layers of build-up welding.

c.

Hard-facing
The procedure

for hard-facing is to start with the side face of the protruding

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.

Build-up of side face of protruding


Set the

part of idler

idler on a flat surface, and rotate the idler to carry out edging with

straight bead around the whole circumference

at outside edge 0.

EdgingQ
Edging Q
Edging 0

Next,

carry out edging with a straight bead at inside corner

part.
When carrying
welding

@ of the protruding

out edging of the outside edge, if a low value is not

rod current

range, the bead will droop, and it will be difficult

the edging of the protruding

used for the


to carry out

part.

uild-up welding of protruding part

When the inside and outside edging of the protruding

part is finished, fill in the

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

120 mm in the same way on the oppo-

site side at point 0.


Following

this, carry out welding at points @

and @ in order, to complete the welding of the


whole circumference

of the protruding

Overlap the bead about II3

- l/2

part.

between the

passes, and be careful to keep the surface of the


deposited metal flat.
After

completing

the

first

layer

of welding,

remove all the slag from the first layer with a


chipping

hammer,

and carry out edging in the

same way as for the first layer. Then use the


weaving method

to weld the second and third

layers.

WELDING

12-33
a

APPLIED

INSTRUCTION

HARD

b.

FACING

OF WEAR

PARTS

Building up idler tread


After

completion

of welding of the side face of the protruding

part of the idler, set

the idler in an upright position.


Rotate the idler, and carry out edging with a straight bead at outside edge 0

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

welding rod current

range, the bead will droop, and it will be difficult

the edging of the protruding

After

completion

to carry out

part.

of the tread edging, build up the space between the edges with

weaving welding parallel to the direction of the idler shaft.


Make

the

l/3 -

l/2 to build-up and make a smooth surface.

width

of the weaving

Hold the welding


30

from

welding

Next.

of

the
a

bead 7 - 8 mm and overlap

each pass about

rod at an angle of 10 vertical,

width

and

of

carry

100 -

out

120 mm

rotate the idler 180, and carry out

build-up

welding

in the same way at the

opposite side at point


and @

0.

Weld points @

in turn to complete

the whole of

the first layer of build-up.


After

completing

the first layer of welding,

remove all the slag from the first layer with


a chipping hammer, then carry out welding
of the second layer in the same way as for

12-34
a

WELDING

APPLIED

HARD

INSTRUCTION

FACING

OF WEAR

PARTS

Content of operation

Operation

*
a.

Track roller, carrier roller


Build-up welding of flange
Set the flange of the roller on a flat surface, and rotate the roller to carry out
edging with a straight bead around the whole circumference

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

welding rod current

range, the bead will droop, and it will be difficult

to carry out

the edging of the flange.

When the inside and outside edging of the


flange is finished, fill in the space between
the edging with

wide

weaving concentric

with the roller.


To spread the welding

heat evenly, divide

the whole circumference

into eight parts,

and weld on opposite sides.


Overlap the bead about l/3
the

passes, and

be careful

surface of the deposited

l/2
to

metal

between
keep

the

as flat as

possible.
After

completing

the first layer of welding,

remove all the slag from the first layer with


a chipping hammer.

Then carry out edging

in the same way as for the first layer, and


use the weaving method to weld the second
and third layers.

WELDING

12-35
0

APPLIED

HARD

INSTRUCTION

Operation

FACING

OF WEAR

PARTS

Content of operation

b.

Building up roller tread


After

completion

of welding

of the roller

flange, set the roller on its side and build


up the tread.
The roller tread normally
hollow
large,

in the center,
start

in the

wears to form a

but if the hollow is

center

and weld

the

tread to make it flat,

For

single-flange

rollers,

carry

track

out

rollers

or carrier

edging with

a straight

bead at the inside corner of the tread, then


build up the tread.

After

completion

of the tread edging, build up the space between

the edge and the

flange with weaving welding.


Overlap the bead about l/3

- l/2

between the passes, and be careful to keep the surface

of the deposited metal as flat as possible.


To spread the welding heat evenly, divide the whole circumference

into eight parts, and

weld on opposite sides.


With manual build-up welding, the distortion

of the inside diameter

is a contraction

of

about 0.3 + 0.1 mm.


It is important

to keep this distortion

the rise in temperature

as small as possible, and care must be taken about

during welding.

umference

12-36
0

WELDING

APPLIED

HARD

INSTRUCTION

OF WEAR

PARTS

Content of operation

Operation

*
I

FACING

Welding rods

Welding rod
Step

Dia. of rod (mm)


JIS

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

1 Cleaning roller assembly

+,

10

t
Filling with
lubricaring oil

Setting roller in position


I1

I Inspection,

12-38
Cc

measurement

WELDING

APPLIED

HARD

INSTRUCTION

Operation

I.

Removing rust

FACING

OF WEAR

PARTS

Content of operation

Using a wire brush, remove all the rust from the


roller tread and flange.
If the rust is not completely

removed, it may

cause blow-holes in the deposit metal surface.

!.

Inspection,
measurement

a.

Inspection
Before carrying

out any build-up welding,

always check visually for any cracks in the


tread

and flange.

If a crack is suspected,

carry out a color check or use a magnetic


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

welding rod, then carry out

hard-facing.
Check that there

is no oil leakage. If any

oil leakage is found,

locate the source of

the leak (cause of the failure) and consider


the following disassembly steps.

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

the amount of build-up.

12-39
0

APPLIED

HARD

INSTRUCTION

Set roller in position

OF WEAR

PARTS

Content of operation

Operation

5.

FACING

Set the roller on the welding machine.


/

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
/:

The idler is set with the yoke still installed, so

there will be variations in the rotating speed of :


the idler during welding.

To prevent this, weld

a balancer weight to the opposite side from the

yoke.

1. Preheating

a.

Preheating with burner


Set the burner to both tread surfaces of the roller, and rotate the roller to preheat.

WELDING

APPLIED

HARD

INSTRUCTION

Operation

FACING

OF WEAR

PARTS

Content of operation

Move the burner so that the temperature

of the

roller surface is 130 - 1 50C, and carry out the


initial welding while heating with the burner.

b.

Preheating with preheating furnace


If preheating is carried out with a burner, it
is common

for the area near the roller sur-

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

with the base metal will be poor,

or there will be a difference

in the cooling

rate when cooling between the base metal


and the welding build-up.
Therefore,

it

is important

to

bring

whole roller to a uniform temperature,


the best way to do that

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

to raise the temperature

the whole roller to 130 -

5.

Build-up welding

Carry

out

build-up

welding

15OC.

starting

with

the

flange on the roller. For the idler, start with the


side face of the protruding

parts.

When carrying out build-up welding of the side


face of the roller flange and the side face of the
protruding

part of the idler, set the roller and

idler at an angle and build up from the bottom.

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

up the roller tread,

build up both treads starting from the inside and

working to the outside flange.

To

keep

the

temperature

constant

when

carrying out the build-up welding, water can be


passed through

the

plug

hole

in

the

shaft

instead of oil to cool the inside surface of the


roller. (Internal

water circulation

cooling)

This prevents damage to the internal


and floating
tortion

of

O-rings

seals, and also keeps internal disthe

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

metal for the next layer.

6.

Gradual cooling

When the build-up

welding

is completed,

pass

water through

until the deposit metal surface is

about 2OOC.

Following

this, blow compressed

air through to remove the water from inside the


roller, then remove the roller assembly from the
welding machine.
After

completing

the

build-up

welding

and

removing the roller assembly from the welding


machine, do not just leave it to cool. Keep it in
a furnace at 150 - 200C

for about 3 hours to

remove the welding distrotion,

then allow it to

cool slowly in the same furnace.


By keeping it at 150 - 2OOC, the cooling of
the

outside

prevents

circumference

cracking,

and

is delayed.

This

also removes welding

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

check to check for cracks. If any crack is


found,

repair it, or carry out the rebuilding

again.

b.

Rotation

inspection

Rotate the roller 3 or 4 turns to check that


the shaft rotates.
If it does not rotate
been

internal

smoothly,

contraction

there has
caused

by

welding heat, so disassemble the roller and


correct the inside diameter.

c.

Checking clearance between shaft and


bushing

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

pull or push the shaft to

side clearance

(amount

of

wear of the side face of the bushing and


shaft flange).
If the side clearance of the shaft is greater
than the repair limit,
of the floating

the surface pressure

seal becomes too large or

too small, and this causes oil leakage.


Therefore,

disassemble

and

replace

the

bushing and shaft.

Top clearance
Set the roller assembly on a bench, mark
the horizontal
the

shaft

lower

position on the end face of

with

the shaft

a marker,
vertically

then

raise and

to measure the

clearance between the circumference

of the

shaft and the bushing.


If the clearance
limit,

is more than

the repair

disassemble and replace the bushing

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

welding, the O-ring may deteriorate

due to the

internal

effect

cooling

of the welding

heat.

Therefore,

use a

collar removal tool as shown in the photograph,


and replace the O-ring.

9.

Air check

After

replacing

rotate

the

contact

the

roller

of the

through

the

floating

4 or

seal and O-ring,

5 times

to settle the

seal ring, then

plug

hole

and

pump

check

in air

for

any

leakage of air from the floating seal.


*
Air pressure: 3 kg/cm2
Before

applying

check first

air pressure at 3 kg/cm*,

at 0.5 kg/cm.

leakage at 0.5 kg/cm*,


for

If there

is no

hold at 3 kg/cm2

10 seconds and check that the gauge

indicator does not go down.

IO. Fill with lubricating


oil

After

completion

of the

welding,

flush

the

inside of the roller, then fill with lubricating oil


through the plug hole.
Stand the roller and add oil through
hole repeatedly

until

no more

the plug

bubbles come

out. When no more bubbles come out, leave the


roller

as it is for one night, then tighten

plug after

checking

the

that the oil level has not

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

For details, see DISASSEMBLY

AND

ASSEMBLY.

12. Cleaning parts

For details, see DISASSEMBLY

AND

ASSEMBLY.

measurement of part

OF WEAR

PARTS

Content of operation

11. Disassembly

13. Inspection and

FACING

Measure
diameter
calipers.

the

outside

diameter

of the bushing with


Rebuild

of the

shaft with

a cylinder

a micrometer;

measure the

gauge; and measure the flange width

inside
with

or replace the parts to give the values specified in the Maintenance

Standards Table.

14. Correcting
diameter

inside

Correct the inside diameter


1)

Sizing disc method

2)

Lathe method

For

details

of these

using one of the following

methods,

see Correcting

methods.

distortion

of inside diameter

after

build-up welding.

I5

Assembly

WELDING

For details, see DISASSEMBLY

AND

ASSEMBLY.

12-45
0

APPLIED

HARD

INSTRUCTION

Operation

FACING

OF WEAR

Content of operation

Wire flux (Underlaying)


Maker
K&E

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

Types of covered arc welding wire flux for underlaying


Maker
KBBE SEIKO

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

This table should be used only for reference.

Wire flux (hard facing)


Maker
K&E

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

the inside diameter


This contraction
during welding.

OF INSIDE

FACING

of

(bushing press-fitting portion).


can be prevented

However,

to a certain extent

it cannot be completely

by control

of the heat before and after welding as well as

avoided. Therefore,

when disassembling the roller and carrying

out build-up welding, it is necessary to correct the inside diameter.


For additional

build-up repair of the track roller, the distortion

of the inside diameter after build-up is 0.2 - 0.4 mm

smaller.
(The contraction

or distortion

and the temperature


Therefore,
diameter

of the inside diameter

varies greatly according to the outside diameter

of the roller

during welding.)

the inside diameter

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)

Sizing disc method

2)

Lathe method

When using either a hand lathe or an automatic

lathe, the welding heat caused by continuous

methods.

welding anneals the

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

parts of the roller is not rebuilding but destruction,

so it is

again and to correct the inside diameter.

given, the second method

can be used to remove the contracted

portion

by cutting

and

grinding.
The build-up weld at the outside diameter
stress of the contracted
worn,

the internal

stress disappears and the situation

happens, the dimension


by the amount

causes contraction

part. By removing only the contracted

that

of the inside diameter

of the inside diameter of the hole due to the internal


portion,

returns to that

if the roller is reused and the build-up weld is


before welding

was carried out. When this

becomes larger than the original diameter

has been removed, so the interference

(before build-up welding)

between the roller and bushing (the force holding the

bushing) is lost, and there is danger of oil leakage.


Therefore,
control

it is considered better to use a sizing disc to correct the inside diameter.

However, in this case also, heat

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

on the right. A tempered

into the inside diameter

tool steel cone is press fitted

of the roller and pushes to widen the con.--

tracted part of the inside diameter.


After

completion

of the build-up welding, cool the roller completely,

then remove all dirt and rust from the inside diameter

of the roller,

and measure the inside diameter.

the measure-

ment for the inside diameter,

Taking

select a disc from the wide variety of

discs to match the amount of contraction,

WELDING

into account

then push it in with a press.

12-47
0

APPLIED

INSTRUCTION

The press-fitting
D80/85

HARD

FACING

OF WEAR

PARTS

force for D50 class parts is 40 - 60 tons, but for the

class and above, a larger press-fitting

force is required,

so a

IOO-ton H type press is needed.


If the amount

of contraction

is excessive, it may be necessary to use

first a small disc and then a large disc to correct the inside diameter

in

two stages.
Generally

speaking, a disc with

a diameter

larger than the specified

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

will be too large. For this reason, it is pre-

ferable to carry out heat treatment


disc.
*
Example of use (Company

of the roller before using the sizing

Y)

Dimension of discs used


No. 1 disc: +0.16 OS
No. 2 disc: +0.25

OS

No. 3 disc: +0.35 OS


Press-fitting force:

In addition,

20 tons

in America,

the following

kinds of combination

Six discs, the first with an outside diameter


0.05 mm larger than the one before
inside diameter

of disc are apparently

used.

0.05 mm larger than standard dimension

(final disc:

A, and each succeeding disc

A + 0.3 mm) are pushed through the roller.

In other words, the

is widened to a 0.3 mm oversize.

If there is excessive contraction

of the inside diameter,

a second and third stage of discs, each 0.07 larger than the

previous stage, are passed through.

t-85-1

12-48
0

Stage

Stage 2

Stage 3

WELDING

APPLIED

(8)

INSTRUCTION

HARD

FACING

OF WEAR

PARTS

SHOE LUG WELDING


Machine

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

Removing mud and

After

rust

use an air brush to remove the rust completely.

cleaning

the shoe assembly thoroughly,

Measurement

Meaure the wear of the grouser height to decide

(for judgement

the heights of the lug to be welded. Then using

standard values,

a gauge like the one shown

see values table)

mark a cutting line.

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

of the shoe grouser wear quickly,

so the grouser

and cut off the grouser with an arc or by gouging.


Cut
/

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

Spot welding the


lug material

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

For the first

material completely

front

layer,

in turn

to

Spot

weld

the

back and

a bead of

less than

weld

make

from

100 mm as shown in the diagram. (Zigzag)


Using the same procedure, weld the second and
third

layers,

then

finally

weld

a continuous

bead along the whole length.


Before welding

fully,

use a gas burner to pre-

heat the edge to 2OOC.


Keep

the

maximum

temperature

between

layers

to

of 2OOC, and after completing

the

welding, allow it to cool gradually.

With

oil sealed track,

if the welding

is carried out with

the shoes

installed to the link assembly, do not weld the lug on to each shoe as
a continuous

operation.

After

completing

the work for l/2

units or

114 units, go on to the next process.


If welding
heat when

is carried out on one shoe as a continuous


cutting

operation,

the grouser and the heat when welding

the

the lug

material will have an adverse effect on the built-in dust seal.


For spot welding

Welding

rod
Dia.

of rod

Welding

current

Remarks

(A)

(mm)
AWS

JIS

D4316

190

E7016

Covered

250

arc rod

For complete welding


Welding

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

LUG ON ROCK SHOE

Rock shoes differ


during operation
Therefore,

HARD

from other shoes because they are made from high-manganese steel, which hardness is increased
on rock by peening.

the operation

for welding lugs on to rock shoes is different

from the welding procedure

used for other

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.

Preparations before welding


Remove the shoe from the link, and then remove all dirt, sand,
and rust from the part to be welded.

b.

Generally

speaking, the ends of the grouser wear more quickly,

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

the spot welding is finished,

lay beads in the order shown

in the diagram.
4)

Following layers
When the first layer is finished, weld the following

layers in the

order shown in the diagram.

12-52
0

WELDING

APPLIED

5)

HARD

INSTRUCTION

If the welded part on the grouser is as shown in the diagram (four


to five layers), the installation

of the lug is completed.

l-2mm

FACING

OF WEAR

PARTS

Lw3

Grouser

6)

Welding of side rib


After

welding the lug, weld the side rib in the same way in the

order shown in the diagram.


*

When welding

lugs to an oil-sealed track

with the shoe still in-

stalled to the link assembly, the cross-sectio,nal area of the edge of


the lug material

for the heavy-duty

shoe and rock shoe is large,

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 -

Preacutions when welding

a.

Welding bead

The

Used to:

180

Used to: 2 to 5 layers

Lug welding

C.

a medium

Time

until

making

bead in one pass: 1st layer:

20

out to rebuild the grouser

to high arc shape, so if the shoe is used

the center

amount

layers: Max. 40 seconds.

of

of the grouser is 30 mm, a large

underlaying

will

be needed

for

both

ends. For this reason, rebuilding should be consider-

Cooling, drying
After

is carried

when the height is 30 mm, but the grouser wears in

100 mm.
for

1 st layer

16 Cr.

bead height for one pass should be less than

seconds, 2nd and following


b.

Remarks

laying one bead, pour water immediately

ed at the point where the top is to be cut.

on

the bead to cool it (rapid cooling) to a temperature


where it can be touched by hand (below 4OC).
After
wire
to

cooling,
brush,

remove the slag with a hammer and

then

blow

dry it completely

the weld with

compressed

air

before going on to next stage

of welding.

Rock lug part Nos.


Model

Lug part No.

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

still installed to the link assembly, the heat will be concentrated

on one shoe with the shoe

in one place, and the seals will be affected by the

As this means that there is a danger of deterioration

the order in which the operation

OF WEAR

of the seals, careful attention

must be paid to

is carried out.

Example of method to dissipate heat


To prevent the heat from concentrating
and, in addition,

Example:

at one seal, divide the lug rebuilding operation

Process

1. Gas cutting

to shape

g1-0user
l

To prevent the heat from concentrating in one place,


carry out the work on every 2nd or 3rd shoe.

@
Example

Process

2.

into several smaller processes,

carry out work on every second or third shoe.

Spot welding of lug (face A)

of order

1426@i527@l628@1729@

I3

Process 4. Main welding of 1st layer on face A

Process 3. Spot welding of lug (face 5)

the

Process

Process

Process 6.

5.

Main welding of 1st layer of face B

Main

welding

of 2nd

layer

of face

Main

shoes given in the

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

steel teeth and low-alloy


repair

teeth.

must also be changed to

match the material of the teeth.


I)

High-manganese steel teeth with little wear


High-manganese
magnet.

steel

teeth

teeth, it will not be attracted,


Remove

can

be distinguished

by

using a

If a magnet is put in contact with high-manganese steel


the

hardened

possible, then

carry

type or D316

(AWS.

so in this case, repair as follows.

surface at the tip of the teeth as far as

out underlaying
E316)

with

a low-carbon

DFME

type austenite type welding rod, and

follow this by building up to the specified dimension as shown in


Fig. 1.

Underlaying

DF2B-4 or DF3G4

I-

1
Specified dimension

Angle build-up:

Fig. 1

Tungsten carbide type or


high chrome steel type

Procedure for build-up repair of low-wear high-manganese steel teeth

WELDING

12-55
a

APPLIED

HARD

INSTRUCCTION

When selecting
conditions

the build-up

welding

FACING

OF WEAR

rod to match the ground

for soft rock or hard soil as shown in Table 1, selec-

tion is not made simply from grinding wear. Other elements, such
as gouging wear
extent,

and

impact

wear are also included

to some

so it is also necessary to select a welding rod which gives

build-up

metal of high toughness. On other hand, if the welding

rod is selected for soft soil and sand, factors such as scratch wear
become

more important,

so a metal with a high degree of hard-

ness has better resistance to wear.


However,

even in this case, the

steel, SO this point


with

base metal

is high-manganese

must also be considered and a deposit metal

good weldability

must be selected.

1 gives welding

Table

rods selected from this point of view.

Table 1.
Finishing layer

Build-up

Underlay

Welding rod

Soil condition
JIS

Soft rock,
hard soil

AWS

DFME or
D308
D316 type

Soft soil, sand

Si

Mn

Cr

DFMA type

DF2B-4
tvpe

l2

D308or
E3 16 type

Example of chemical composition

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

for deposited metal (%I.

MO

Tungsten carbide type or high chrome steel and boron


content type.

After

building

auxiliary
When

up as above,

the surface

may also be given an

finishing build-up.

building

up

high-manganese

steel teeth,

the

following

procedures must always be strictly followed.


High-manganese steel easily fragility
fore, when welding,
temperature
metal.

after

when heat is applied. There-

use water cooling, or cool with air to room

each pass to prevent overheating

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

rod also has a high-manganese

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

Marked wear of high-manganese steel teeth


in this case, if the part is built up as in case I), the manhours and
number

of welding

rods needed will

Underlaying

be large, and defects will

easily occur, so repair as follows.


One way is to add steel as shown in Fig. 2. High-manganese steel
or

low-alloy

steel are used for the additional

*;,;;

ziz,el

steel, but they

should be used as follows.


a.

For parts subjected to large impact, use high-manganese steel.

b.

For parts subjected to little impact, use low-alloy steel.

When repairing,

Joint

remove the edge as shown in Fig. 2. When doing

this, carry out underlaying

with the welding rods in Table 2 on

both edges of the contact

surfaces regardless of which metal is

being used. After

doing this, it is safe to proceed with the main

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,

it is usual to carry out the finishing

build-up shown in Table 1.


When adding high-manganese steel, carry out lattice build-up with
a DF2B-4
alloy

type

of DF3C4

steel, carry

type welding rod; when adding low-

out layered

build-up

with

a tungsten

type.
When carrying out the welding, to prevent overheating,

carbide

follow the
Underlaying

same precautions as in case 1).

Underlaying

(but for DFME

The second method is to use soft steel. In this case, underlay the
tooth tip with

DFME

type or D316 type as shown in Fig. 3, then

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

When building up with a DFMA

type welding rod as shown, it is necessary to carry out underlaying with a DFME

type or D308

high-manganese

type or D316 type on top of the

steel teeth -

Inserting

worn
soft steel

soft steel material.


Table 3 Welding rods for welding repair of high-manganese steel teeth

Underlaying

of tooth

tip

Joint of soft metal

Underlaying

of soft metal

Build-up

Soil condition
JIS

AWS

JIS

AWS

Soft rock hard soil


DFME or
D316 type
Soft soil or sand

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

finishing the build-up,

FACING

OF WEAR

a finishing build-up can be made for

the surface. The procedure given above can be followed.


Little wear with low-alloy

3)

steel teeth

In this case, preheat to at least 250C,


the original
about

shape. However,

then build-up to return to

if the amount

of build-up

10 mm, the build-up can be carried out directly

is up to
using the

welding rods shown in Table 4.


However,

if the amount

carry out underlaying

of build-up exceeds 10 mm, it is safer to

with a D4316

type or other low-hydrogen

type welding rod before carrying out build-up welding.


The welding rod used for the build-up should be selected according to whether

the part is used on hard ground or soft ground.

Examples are given in Table 4.


Table 4. Welding rods for welding repair of low-alloy

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

Method of rebuilding conical nose


The

FACING

nose

Point gauge

nose surface

is made of a very

hard

material with a Brine11 hardness of 321 to 555.


In this type of hardness range, the effect of heat during welding may
destroy

the heat treatment

does not recommend

and cause cracks. Therefore,

rebuilding

the conical

the maker

nose surface.

However,

if you still wish to build up the worn part, do as follows.

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

the tip of the nose to fit the point so

that it does not move.


*
If the point still moves, continue the rebuilding welding until
it does not move.
3.

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

(AWS E7916 or E8016)

When making straight beads or overall build-up, if the whole


part is welded at the same time, it becomes difficult

to align

the dimensions (align the point) or finish with a grinder afterwards.


*2

When making straight

beads or overall build-up,

first carry

out spot welding, then align these spots with the point to use
as a guide when finishing.
After

carrying out spot welding, it is easy to check the condi-

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

only the adapter stabilizer

and

portion.

Build-up space between the spots.


If the spots made in *2
which

are used as a guide, it is easy to judge

parts of the face in contact

with

the point

need to be

removed with a grinder.

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.

Repair tools and equipment

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

Factors causing water leakage

5. Removal

12.

13-2

to take when water

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

If water leakage occurs due to cracks in the radiator

FROM

FACTORS
(1)

OF RADIATOR

RADIATOR

CAUSING

OIL COOLER

CORE

WATER

LEAKAGE

If there is leakage of water from the radiator, it

core, repair according to this procedure manual.

is important

Note:

but also to understand the cause so that action

This

repair

procedure

manual

is applicable

not only to take suitable action,

for cases where cracks have occurred in the

can be taken

solder at the mounts of the upper and lower

problem.

tank

with

other

the core due to distortion

product

applicable

quality

to

problems.

Therefore,

and

to prevent

reoccurrence

of the

if there is any water leakage, always

try to find the cause of the problem.

It is not

(2) If there

wear of the tubes by sand,

is water

leakage

from

around

the

breakage of the tubes when hit by rocks, or

soldered part of the core, the cause may be high

leakage from the gasket caused by incorrect

stress around

tightening of the bolts.

deformation

the

soldered

of the

radiator

expansion and contraction


2.

AND

ACTION

TO TAKE

WHEN WATER

STARTS

joints

caused

guard

of the core tubes.

If the core has been repaired or replaced, defec-

LEAKING

tive shim adjustment

(I)

If leakage of water from the core is discovered,

tor may cause the lower tank to interfere

stop or move the

the radiator

level safe place,


lower the work

machine
apply

the

equipment

immediately
brake

by

and heat

to a

when installing the radiawith

guard and damage the core. There-

fore, it is necessary to investigate the condition

lock, then

of the failed machine.

to the ground and

apply the safety locks.

(2) Stop the engine, wait for the cooling water to


cool down,
operating

then follow

the instructions

manual to open the water

5.

in the

REMOVAL
Remove the radiator assembly from the machine.

filler cap

For details, see Shop Manual.

and check the cooling water level. If the level is


low, add more water.
3.

CONFIRMING

LOCATION

OF WATER

LEAKAGE

(I) Start the engine, and confirm the location of

4- _

the water leakage.

(2) If it is impossible to locate the water leakage


with

the

radiator

still

installed,

remove

the

radiator assembly from the machine, and check


as follows.

1) Remove the radiator from the machine, set


as

upper

tank,

core,

and

lower

5
5

tank

assembly, and stop the openings with blind


covers.

2) Put the radiator assembly into a water bath


large enough to hold the radiator.
3)

Pump in air at 1 - 1.5 kg/cm

through one

of the openings in the tank, and look for


air bubbles to locate the leak.
!
Q

When pumping compressed air into the


radiator,

do not use a pressure of more

than 2 kg/cm2.
high,

the

If the pressure is too

upper

may be deformed
*

tank

or lower

tank

or damaged.

Another

method of locating the water

leakage

is to coat the core and the

areas around the connections


the core and tank with

between

soapy water,

and to pump air into the radiator

to

locate the leakage. However, it is difficult

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 lower tank,

and dis-

awsemble so that the core is an individual part.


Note:

The core and lower tank are stuck together


with adhesive, so they cannot be separated
easily. In this case, knock a wedge between
the

plate

and tank,

to make

it easy to

remove the core.

-Core

Wedge

Lower tank

The same applies to the upper 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

For adjusting clearance of


bracket (replace when
reassembling)

Solder
(15 kg)

Flux
(powder)

WELDING

and tools

Propane gas cylinder and oxygen cylinder

Remark

Equipment
@

No. Iart Name

(2)

7.5 kg

45 mm type solder
JIS, H4341, H40A
ASTM, B32-70,40A
(equivalent)

500 g

Dissolve 500 g of ZnClz


powder in one litre of water
to use.

13-3
a

APPLIED

REPAIR

INSTRUCCTION

Pressure detection

water bath

Water bath big enough to take the radiator

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

Set of blind covers for radiator

(with air filter).

Use a steel plate

the pressure of the radia-

blind caps for the piping joints.

tor, set the air pressure to 2 kg/cm.

It is also possible

and rubber

openings
seat to make

to make an O-ring type

flange and use it as a blind cover.

Brush:

For coating

Brush:

For cleaning

Wire:

For cleaning

flux
between

core

Wire brushes (large, small):


For removing
@

solder

Burner pressure regulator

WELDING

APPLIED

8.

REPAIR

INSTRUCCTION

REPAIR PROCEDURE
*
Regardless of the size of the leak, solder the

2)

OF RADIATOR

AND

OIL COOLER

Using a gas burner and wire brush on the


solder at the water side, remove the solder

water side and air side of the hole plate service

from the whole surface of the header plate

again.

and brush until the surface of the header


plate can be seen.

(1)

Set the removed core with the plate on one side

Burner

at the bottom in a stable position.

(2)

3)

Cleaning method
Remove

the soil, dirt,

compressed air.
*
The whole

or grit with

solder from the whole circumference


surface of the plate

of the

leakage,

but the whole

and

brush until the surface of the header plate

must be

and patch plate can be seen.

soldered again, so clean not only the location

Using a gas burner and wire brush (small)


on the solder at the air side, remove the

steam or

plate

surface.
*

If there is any scale or rust remaining,


solder will

not flow properly

the

and will not

nn

become attached, so be careful to clean the


plate surface thoroughly.
1)

Clean the water side and air side at the root


of the tube to remove all grit, scale, dirt,
earth, etc.

Wire

4)

brush

(small)

Even if there is no water leakage, clean the


header plate on the other side and check

Tube

for cracks in the solder.


*
If there are any cracks in the solder,

carry out Steps


5)

1) - 3) above.

Set the core on its side in a stable position


and wash the part to be soldered and the
inside of the tubes. Then blow with air to
remove the water.

WELDING

13-5
a

APPLIED

(3)

REPAIR

INSTRUCCTION

Removing

temporarily

repair

leak stopping compound

material.

If any

such as Bars Leak or

Leakend has been used to temporarily

(4)

OF RADIATOR

AND

OIL COOLER

Resoldering water side


1)

Coat

soldering

part

between

tube

and

header plate with flux.

stop the

water leakage, remove it as follows.

1)

Bars

Leak

contact

hardens

with

when

air, so when

it

comes

which have been repaired with

2)

into

2)

Do not heat a small area; always move


the burner when heating.

Bars Leak,

a system with more processes than normal

3)

Coat again with flux.

is repeated.

4)

Supply

When cleaning steps 1)

- 5) have been com-

pleted, carry out the following

small amount

of solder from

the

water side, and repeat the heating until the


solder flows to the bottom side.
Burner

additional

operations again.
3)

Heat with the burner.


l

cleaning cores

Set the core at an angle of approximately


lo,

direct the burner at the area around

the bolt holes of the plate as shown below,


and reheat gradually to the side.
4)

When doing this, continue


melts and penetrates

until the solder

from the air side to

the water side, and then starts to drip from


the water side.
5)

When this operation


for

the

whole

has been completed

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)

Repeat Steps 1 ) to 4) for each tube.


*
When soldering the tubes, follow
zag path

(shown by the arrow)

make blocks of 10 roads each.

First block

yond

1~

Solder drips from water ;ide

13-6
0

WELDING

a zig
and

APPLIED

REPAIR

INSTRUCCTION

6)

Continue
water

4)

to make an extra build-up on the

moving continuously

OIL COOLER

Melt solder into the clearance at the patch

to shape the

build-up.
*

AND

plate joint.

side as shown below and keep the

burner

OF RADIATOR

Header plate

000,

If the burner is used to heat one place,


it will

flow

off,

so always

keep the

burner moving.
*

Be careful not to let the solder fall off


to the air side.
Extra build-up
Joint
\

block,

second block, and following

blocks

for each tube root.


(5)

Melt the solder to the bottom of the clearance


so that there is no air pocket. Then build up
to form section A-A.

Carry out Steps 1) to 6) to make the first

7)

lmm

Min. 1

Back fillet soldering


Carry

out

back fillet

soldering of the outside

tube root.
1)

Set the core at a 45

angle and fix in a

position where the tube root is easy to see.

Section A-A
Detail of joint

5)

Tube root

Make a fillet of approximately


the

whole

circumference

2R around
of

the

joint

between the header plate and the reinforcement plate.

2)

Coat

the

soldering

part

with

flux,

then

4%

So\der

repeat Steps 1) to 3) for resoldering.


3)

Supply solder between the tubes, and cool


from

time to time with

flux to form the

fillet shown below.


Solder

-L-

Heat base metal of header Plate

flux,

then

repeat Steps 1) to 3) for resoldering.

Coat

Melt

the

the
solder

header

soldering
with

the

part

with

temperature

plate base metal,

of the

and at the same

time repeat cooling to form the fillet.


Fillet

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

Start tightening bolts here


,2----A

----L

Check the top and bottom

soldered

parts for any


View Z

pin holes or unsoldered parts.

(1) There are gaskets stuck to the core mounting

Check items
(1)

Are there any pin holes or forgotten

surface of the upper and lower tanks, so remove

parts in

them completely.
*
To remove the gasket, scrape off with a

the soldering of the tube and header plate?


(2)

Is the condition

of the build up on the water

knife or similar object.

side good? Has any part been forgotten?


(3)
(4)
(5)

Is the condition

Do the same for the tank mounting

of the back fillet of the outside

tube root good?

the

Has any part been forgotten?

gasket can be stuck on without

Is the condition

of the build up at the clearance

Is the condition

of the approx.

and

clean

the

surface of

surface so that

the

problem.

surface of the upper

tank and gasket evenly with liquid gasket LG-7,


and stick the gasket to the core mounting

2R fillet at the

sur-

face of the upper tank.

joint between the header plate and patch plate


good?

core,

(2) Coat the core mounting

of the patch plate joint good?


(6)

AStart tightening bolts here

(3)

Carry

out the same procedure

for the

lower

tank end and stick the gasket in position.


*

Align the bolt holes of the tank and gasket


sides correctly.

(4)

Set the upper tank

horizontally

with the core

mounting surface at the top.


(5)

Coat the core mounting

surface of the gasket

evenly with liquid gasket LG-7 and set the core


on top of the gasket.

13-8
a

WELDING

APPLIED

(6)

REPAIR

INSTRUCCTIDN

Set the tightening

OF RADIATOR

AND

OIL COOLER

plate in position and tighten

the bolts of the upper tank and core.


m

Bolt:

3.5 - 7.5 kgm

Method of tightening bolt


After

inserting

all the

circumference,
tightening

two

bolts around

workers

should

from opposite corners.

the
start

(1) (2) -

(1) (2)
When all the bolts in line A are tightened,
tighten the bolts in line B.
(7)

Carry

out

the same procedure

to install

the

lower tank and core.

11.

PRESSURIZING
(1)

CHECK

Fit blind caps on the openings, and connect an


air hose to one opening.

(2)

After

fitting

blind caps, insert the radiator

in

the water tank and fill with clean water.


(3)

Pump in air through the air hose at a pressure


of 1 -

1.5 kg/cm*.

Leave for about 10 minutes,

and check for any air leakage.


*
Adjust the pressure so that the air used in
the pressurizing check is not over 2 kg/cm.

A simple method
the

tank

tubes

is to coat the joints of

and plate and the root

and

plate

with

pump in air to check.


method, it is difficult
(4)

If the

pressurizing

of the

soapy water,

then

However, with this

to check accurately.

check shows that

there

is

leakage, repeat the repair operation again.

12.

REASSEMBLY
(1)

If the
remove

radiator

passes the

pressurizing

check,

the blind caps from the radiator

core

assembly.
(2)

Install

the

radiator

core

assembly

to

the

radiator frame.
*
Before tightening the bolts, if the clearance
between

the radiator

frame and the core

assembly is not uniform,

adjust the clear-

ance with shims.


(3)

Install the radiator assembly on the machine.


For details, see the Shop Manual.

(4)

Fill the radiator with cooling water.


*
For details of the anti-freeze density,
the Operation
*

& Maintenance

see

Manual.

When changing the cooling water,

replace

the corrosion resistor element.

WELDING

13-9
0

APPLIED INSTRUCTIONS
20

REPAIR OF BULLDOZERS
SHOVELS BY WELDING

MAIN

AND

DOZER

FRAME

Example
TRACK

FRAME

Example

and uses of blades

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

. .

and uses of buckets

Replacing

of blades

Repair and rebuilding


RIPPER

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

for welded structure


Rolled steel for welded structure

SM41 B

Carbon steel castings

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 each section for cracks by means of the dye


penetrant check.
*

Check sections @

and @

in Fig. 1 especially

carefully for cracks.

nting face against steering case

End of main frame

Fig. 1

20-2
0

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

3.

REPAIRING

CRACKED

SECTIONS

1)

Repair procedure for cracked section @

AND

DOZER

SHOVELS

BY WELDING

(End of main frame)

Starting point of crack

Material:

KES SHTGO

Material:

KES SM41 B

Fig. 2
(a)

When the length of the crack is less than 40mm:


(When only the upper plate of the main frame
is cracked:)

(1) Remove parts @

(boss for mudguard side

cover).

(2) Remove the cracked section by arc air


gouging or with gas, then finish the gouged
surface with a grinder.
(3)

Recheck

the gouged section

for cracking

by means of the dye penetrant check.


(4)

After confirming

there are no cracks on the

gouged surface, clean and weld it.


Welding rod

: JIS D5816
AWS E90 16

(Preheating/postheating
(5)

are not required.)

Finish the welded surface with a grinder.


*

Gouge the material 30 mm beyond the


ends of the crack on the surface, and
take

care not to blow the air through

the material.
After

welding, use a grinder to chamfer the

corners

to the

dimensions

marked

* to

about C3.

Fig. 3

WELDlNG

20-3
0

APPLIED

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

(b) When the crack extends to the side plate:


(when only a part of the upper plate is cracked.)
(I) Remove part @

(boss for mudguard side

cover).

(2) Gouge the cracked section according to


procedure (a)-(2).
(3)

Gouge the side plate as shown in Fig. 4.

(4)

Make the back plate shown in Fig. 5.

Td be gouged.

Fig. 4

(5)

Insert back plate

through the gouged

section of the side plate, and install it to

Length of crack +lO mm


16

the gouged section of the upper plate by

(6)

Clean

the

Material:

tack welding.
gouged section,

and weld the

Fig. 5

KES SS41 P
ASTM A283Gr.D

Part @

back plate permanently.


Welding rod:

JIS D4316
AWS E70 16

(Preheating/postheating
(7)

are not necessary.)

Fill the gouged section of the side plate by


welding,

then

finish

smoothly

with

grinder.
(8)

Install

bracket

mudguard

(198-54-l

8790)

for

the

side cover together with blocks

(198-61-15271)

or (198-61-15191)

for the

piping of the blade (Fig. 5).


Fig. 6

side cover

B&in

frame

Fig. 7

20-4
0

WELDING

APPLIED

2)

INSTRUCTION

BULLDOZERS

Repair procedure for cracked section


(Welding section against steering case)

Material:

AND

DOZER. SHOVELS

0B

KES SHTGO

Material:

KES SC63W

Cracked section

Material:

KES SM41 B

Material:

KES SC55W

Fig. 8
(a)

When only the side plate is cracked:


(1)

Remove

the

cracked

gouging or with
surface with

section

by

arc air

gas and finish the gouged

a grinder.

gouged surface for

Then, recheck the

cracking

by means of

the dye penetrant check, and weld it.


Finish the surface with a grinder.
*

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

Make through holes approximately


6@ x 2

6 mm in diameter

Fig. 9
Welding rod:

JIS D4316,
AWS E7016

(Preheating/postheating

WELDING

are not necessary.)

20-5
0

APPLIED

(b)

BULLDOZERS

INSTRUCTION

AND

DOZER

SHOVELS

When the crack extends to the bottom plate:


(1)

Repair the side plate according to procedure (a)-(1 1.


*

If the back plate is cracked,

replace it

with a new one.


(2)

Remove the cracked section of the bottom


plate

by arc air gouging or with gas and

finish

the gouged surface with

Then,

recheck

cracking
check,

the

gouged

by means of the dye


and weld

it.

a grinder.

surface

for

penetrant

Finish the surface

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

from the surface.


(5)

Fit

reinforcement

plate

to the base

metal, then weld it.


*

If there
ment

is a gap between the reinforce-

plate and base metal

because of

Material

KES SS41 P
ASTM A283Gr.D

the curve of the base metal, weld the


special plate to the base metal as shown
in Fig. 13,

and hit in a wedge to fit

reinforcement

plate

to the bottom

plate.
Welding rod:

JIS D4316,

(Preheating/postheating

20-6
a

Thickness:

16 mm

Reinforcement plate @
Fig. 11

AWS E7016

are not necessary.)

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

AND

B-

1G-v

(D

Xl&

Finish the surfac


witSin this range.

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
*

If the levels of the main frame and the steering


case are different,

repair as shown below.

repair must be done if dimension

(This

T is 2 mm or

more).

finish with a grinder.

Fig. 14

WELDING

20-7
0

APPLIED

TRACK
(Equipped

1.

BULLDOZERS

INSTRUCTION

FRAME

DOZER

SHOVELS

(Example of D455A)

with a reinforced

MAJOR

AND

MATERIALS

type track frame)

OF

FRAMES

TRACK

[Reference]

\
SHTGOH

Metal group

KES symbol

High tensile strength rolled steel plates


SHTGOH, SHT80A

for welded structure

SC55W. SC63W

Carbon steel castings

The materials and dimensions of products are subject to


change without

notice in order to incorporate

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

hand air brush.


2)

Check each section

for cracking

by means of the

dye penetrant check.


*

If it is difficult
remove

according

to the section

Assembly

20-8
0

to repair a cracked section by

welding,

the

track

frame

assembly

on Disassembly

and

in the Shop Manual, then repair it.

WELDING

APPLIED

3.

INSTRUCTION

REPAIR

BULLDOZERS

OF CRACKED

SECTIONS

AND

DOZER

SHOVELS

BY WELDING

frame and brace

rame
and brace

Fig. 1

I)

Repair of a crack in section

@
Cracked section

Material:

Fig. 2

la)

KES SHTGO

Detail of section @

When a part of the upper plate is cracked:

(I)

Remove

the

cracked

section

gouging

and

prepare

it for

by

arc air

rewelding

as

shown in Fig. 3.

* When gouging, take care not to blow the


air through the plate.

(2) Remove the spatters and slag from the


gouged section with a grinder.
(3)

Recheck the gouged section for cracks by


means of the dye penetrant check.

(4)

After confirming

there are no cracks on the

gouged section, clean and weld its surface.


Welding rod:

JIS D5816,

(Preheating/postheating

WELDING

Area to be gouged

AWS E9016

are not necessary.)

Fig. 3

20-9
0

APPLIED

BULLDOZERS

INSTRUCTION

AND

DOZER

SHOVELS

Build up by welding, then finish


with a grinder.

(5)

If there is a level difference


build

up by welding,

on section @,

then

finish

with

grinder (Figs. 3 and 4).


(6)

After

welding, finish the surface smoothly

with a grinder.

Fig. 4

(b)

When all the upper plate is cracked:


(1)

Remove

the

cracked

section

by

Approx. 25

arc air

gouging to prepare it for rewelding.


(2)

Cut the side plate with


Fig. 5 @

(3)

t---I/

gas as shown in

Make backing strip

, insert it through
Fig. 5

the cut zone of the side plate, and install it


to the gouged surface by tack welding.
(4)

(5)

Clean the gouged section and weld it.


Welding rod:

JIS D5816,

Build

cut zone of the side plate.

up the

AWS E9016

Finish the welded section with a grinder.

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

Repair procedure for cracked section @


68 mm drill

Cracked sections
Area to be gouged

*Take

care not to blow the air

through the plate.

Section A-A

Fig. 7
(a)

Make

Fig. 8

holes 8 mm diameter

at IO mm from

both ends of the crack, and remove the cracked


section by arc air gouging or with gas.
*

Gouge 30 mm beyond the crack on the surface,

and take

care

not

to

blow

the

air

through the plate.

lb) Finish the gouged section with a grinder, then


weld it as shown in Fig. 9 and finish smoothly
with a grinder.

Fig. 9

WELDING

20-11
0

APPLIED

3)

INSTRUCTION

BULLDOZERS

AND

DOZER

SHoVELS

Repair procedure for cracked section @

-Reinforcement plate
Material: KES SHT80A

Cracked sections
Viewed from under the brace

Fig. 10
Remove the cracked section by arc air gouging

(a)

as shown in 2). Fig. 8.


After

b)

finishing the gouged surface with a grind-

er, weld

it as shown

in

Fig.

9, then

finish

smoothly with a grinder.


Make the reinforcement

(cl

Material:

plates.

KES SS41P (14t)


ASTM A283Gr.D

Material:

Part @
The dimensions in

Part @

( )* are shown only for reference.

Smooth both ends of parts @

(d) Weld

reinforcement

the position

KES SS41P (14 t)


ASTM A283Gr.D

plates @

and @
and @

by actually placing them on the machine.


to

shown in Fig. 10 as indicated by

the hatching in Figs. 11 and 12.

or 03
Reinforcement

plate

Welding

rod:

JIS D4316
AWS E7016

Smooth both ends


Section A-A
Fig. 11

20-l 2
Cc

Fig. 12

WELDING

APPLIED

4)

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

Repair procedure for cracked section @


(a)

Prepare the parts and welding rods required for


the repair.

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

JIS 5016, AWS E7016

arc air

13 to prepare

for

rewelding.
Deposited metal

Sectional drawing not gouged yet

Fig. 13
*

Gouge

not

also the

only

the

area shown

cracked

section

in

14,

Fig.

but

even if

there are no cracks on that area.

WELDING

20-l 3
0

APPLIED

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

to be

Fig. 14 shows the section of this part.

Fig. 14

(c)

After

gouging,

with

a grinder

remove
or

the

slag and spatters

pneumatic

chipping

Deposited metal

ham-

mer and clean the surface.


(d)

Weld the gouge section as shown in Fig. 15.


*

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

centers to the weld line, and finish both ends


smoothly
burning

with

a grinder.

and bending

them

Weld them
along the

by
base

metal so that the gaps between them and the


base metal is reduced as much as possible.

20-14
0

WELDING

APPLIED

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

After welding, finish smoothlv

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

and cutting soil, the angledozer can be used for


angling work

by changing the position

pins to install the arm to the frame.

of the

It also can

be used for tilting work by adjusting the length


of the brace.
I OOF347

(b)

Straightdozer
The frame supporting

the blade on a straight-

dozer has an l-shape or an L-shape. Therefore,


it cannot
stand

be used for angling work,

continuous

strengthening

the

heavy
frame

cutting
and

but can
work

by

its connection.

The blade has a larger capacity than the blade


on an angledozer.
I OOF348

Straight tiltdozer
The

straight

draulic

tiltdozer

cylinder

is equipped

installed to straightdozers).
can perform

with

a hy-

instead of a brace (which

tilting

is

Thus the operator

work by operating the con-

trol levers in the operators cab.

I OOF349

(d)

Udozer
The Udozer
of a straight

is equipped with a U-blade instead


blade.

It used to carry a large

amount of soil at one time.

I OOF350

20-l 6
0

WELDING

APPLIED

(e)

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

Coaldozer
The coaldozer

is not used to cut ground.

In-

stead, it is used to carry material of low specific


gravity
that

such as coal and coke.


has a large capacity

blade

the

will

material

Therefore,

the

and is designed so

not spill over the side

plates.

I OOF35

n
(f)

Chipdozer
.The chipdozer

is not used to cut ground.

stead, it is used to carry material

In-

of very low

specific gravity such as wood chips. Therefore,


the

blade has a remarkably

that

large capacity

so

a large amount of material can be carried

at one time.

IOOF352

kl)

SnowplOw
The

(V-plow)

snowplow

has a V-shaped

blade, and is

used to remove the snow from roads.

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

The materials and dimensions of products are subject


to change without
notice in order to incorporate
improvements of technology or for reasons of manufacture.

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

Rolled steel for welded structure

SM41

High tensile strength rolled steel plates for welded structure


Steel casting for welded structure
Carbon steel for machine structural
Low alloy steel castings

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

* Inside structure of blade

AND

TO WEAR

As shown in the sectional drawing, a blade consists


of a front
brackets,
frame,

plate which
a rear

directly

plate

which

and rib plates which

contacts the soil,


is also the outside

support

those parts.

The tip of the blade consists of a plate, to which the


edge is installed,

and the rib plates, which support

the plate from the rear side.


While the blade is in use, the sections which contact
the soil are gradually
tinuously

worn.

used without

If the blade is con-

being repaired,

Rib plate

the front

&xztion A-A

plate may become very thin or holes may be made


on it.

If the blade is worn to this stage, welding a

new reinforcement
rib plates would
hours.

front

plate to the intermediate

require high skill and many man-

If the tip of the plate to which the edge is

installed

is worn

too

much,

the area around

the

Detail @

mounting holes will lose strength.


In any case, wear of the blade can not be avoided.
Therefore,

the distributors

of the blades and train

must learn the structure

Tip of blade

//

so that the customers can

repair the blades before they wear out.

\
Plate to which rib
plate is installed.

,
&tieal

Detail @

WELDING

20-19
a

APPLIED

2.

INSTRUCTION

PREVENTING

BULLDOZERS

WEAR

OF THE

DOZER SHOVELS

BLADE

Since blades receive large impacts and the abrasive


force

AND

. All surface reinforcement

procedure

of soil and rocks, they should be protected

with reinforcement

urn and smatl-

plates or wear plates. The num-

ber of man-hours and the cost of repair largely depend

on whether

those protective

measures have

been taken.
If plates are installed to a worn or deformed

front

or side face of the blade, the base metal of the blade


will

not be worn even if those added plates wear

out.

Therefore,

time.

repairs can be done easily in a short

As a result, the cost of repairs is reduced and

the down time of the machine is shortened.

I)

TYPICAL

PROTECTIVE

MEASURES

FOR

BLADE
(a)

All surface reinforcement


In this method,

procedure

the entire

front

face of the

For

large-sized models,

blades which are reinforced

by this method are

blade

is reinforced.

available as options.
The

reinforcement

plate for the front


into

three

or

five

face is

generally

divided

However,

it may be divided into other numbers

pieces.

considering the yield of the material.


The

reinforcement

plates must be cut a little

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

steel plates for

Detail @

Section E-E

welded structures)
SHTGO:

Tensile strength

60 kg/mm2

class

SHTllO:

Tensile strength 110 kg/mm2

class

20-20
0

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

To further

reinforce

AND

DOZER

the blade, make holes at

several places on the upper and lower parts of


the reinforcement

plates, and weld those places.

If the entire front face of the blade is covered


with

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

much that holes are made and the base metal of


the blade can be seen, replace all the reinforcei

ment plates. This work can be done in the field


after preparing new reinforcement
To

install

the

reinforcement

Detail @

plates.
plates

Section

C-C

snugly

against the base metal of the blade, press them


against the blade with

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

side wear plates.

* Reinforcement

of the front face with a strip

with strip plate

plate
In this method,

reinforcement

strip plates of

the same width are welded at equal intervals on


the

front

face of

blades

reinforced

strong

as those

reinforcement

the

blade.

Although

by this method
reinforced

the

are not as

by the

all-surface

method, they are much stronger

than those not reinforced.


The reinforcement

plates used in this method

do not need to have a powerful

but are made with a portal press used for metal


sheet work.
If

material

amount

of

standard

of cutting

addition,

work

width

Reinforcement

plat

bending roll,
* Pusher plate

is used, the

can be reduced.

In

since a plate is not heavy, it can be

handled easily and installed to the blade in the


field.
(cl

Installation

of pusher plate

A pusher plate can be installed to the center of

Reinforcement

the blade when pushing a scraper, etc.

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

and larger models, optional

are available.

The reinforcement

pusher plates

plates are also avail-

able as spare parts.

WELDING

20-21
0

APPLIED

INSTRUCTION

Installation

(d)

Since

BULLDOZERS

AND

DOZER

SHOVELS

* Side wear plates

of side wear plates

the side faces of the blade wear relatively

rapidly, they should be covered with reinforcement

If

plates.

used as the

discarded

reinforcement

faces, the durability

cutting

edges are

plates for the side

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

plate for side face

A576-1049
Reinforcement plate made of
a discarded cutting edge

19mm
22mm

For D60A and larger models, optional side wear


plates are available.

The reinforcement

plates

are also available as spare parts.


When welding wear plates @

S53C. be sure to pre-

heat and postheat to prevent cracks from occurring


in the weld zones.

Preheating temperature:

29OC

Postheating temperature:

590 to 68OC

Welding rod:

AWS E7016

(e)

JIS D5016,

Wear plates for frames


Since the frames which support the blade also
wear quickly,

wear plates should be installed to

the

face

bottom

and

outside

faces

of

* Reinforcement

of frame

the

frames.
Welding precautions

(1) Reduce the gap between the reinforcement

plates

and the base metal to 1 mm or less. (This is required to maintain the quality of welding.)
(2)

Dry the welding


rods,

before

use.

rods, especially
If moisture

low hydrogen
remains

in the

Reinforcement

of frame

welding rods, it will cause weld cracks.

1 mm or less
i

I\

20-22
0

WELDING

APPLIED

3.

INSTRUCTION

PLANNED

BULLDOZERS

REPAIR

Blades should be repaired periodically


time

of the

SHOVELS

to reduce the
on the

Planned

machine.

means to grasp the condition

repair

of parts and devices on

a daily basis, use that information


repairs or rebuilding

DOZER

OF BLADES

repair cost and to avoid putting restrictions


operation

AND

to estimate when

will be required,

and prepare

for the repair or rebuilding in advance.


By planning the repairs, the operation
machines will not be limited.
and materials
and tools

required

time of the

In addition, the parts

for the repair and the shop

can be prepared

in advance,

making

possible to repair the machines in a short time.


repair

machines

according

I OOP80 I

it
To
Estimate of repair/rebuilding

to plan, the following

items should be understood.


I)

BASIC
AND

CONCEPT

OF

REBUILDING

[Example]

ESTIMATING

used under the same con-

it will wear in proportion

time of the machine.


of parts which

REPAIR

Estimated time when


the blade must be repaired
or rebuilt.

When the blade


is measured.

When the
blade is new.

TIMES

If a blade is continuously
ditions,

time

to the operating

The repair and rebuilding time

are worn

in this way can be estiWear

mated.

Omm

Operating time of blade


[Procedure]

i)

2350H

Hour meter reading

Measure the remaining


worn

OH

thickness

15mm
x=?H

3550H

X=?H

of the most-

plate on the blade (remaining

length, in

case of the cutting edge).


ii)

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

check the hour meter reading taken when the


new

blade

(or

rebuilt

blade)

was installed.

Then calculate the actual operating time of the


blade.
iv)

Find the expected service limit of the blade (for

2000
Operating time of blade (H)

example, the period up to the time when a hole


will

be made on the plate) by linear interpola-

tion from the operating

VI

time and wear of the

blade before the measurement was taken.

x = 1200 x (+,

To obtain the time when the blade should be

X = 2350 + 2000 = 4350 (H)

repaired,
in

iv)

add the service period limit obtained


to

the

hour

meter

when the new (or rebuilt)


Alternatively,
obtain
repaired.

= 2000 (H)

the

reading

recorded

blade was installed.

use the graphs described later to


time

when

the

blade

should

be

Therefore,

the

blade

should

hour meter reading is 4,350


*

be

repaired

when

the

hours.

If the blade has not been repaired since the machine


was

put into

operating

time

use, the hour meter

reading and the

of the blade are assumed to be the

same.

WELDING

20-23
0

APPLIED

2)

FIELD
(a)

BULLDOZERS

INSTRUCTION

MEASUREMENT

DOZER

SHOVELS

OF WEAR
Sections to be measured for wear

Sections to be measured for wear


Generally,

AND

the sections of a blade which

(1) Cutting edge

are

most worn vary with how the blade is used. In

(2)

the field,

(3)

Front plate or front reinforcement

(4)

Side plates or wear plates

the wear of the sections shown at

right must be measured as a minimum.

Since

End bit
plate

parts do not wear evenly, the place most-worn


must be measured and recorded.
(b)

Measuring instruments and measuring method

Measuring instruments

Auxiliary

The

(I) Thickness meter

instruments

and tools shown at right are

(1)

Wire brush

(799-I 01-2000)

(2)

Sandpaper

(2)

Tape measure (Steel measure)

(3)

(3)

Straight plate

(4)

Square plate

required to measure for wear in the field.


Auxiliary
(cl

tools are also required.

Check sheet for measurement in the field


It is convenient

tools

Record binder
or notebook

to use a check sheet, in which

the degree of wear can be seen at a glance.


Example of filling in the measurements in a check sheet

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

to wear to its present


of the

condition

blade.

indicates the amount

The remaining

of time

life

from the time of

measurement to the service limit.


[Procedure]
See where the remaining thickness of the plate
(remaining

wear allowance,

in case of a cutting

edge) is located in the Table of Percentage Wear.


*

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

Go down from the thickness of new one in

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)

until the measured thickness


example)

is found.

(6 mm in this

If the measured thick-

ness is between two figures, divide it proportionally

to obtain the percentage.

Move to the left from the position of the measured thickness

to see what the percentage

of

wear is (60% in this example).


*

I9

I6

described before.

by the

of new one imml

The basic con-

The (%) wear indicates how much the blade has

service limit

ii)

ickness or wear allowance

IO

blade

i)

l7h

Vear %

cept of this method is the same as that of the rule of


linear interpolation

SHOVELS

Table of Percentage Wear [Example]

AND

using a graph to estimate the

time to repair or rebuild the blade.

DOZER.

LIFE

In this section, the (%) wear and remaining life of a


blade are obtained

AND

If the obtained

0.0
-

(%) wear is less than 30%,

the accuracy of the estimated

remaining life

Remaining life curve

[Example]

is low.
iii)

On the remaining
operating

time of the blade on the horizontal

axis (1,200
the

life curves, go up from the

line

H in this example)

of

percentage

until intersecting

wear obtained

before

(60% in this example).


iv)

Go to

left from

obtain

the remaining

the

C
6

E
;$

800
(H)

point

of intersection

to

life (800 H in this exam-

ple).
v)

The time

of service limit (4,350

vice meter)
maining

can be obtained

H on the ser-

Operating time of blade (HI

by adding the re-

life to the hour meter reading at the

time of measurement (3,550 H in this example).


*

Indicate the situation of the blade with a bar


graph

so that

it can

be seen at a single

glance.

When newly When


installed
measured Eemzce

3550

2350

1000

2000

Hour meter (H)

WELDING

3000

14000

4350

5000

Remaining life

20-25
a

APPLIED

INSTRUCTION

BULLDOZERS AND DOZER SHOVELS

Table of Percentage Wear

Thickness of new blade or allowable wear (mm)


Wear (%I

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

Thickness of new blade or allowable wear (mm)


Wear i%)

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

Thickness of new blade or allowable wear (mm)


Near (96)

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

Thickness of new blade or allowable wear (mm)


Near (%)

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 curve

Remaining-life

20-28
0

(H)

WELDING

APPLIED

INSTRUCTION

BULLDOZERS

[Example]

4)

AND

DOZER

SHOVELS

Made according to example of entry of


measurement on check sheet (page 20-24)

measuring the wear of the blade in the field,

Table of comparison of wear and


estimated lives of various sections
Tlnx Of meawremenf
Check

it is necessary to report the result and to describe

MAKING
After
the

plan

llil

REPORT

for

repair

or

rebuilding

based on that

result.
The following

items must be entered and described

on the report sheet:


(1)
(2)

The measurements of wear of various sections


Comparison

of

wear

and

estimated

lives of

various sections

i
(3)

Plan for repair or rebuilding

These items should be summed up on one sheet if


possible.
(a)

Measurement

of wear of various sections

Enter the measured value and percentage wear


of various sections on the check sheet described
before

(using the table of percentage wear and

the remaining life curves).


(b)

Comparison of wear and estimated lives of


various sections
Prepare a sheet on which the estimated lives of
various sections can be seen at a glance.

(See

When newly
installed

the example at right.)


*

Refering

When
measured

2350

to the scales at the bottom

sheet, divide the life bars properly.

Service
limit

3550

4350

of the

General-

ly, these bars should be divided so that their


Hour meter

full scale is three or four times longer than

(H)

Remaining

life

the length of the shortest life.


The

Plan of repair and rebuilding

q must be repaired or

sections marked

1.

rebuilt.

q do not need to be re-

The sections marked

Repair/rebuilding
time estimated from the
meawrement~ taken
Estimated hour meter

readlng:

H(

H later)

paired.
Estimated date of repair/rebuilding:

(cl

Plan of repair or rebuilding


A

planning

sheet

should

shows the optimum

repair

must be repaired.

the replacement
should

Determine

Cutting edge to be
replaced.

(21 End bit to be replaced.

If re-

13) Front plate to be


replaced.
(4) Deformation of IOme
sections to be repaired.

parts and the cost of

also be entered

items which should be repaired or rebuilt


(1)

time of repair or rebuilding

and the items which


quired,

2.

be made up which

on this sheet.

the proper time for repair or rebuild-

ing based on the comparison


lives of various sections.
the service limit
shortest life.

sheet of wear and

It must be previous to

of the section which

has the

As the items to be repaired, enter

all the sections which

may reach the end of

their life by the next repair time.


3.

Other remarks

WELDING

20-29
0

APPLIED

INSTRUCTION

BULLDOZERS

AND

DOZER

SHOVELS

Example of inspection report

INSPECTION

REPORT

mrj

Otherremarks

q Table of comparison

:
1

of wear and
estimated lives of various sections

q Plan of repair and rebuilding


1. Repair/rebuilding
time estimated
measurement taken

from the

Estimated hour meter reading


Estimated
Left end bit

20-30
0

n!

( Hlater)

date of repair/rebuilding

2. Items which should be repaired or rebuilt

WELDING

APPLIED

4.
a)

INSTRUCTION

BULLDOZERS

REPAIR/REBUILDING

PROCEDURE

This section describes how blades are rebuilt


workshop.

AND

DOZER SHOVELS

FOR BLADES
in a

This work procedure can be applied to

Work procedure

simplified work or repair in the field.


-1
b)

The blades are repaired or rebuilt according to the


procedure

shown

at right.

The

rebuilding

work

often continues for several days, and the shop space


may be occupied for the entire time.
is very important
an efficient

to perform

procedure.

Therefore,

1lnqx9ztion

it

the work according to

Especially, the materials and

parts must be prepared systematically

to eliminate

waiting time.
c)

The most important

point in the work procedure is

to make a plan of the repair.


of the items to be repaired
before

In many cases, most


have been determined

this stage by previous arrangement.

Tack welding

How-

ever, they should be checked again after the inspection.

The repair work procedure

so that

must be arranged

it can be explained to the customer when-

ever required.
Especially, cracks and excessive wear must be examined carefully,

since they

can make another repair

necessary if they are not repaired at this stage.


d)

Usually,
blade.

it takes two or three workers to rebuild a


The work

procedure

should be determined

so that the workers can work efficiently.


Especially,

all the sections to be welded

must be

tack welded first, then welded by all the workers so


that

the

light made in welding

will

not interfere

with the work of other workers.


It is also necessary to plan the procedure so that the
heavy blade will not need to be reversed.

I ooP602

WELDING

20-31
0

APPLIED

BULLDOZERS

INSTRUCTION

REMOVING

SOIL AND

In order to

AND

DOZER SHOVELS

RUST

inspect the

blade for cracks and

wear, the soil and rust must be removed.


Remove all the soil with a high-pressure washer
or steam cleaner so that no soil will be carried
into the shop.
Remove the rust with

a pneumatic

grinder or

wire brush.

Clean corroded surfaces, worn sec-

tions,

lines of reinforcement

weld

plates, and

wear plates especially carefully.

INSPECTION
Generally,

the wear of major sections of the blade

are measured in the field before the blade is carried

into the shop.

However,

the blade should be in-

spected in detail again in the shop.


This inspection

is very important

the plan of repair.

in order to make

Newly-found

sections must be checked

cracks and worn

in detail.

The result of

the inspection must be recorded to prevent troubles


that may occur after the repair.

Major sectionsto be measured

* Cutting edge
* End bit
* Front plate
- Side plate
- End of bottom plate
* Frame
- Various brackets
* Other sections

Each section must be checked for wear, cracks, and


deformation,

and the condition

of wear of all the

sections must be shown clearly.

These records are

very important

repair or the working condition


(1)

* Straight tilt blade (Large model)

in order to estimate the next time of


of the blade.

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

of wear, the wear of the points

shown in the figure at right (Points A to J) may


be measured as representative.

If the standard

wear plates are installed,

wear must also

their

- Straight tilt blade (Medium/small

be measured.

model)

Standard wear plates

20-32
0

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

If the reinforcement
installed,

their

AND

DOZER

SHOVELS

plates or a pusher plate is

wear

must also be measured.

The cracks or deformation

of the worn sections

must be checked and recorded.

- Reinforcement

- Pusher plate

plate

- Pusher plate

To

measure the wear,

measure the remaining

thickness of the plates with a thickness meter.


*

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

of side plates varies accord-

and the standard

in a different

wear

plate is

way to each model, the

wear of the base metal and wear plates must be


measured separately.
The cracks, deformation,

and falling off of wear

plates must be checked and recorded.

To meas-

ure the wear, measure the remaining thickness


of plates with a thickness meter.

WELDING

Wear plates

20-33

APPLIED

(3)

BULLDOZERS

INSTRUCTION

Tip of bottom

AND

DOZER

SHOVELS

plate

(Tip to install the cutting edge)


The

wear of the tip of the bottom

vances as the cutting edge wears.

plate ad-

If this tip is

worn excessively, the strength of the holes used


to install the edge will be seriously reduced.
New one

(4)

Worn a little

Frame
Since the outside and bottom

of the frame are

subject to the most wear, check those sections


mainly.

Check

all the

sections of frame for

cracks.

To

measure the wear,

measure the remaining

thickness of the plate with


If reinforcement

a thickness meter.

plates (wear plates) are used,

measure their wear, too.

Reinforcement

20-34
0

plates

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

Brackets
Check

AND

DOZER SHOVELS

._
- Installed bracneLs
_I__&_

each bracket

for

damage

and cracks.

The wear of the bore must be checked with


special care.
Check them visually.
To check the wear of a bore, insert

pins in it,

and check the play.

* Rear view of D355

(6)

Cracks and deformation


Visually

check

deformation.

other

Deformation

of other sections
sections for

cracks and

Carefully check the cracks on the

Deformation

weld lines.
The cracks, holes and unevenness of the front
plate are very important
characteristics

symptoms

to see the

of the field where the machine is

being used, and therefore

they

must also be

recorded.

Failing off

Since the deformation

of the side plates and

various protectors detracts from the appearance


of the machine.they
(7)

must be checked carefully.

Recording the results of inspection


The results of inspection
detail.

must be recorded in

A record sheet should be used so that

the result can be recorded easily.


The

record of inspection

is used to plan the

repair, estimate the cost of repair, and estimate


the next time of repair.

Therefore,

the result of

inspection must be recorded so that the overall


wear of the blade can be seen at a glance and
the

repair work

can be planned according to

this record only.

WELDING

20-35
f&

APPLIED

3)

BULLDOZERS

INSTRUCTION

MAKING

THE

REPAIR

AND

DOZER

SHOVELS

PLAN

Usually, most of the items to be repaired are deter-

Items-to be examined when making a repair plan

mined before the machine is carried into the shop.

1. Determination

This section describes how to make a plan for the


repair

work

according to the official

inspection in

the shop.
When

making

the repair plan, examine

and deter-

mine the items shown at right.


(I)

Determination

of items to be repaired and work pro-

cedure
2. Determination

of repair procedure

3. Determination

of man-hours and number of workers

4. Selection

and

preparation

of

required

parts

and

materials

of items to be repaired and work

5. Preparation of required facilities and tools

procedure
Determine
the

the items to be repaired according to

inspection

record

and the customers

in-

structions.
The most important

purpose in this stage is to

select the items and work procedure

according

* Replacement

of wear plate

to the features of the field where the blade will


be used and the kind of work to be done with
the blade.
.

Replacement

of the front

tion of a reinforcement
The front
the

plate or installa-

plate

plate can be repaired

following

methods,

Removal of present
wear plates

by one of

depending

on the

level of wear or damage and the conditions


of use.
i)

Replacement
forcement

or

installation

If the reinforcement
significantly
Most

a rein-

plate (wear plate) is

worn, it should be replaced.

large models

method.

of

plate (wear plate)

are repaired

by this

The wear plate must be replaced

before the base plate starts to wear (before a hole is made on the wear plate al-

Reinfocement plate
(wear plate) for front

lowing the base plate to be seen).

Spare plates are

standard

replacement

plate,

Use the

or make a

special one if required by the customer.


Main work:
a) Removal of present wear plate
b) Welding of a new wear plate
Material and parts:
a) Reinforcement

plate for front plate

D80A or larger mod


Standard wear plates
for corners.
Spare plates are available.

b) Standard wear plates for corners


Reference
D155A

D65A
a) Material

of front
reinforcement plate

KES SHTGO
ASTM A51 4-65(G)

Thickness

9mm

Welding rods

JIS D5016,

b) Material of corner wear plate


Thickness
Welding

20-36
@

KES SHTI IOA


High tensile rolled steel
(Tensile strength: 110 kg/mm*

class)

12mm
AWS E7016

JIS D5816,

AWS E9016

KES S53C, ASTM


@

=12mm,

JIS 05016,

A576-1049
@

=22mm

AWS E7016

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

Installation

ii)

of reinforcement

* Installation

plates

AND

DOZER SHQVELS

of wear plates to the base plate

(wear plates)
If

the

standard

without

blade

has been

reinforcement

used

plates

(wear

plates) and it has not worn much, it can


be repaired by this method.

In the same

way as in the replacement

of the rein-

forcement
wear

plates described before,

plates

are installed

the

to the worn

base plate.
Main work:
a) Welding of new wear plates
Material and parts:
a) Front reinforcement

plates

If the standard wear plates


of the corners are worn, replace them with new ones.

iii)

Reinforcement

of the ribs of the base

- Reinforcement

of ribs of base plate

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

which do not receive impact loads.


Install

the

the worn

reinforcement

rib plates to

sections or holes where

wear plates will

be welded.

the

The wear

plates can be welded as described before.


Weld line

Main work:
a) Welding of reinforcement

ribs

b) Welding of new wear plates


Materials and parts:

a) Front reinforcement plates


b) Standard wear plates for corners
cl Reinforcement rib plates

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

of front plate from back

side
If a blade which
pact

receives frequent

loads is worn

scribed

before,

excessively

im-

as de-

it should be reinforced

from both the back side and front side.


In this repair, several holes are made on
the back side of the blade, and the ribs
and front

plates

forcement

through

welding

them,

are welded

for

those holes.

reinAfter

the holes are closed by

the welding plates.


Main work:
a) Removal of present plates
b) Welding of reinforcement
c) Welding

for

ribs

reinforcement

from

back side
d) Restoration

Reinforcement of welded
sections of front plates

of back side

Material and parts:


a) Front reinforcement

plates

b) Standard wear plates for corners


c) Reinforcement

rib plates
Reinforcement
plates

d) Plates to cover holes on back side


* Reinforcement

from back side

Make holeyto weld for reinforcement

* Restoration

of back side

all plates to cover the holes

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

Since the side plates are installed to drive the


blade straight and prevent the soil from spilling from the two sides, they must be repaired carefully.

In addition, since the deforma-

tion of these sections detracts from the external appearance of the blade, they must be
replaced

or

covered

with

reinforcement

plates during the repair.


There are two types of plates to prevent the
soil from
right.

spilling,

as shown in the figure at


u
Wear plates @

On large models, the plates are welded

to the blade, on medium and small models,


the

side plates are lengthened

forward

to

prevent the soil from spilling.


i)

Replacement

of plates of large models

Wear plate

If the plates are not worn much, replace


$

only the wear plates and the plates to prevent the soil from

spilling.

If the side

plates of the blade are also worn,


the

unit-type

reinforcement

install

plates, then

- Replacement

of side plates (Large models)

install wear plates to the bottom of them.


Main work:
a) Removal of present plates
b) Installation

Removal of present plates

of plates to prevent soil

from spilling
c) Installation

of wear plates

Material and parts:


a) Plates to prevent soil from spilling
or unit-type

plates

b) Lower wear plates

Reference
D155A
@

Material of plate to

KES SM416

prevent soil from spilling

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

- Replacement of plates (Medium and small models)

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-

\:

cedure because of the time required.


If the present wear plates are not worn
much, remove them.

Then install unit-

type plates from outside.


If the sections to prevent soil from spilling are significantly

worn or deformed,

gas cut those sections according to the


form of the front face, then weld semicircular

plates

and

weld the unit-type

rib

plates.

Next,

* When significantly worn or deformed:

plates from outside,

and weld the wear plates to their

bot-

tom.
Main work:
a) Gas cutting the present plates
b) installation

of sections to prevent

soil from spilling and rib plates


c) Installation

of unit-type

d) Installation

of lower wear plates

plates

Material and parts:


a) Plates to prevent soil from spilling

b) Rib plates
cl Unit-type plates
4 Lower wear plates

Reference
D65A
@

Material of plate to

KES SS41 P

prevent soil from spilling

AMST

Material of wear plate

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

of tip of bottom plate

the wear of this section is affected

by the maintenance

condition

of the cutting

edge, it should be reinforced

regardless of its

level of wear when the front

plate is repair-

ed.

AND

Gas cut the top, then reinforce

square bars.

The mounting

end bits should

it with

sections for the

be reinforced

in the same

way.
Main work:
a) Gas cutting the tip
b) Reinforcement

with square bars


Cut the tip

Material and parts:


a) Square bars

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

plate (wear plates) on the

frame or the base plate of the frame is worn,


repair with this simple method.
Main work:
a) Removal of present outside and lower
plates
b) Installation

of reinforcement

plates

Material and parts:


a) Outside

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

If any bracket is significantly

worn or dam-

aged, replace it.


Main work:
a) Gas cutting of worn brackets
b) Installation

of new brackets

Material and parts:


a) Brackets (to be supplied as spare parts)

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

welding the brackets,

be sure to preheat and

postheat them to prevent cracking.


Preheating
temperature

Postheating
temperature

KES S43C
ASTM A576-1040

150 to 200C

590 to 680C

Cast steel

100 to 2ooc

200 to 250C

Material

Do not strike an arc on cast brackets before starting


welding.

* When welding a cast bracket to the base metal, aim


the first layer at the bracket and the second layer at
the reinforcement
penetration

20-42
0

part so that there will be sufficient

at the root.

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

AND

DOZER SHOVELS

Repair of cracks and deformation

If any bracket is cracked or deformed,

repair

it by welding.

Reference

Welding rods @

JIS D5016

JIS D5816

AWS E7016

AWS E9016

JIS 05816
AWS E9016

When

welding the brackets,

be sure to preheat and

postheat them to prevent cracking.


Preheating
temperature

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

. Turning the blade and main works

Work procedure
After

AND

determining

the items to be repaired and

how to repair them, examine the repair procedure.


Pay

special

consideration

to

the

following

points.
a)

Blades are large units, and turning or positioning

them

is dangerous work.

tion,

many man-hours

pair

them.

are required

Therefore,

Remove the side plate


and tack weld the new

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

at the same time

welding

should be done by all


after tack

so that the other workers are not

disturbed by the arc and so that the blade


will

not

be subject

to

strain

in certain

upper end of the

areas.
(3)

ly weld the upper

Preparation of materials and parts


Prepare the required materials and parts in advance in order to minimize waiting time.
Generally,

the basic materials and parts should

be prepared

before the machine is carried into

the shop, and all the required materials should


be ready when starting the repair.
used materials

Frequently-

and parts should be stocked in

Replace brackets

the shop so that sudden changes in the repair


work will not cause a change in the schedule.
Since

the

blades

must

be strong

and wear-

Perm
weld

ir back side of tip

resistant, the correct materials must be used.


(4)

anently weld upper


end of side plate

Preparation of facilities and tools


To

prepair the blades rapidly

pare special facilities and tools.

and safely,

prePermanently weld upper end of side Plate

Permanently weld upper


,end of side plate

Gas cut and shape

20-44
0

WELDING

APPLIED

4)

INSTRUCTION

MAKING

THE

BULLDOZERS

FRONT

PLATE

For the usual rebuilding


forcement

OF

AND

DOZER

SHOVELS

A BLADE

of a blade, the spare rein-

plates (wear plates) can be used.

How-

ever, if customers request you to use specially-made


plates, make them according

to the following

pro-

cedure.
(1)

Determine

the thickness of the plates

Use plates which have the same thickness as the

new base plate.


(2)

Cutting materials
al Measure dimensions A (length of arc) and B
of the blade to be repaired.
b) Examine

how to cut the material by looking

at the standard

plate and observing the fol-

lowing points.
i)

Divide

the

front

pieces

as

possible

plate

into

to

as many

increase

the

strength of the blade by increasing the


number of welding lines.
ii)

Decide

the

dimensions

of

the

plates

according to the capacity of the bending


machine, that is, if the bending power is
small, the width

of the plates must be

reduced.
iii)

Cut

the

plates 50 to

than dimension

100

mm

A so that they

longer

Adjust according to the thickness of the plate

can be

cut and shaped after welding.


c) Line the material

carefully

to maximize

its

yield.
When

drawing

allowance
in.

lines on the

for gas cutting

material,

the

must be counted

(The distance between

the plates must

be changed depending on their thickness and


welding methods.)
*

Even if the material

is cut accurately, the

crosswise dimension

often

it

is welded.

Therefore,

changes when
the crosswise

dimension of one plate must be increased


so that

At the end of tack welding, gas cut this portion


adjust the overall width of the plates.

it can be cut with gas at the end

of the blade to adjust the overall width of


the plates.

WELDING

20-45
0

APPLIED

(3)

BULLDOZERS

INSTRUCTION

AND

DOZER

SHOVELS

Cutting material
Cut the material

according to the lines drawn

on it.
Since the
they

automatic

(4)

front

plates are large and straight,

can be cut evenly

and rapidly

with

an

gas cutter.

Making a paper pattern of the bending radius


Make a paper pattern of the bending radius.
The

wear

condition

of the

front

surface of

blades varies greatly with the properties of soil

AA

at the site and the kind of work

1R

Therefore,

the

paper pattern

being done.

of the

bending

-50-

IOOmm
Cut longer than the blade.

radius of the blade should be made based on


the radius of the blade to be repaired.
Prepare a sheet of cardboard or vinyl paper, and
cut it into the rough shape.of the,~blade with a
width of 50 to 100 mm.
Prepare paper patterns of rough shape of all the

Rough shape paper patter


Cut longer than the

models so that any one can be reproduced.


Placing the

rough paper pattern

on the front

face of the blade, shape it correctly


little

by cutting

by little with a pair of scissors.

Looking

from the side of the blade, cut off the parts of


the paper pattern which contact the blade.

Cut off the contacting parts

Mark the starting points of the bend.


Starting points of the bend

20-46
0

WELDING

APPLIED

6)

BULLDOZERS

INSTRUCTION

AND

DOZER

SHOVELS

Bending the plates


Use a bending roll to bend the plates.
Mark
end

the starting
face of the

points

points of the bends on the


plates

so that

the

can be seen from the control

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

modify them by tack welding

to fit them to the surface.


The plates whose bending radius is small can be
modified

more easily than ones whose bending

radius is large.

Therefore,

the plates should be

bent to a radius a little smaller than specification to compensate for various errors.
In addition,

if the bending radius of the plates

is too large, the gap between the plates and base


metal cannot
Therefore,

be eliminated

or checked easily.

the plates should be bent to a smallRadius is too large.

er radius as described above.

Radius is too small.

* Correction

of too-large radius

Tack welding
\

Press the center (Requires a force double


that needed to correct a too-small radius.)

* Correction

Tack welding
\

WELDING

of too-small radius

Press this section and fix it by tack welding.


\

20-47
0

APPLIED

5)

BULLDOZERS

INSTRUCTION

EXAMPLES OF REPAIR AND


OF BLADES
All

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.

Since special high tensile steel is used for the blades,


they must be welded carefully.
For the preheating

method and selection of welding

rods, see the 01 GENERAL

INSTRUCTIONS

in

this Shop Manual.


(1)

Carrying in the blade


Remove the blade from the frame

and yokes,

then set the blade with its front face up.

Use

blocks (stands) to position the blade.


(2)

Removing the cutting edge and end bits


Remove the cutting

edge and end bits.

If the

nuts are severely worn, cut them off with gas to


simplify

the work.

In such a case, the nut must

be cut several millimeters

from the washers so

that the base metal will not be damaged.

(3)

Removing the worn front plates


i)

Remove the worn front plates by gas cutting


along the weld lines.
plate in alternation

Melt and blow off the

along the weld lines.

Take care not to damage the bbasemetal, and


cut the plates neatly so that the new plates
can be installed without

modifying

the base

metal very much.

20-48
0

WELDING

APPLIED

ii)

BULLDOZERS

INSTRUCTION

Slanting

surfaces must be cut from

AND

DOZER.SHQVELS

up to

down.

Before cutting the plates, confirm

that

no workers are within reach of the spatters.

(4)

Removing the worn side plates


i)

Remove the worn side plates (which prevent soil from spilling) by gas cutting.

WELDING

20-49
0

APPLIED

(5)

INSTRUCTION

BULLDOZERS

AND

DOZER

SHOVELS

Removing the side wear plates


i)

Remove the side lower wear plates by gas


cutting.
Cut neatly along the weld lines so that no
modification

ii)

Remove

will be required.

all the other

side reinforcement

plates to bare the base metal.

(6)

Grinding

i)

Use a grinder

(pneumatic

disc sander) to

remove the spatters made by gas cutting.

ii)

Remove

the projections

on the cut lines

with a grinder so that the new plates can be


fitted on them.
The

corners

must

be ground

especially

carefully.

20-50
0

WELDING

APPLIED

INSTRUCTION

iii)

BULLDOZERS

Grind the places from which the side wear


plates were removed.

(7)

Preparing for tack welding of the front plates


i)

Weld the

reinforcement

rib plates to the

thinned places or holes on the base plate.


Reinforcement

ii)

rib plates

If the upper end of the blade is made of


one plate, it will often be deformed.

If so,

cut it with gas, then shape it.

If this section is deformed,


the front plates cannot be
fitted to the base plate easily.

(8)

Preparing the front plates


Carry

i)

and place the bent front

plates on

the blade, using an overhead traveling crane


and clamps.

WELDING

AND

DOZER,.SHO\IELS

APPLIED

INSTRUCTION

ii)

Set all the

BULLDOZERS

plates on the

AND

DOZER

SHOVELS

blade to check

their size and shape.

Fitting

(9)

the front

ends of the front

plates by

tack welding
Position the plates on the cutting edge, taking
account of the fitting

allowance,

then fix them

at both sides by tack welding.

Plate to be installed

Base plate

(IO) Fitting

the center of the front

plates by tack

welding
i)

Weld the special plates to the base metal


(or to the adjacent
fitted

plate,

by tack welding)

if it has been

in order to snugly

fit the center of the front plate to the base


plate,

drive

in wedges, and perform

tack

welding.
Plate to be fitted
, by tack welding

Special plate
te or front plate
which has already been fitted

ii)

Many

special plates and wedges must be

made in advance.
iii)

To fit the front

plates to the base metal,

hit the portions near the weld zone with a


sledge hammer while they are still hot just
after welding.

20-52
0

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

(11) Fitting

the upper ends of the front

AND

DOZER

SHOVELS

plates by

tack welding

i)

To fit the front


weld

plate to the base plate,

small plates to the base metal,

and

clamp the upper end of the plate with a Cclamp.

C-clam
late to be installed

ii)

Weld the special plates to the upper end of


the base plate (or to the adjacent plate, if it
has been fitted

by tack welding)

to fit the

plate to the base plate, drive in wedges and


tack weld.

iii)

If the interval with the adjacent plate is not


sufficient,

(12)

gas cut the plate to repair it.

Drawing lines on the tip of the blade


i)

To prepare for the reinforcement

of the tip

of the blade, draw lines to cut off the tip


with

gas.

Use white

chalk to draw the

lines.
25 -3Omm

Gas cutting line


\~

FittLng hole

WELDING

20-53
0

APPLIED

INSTRUCTION

If the fitting

ii)

BULLDOZERS

AND

DOZER

SHOVELS

sections for the end bits of a

medium or small model are severely worn,


do not draw

lines in alignment

with the

cutting edge, but bend them outward along


the worn surfaces.

Line bent outward

o__-__0
t-

(13)

l- __-__-___
Cutting edge

End bit

Gas cutting the tip of the blade


i)

Gas cut the tip of the blade, using guide


blocks.

ii)

Prepare

guide blocks with

handles in ad-

vance.

(14)

Grinding the cut surfaces of the tip of the blade


Finish

the

(pneumatic

cut

surfaces with

a hand grinder

Prepare the edges to be

sander).

welded with a grinder.

(15)

Installing

reinforcement

square bars to the tip

of the blade by tack welding


i)

Temporarily

install

base plate.

Using this plate

align the fitting

a small

plate to the
as a guide,

face of the cutting

edge

with the surface of the square bar, then install the bar by tack welding.

The sections

of the square bar to be welded

must be

prepared the edges for welding.

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

distance with wedges.

iii)

Fix the square bar from

the back side by

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

with the outside surface of

the side plate which will be installed later.

dutting line

(16)

&are

bar

Grinding the fitting surface of side plates


If the side plates and rib plates of a medium or
small model were cut with
surfaces with
er).

WELDING

gas, finish the cut

a hand grinder (pneumatic

sand-

AND

DOZE6

SHQVELS

APPLIED

(17)

BULLDOZERS

INSTRUCTION

AND

DOZER

SHOVELS

Making a paper pattern of the side plates


Make

rough

plates with

paper

Since

paper.

patterns

of the

a sheet of cardboard
only

side

or vinyl

a rough shape is re-

quired, make the pattern using the cut side


plate.

Place the paper pattern


correct
from

it.

Looking

on the blade, and

at the paper pattern

the side, cut its sections which con-

tact the blade little by little.

(19)

Drawing the pattern of side plates


Draw

the shape of the side plates with

white

chalk

according

Draw

two

to the

side plates for

paper

pattern.

both sides with the same

pattern.

(19)

Cutting the side plates


i)

Gas cut the side plates along the drawn


lines.

If a special bed is available,

the side

plates can be cut off rapidly.

20-56
0

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

ii)

AND

DOZER

SHOVELS

Finish the cut surface with a grinder, then


place the plates on the blade.
Mark the sections which need to be modified.

iii)

Place the plates on the blade and modify


them finely

by cutting the sections which

contact the blade little by little.


modification,

After the

prepare the edges for weld-

ing.

(20)

Installing the side plates by tack welding


Align

the side plates to be installed with the

side of the base plate, then fit them

by tack

welding.

I ooP850
(21)

Permanently

welding the side plates

~ The semicircular rib plates will be welded from


inside, and the unit-type

plate will

be welded

from outside.

IOOP85

WELDING

20-57
Co

APPLIED

(22)

BULLDOZERS

INSTRUCTION

Installing semicircular
Make

two

pattern

AND

DOZER

SHOVELS

plates by tack welding

semicircular

plates

using a paper

made in the same way as for the side

plates.

Semicircular rib plate

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

side plates must be made a little larger than the


side plates of the base plate taking into account
the fillet welding allowance (dimension a).

a
(24)

Drawing the lines of the unit-type


According

to the paper pattern,

of side plates on the


Make

20-58
a

two

plates

side plates
draw the lines

material with white chalk.

using the same pattern.

WELDING

APPLIED.

(25)

BULLDOZERS

INSTRUCTION

Cutting out the unit-type


i)

AND

DOZER

SHOVELS

side plates

Cut out the unit-type

side plates according

to the drawn

When

lines.

cutting

along

straight lines, use guide blocks.

ii)

Since the side plates of a large model are


large, use an automatic

(26)

Installing unit-type
i)

ii)

Finish

side plates by tack welding

fitting

surface

grinder (pneumatic

sander).

Hang

the

gas cutter.

the

side

plate

with

with

an

a hand

overhead

traveling crane and clamps, and install it to


the base plate by tack welding.

WELDING

20-59
0

APPLIED

iii)

BULLDOZERS

INSTRUCTION

If the side plates cannot

be fitted

AND

DOZER SHOVELS

to the

sides of the base plate, use large-sized Cclamps.

,,
, : ,,:,
,, &Jcsmso

(27) Repairing the fitting plates for end bits


i)

If

the

corners

are severely

worn,

repair

them by installing plates.

ii)
iii)

Gas cut and shape the thinned tip.


Install

the proper plates to the triangular

spaces by tack welding.


iv)

After

installing the plates by tack welding,

cut off the tips in alignment

with the side

faces.

v)

Fix the

plates by tack welding

from the

back side, too.

20-60
0

WELDING

APPLIED

(28)

BULLDOZERS

INSTRUCTION

Installing special side plates by tack welding


*

If

requested

more

by the

reinforcement

customer,
plate

install one

over each unit-

type side plate.


i)

Draw the fitting


ment

position of the reinforce-

plates on the

unit-type

side plates

with white chalk.

ii)

Draw the lines of the reinforcement


on the rest of the material

plates

of the cutting

edge.

iii)

Cut out the reinforcement

plates according

the drawn lines. Cut them out carefully so


that they

can not interfere

with the wear

plates at the bottom of the side plates.

iv)

Install the reinforcement

plates to the unit-

type side faces by tack welding.

WELDING

AND

DOZER

SHOVELS

APPLIED

(29)

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

installing wear plates to the bottom of the side


faces
Make the wear plates for the bottom of the side
faces, and install them

by tack welding.

The

wear plates must be made a little larger than the


unit-type

side plates taking

into

account

the

fillet welding allowance (dimension a).

Special side plate

S&are bar at tip

a
Lower wear plate

(30)

Permanently

welding plates with the front sur-

face of the blade up


Weld all the sections which can be welded with
the front

surface of the blade up (i.e., which

can be welded in the flat position).


ing the
change
times

round
the

angle of the

so that

When weld-

sections of the front


they

blade two

can be welded

surface,
or three

in the flat

position.

When welding

the side wear plates, preheat

them at 2OOC.

20-62
a

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

ANI)

DOZER

SHOVELS

Permanent welding

Unit-type side plate


wb,Side

plate

Section A-A

(31)

Grinding permanently-welded
Finish

the

weld

lines

sections

and

their

periphery

smoothly with a grinder.


t

After

welding

permanently,

lines smoothly
concentration

(32)

Permanently

finish the weld

with a grinder to prevent the


of stress.

welding

plates with

the blade tip

UP
With the blade tip up, weld all the sections of
the unit-type

side plates and the wear plates at

the

of the

bottom

side faces which

can be

welded in the flat position.

Permanent welding

Side plate of unit type

Section A-A

(33)

Permanently

welding

plates with the back side

of the blade up
i)

With the front


ed over),
welded

WELDING

surface

of blade down

weld all the sections


in the flat

which

(turncan be

position.

20-63
a

APPLIED

BULLDOZERS

INSTRUCTION

ii)

Permanently

weld

the

upper

section

AND

DOZER SHdVELS

of

blade and the square bars at tip of blade.

Permanent weldi

iii)

If there are gaps among the plates, fill them


with

round

bars, then weld them

perma-

nently.

Permanent welding

Unit-type side plate

Saction A-A

(34)

Preparation for replacement


The fitting

of brackets

positions qf the brackets are shown

below for reference.

For details, see the Shop

Manual.

20-64
0

WELDING

APPLIED

(36)

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

Removing worn brackets


i)

Remove the worn

brackets by gas cutting

them along the weld lines.

ii)

Melt and blow off the weld lines in alternation to remove the brackets.

iii)

The brackets must be removed carefully so


that the base plate will not be damaged and
the cut surface will

not require

modifica-

tion.

iv)

After

removing the brackets, eliminate

the

unevenness of the cut surface.


Finish the cut surface with a grinder (pneu-

v)

matic sander).

(36)

Installing the brackets


Install the brackets to the correct positions by
tack welding, then weld them permanently.
*

When welding the brackets,

be sure to pre-

heat and postheat.

*
*

Do not strike an arc on the cast brackets.


When welding the cast brackets to the base
plate, aim the first layer at the bracket and
aim the second layer at the reinforcement
plates so there will be sufficient penetration
at the root.

WELDING

20-65
0

APPLIED

(37)

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

Repairing cracks and deformation


i)

The fitting

sections of the protectors must

be reinforced

by welding since they may be

cracked or deformed

ii)

If

any

fitting

by rocks.

section

of the

bracket

is

cracked, repair it by welding.


*

Gouge the cracked section, finish it with


a grinder, and recheck for cracks.

iii)

Remove

the burrs and projections

hand grinder (pneumatic

iv)

with

sander).

If the tilt yoke stopper has been removed,


make

a new stopper

by bending

a steel

round or square bar.

20-66
0

WELDING

APPLIED

(38)

BULLDOZERS

INSTRUCTION

Permanently

welding

plates

with

the

AND

DOZER

SHOVELS

blade

stood up
i)

With
end

the blade stood up, weld the upper


of the

unit-type

side plate and the

upper end of the special side plates.


*

Before welding,

be sure to preheat at

2oo c.

ii)

Weld the

upper

end and tip of the wear

plates at the bottom of side faces.

(39)

Modifying

the blade with the front surface of

the blade up
i)

Set the
again,

blade

and

with

cut the

its front
extra

surface

portion

up

of the

front plate with gas.

ii)

Finish

the

cut

surface

grinder (pneumatic

WELDING

smoothly

with

sander).

20-67
0

APPLIED

(40)

BULLDOZERS

INSTRUCTION

AND

DOZER

SHOVELS

Installing a cutting edge


Grind the fitting

section for the cutting edge,

then install the edge.

(41)

Installing end bits


Grind the fitting

section for the end bits, then

install the end bits.

(42)

Replacing the frame bracket


Remove

the

worn

bracket

along the weld line.


by tack welding,

by gas cutting

it

When setting the bracket

check the center of bore of

the bearing and the frame for squareness.


*

When welding
heat

and

the bracket,

postheat

be sure to pre-

to prevent

cracking

of

the weld zone.


Material

Preheating
temperature

Postheating
temperature

KES S43C
ASTM A576-1040

156 to 2OOC

596 to 66OC

Cast steel

100 to 2ooc

200 to 250c

(43)

Replacing the outside wear plates of the frame


i)

Cut off the present wear plates on the outside of the frame with
new wear plates.

20-68
0

gas, then weld on

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

ii)

Extend

the weld

AND

DOZER.

SHOVELS

line at the end of the

plates to prevent concentration

of stress.

P895

Replacing

(44)

wear

plates at the bottom

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

holes at the center

of the

wear plate and weld those sections so that


the plate will not come off even if the outside weld line wears out.
After welding, cover the holes.
Base plate

Section

(45)

A-A

Painting the blade


Paint the blade assembly before or after installing it.

I OOP897

WELDING

20-69
a

APPLIED

BULLDOZERS

INSTRUCTION

AND

DOZER

SHOVELS

BUCKET
1.

TYPES

1)

Type and uses


(a)

AND

USES OF BUCKETS

Large bucket
The volumetric

capacity

larger than that


fore,

of the large bucket is

of standard

buckets.

There-

it is used to load and carry soil or coke

whose specific density is low.

IOOF365

lb)

Rock bucket
The

rock

standard

bucket
bucket

is made
so that

stronger

than

the

it can be used to cut

and load rocks.

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

can dump cross-wise as

Therefore,
the

in a narrow

direction

it can dump withof

the

machine

place such as in a tunnel.

Thus, the cycle time is short and the efficiency


is high.

lOOF

(e)

Three-way

bucket

While the three-way


one

direction

only

bucket
(left

can dump toward

or right),

the three-

way bucket can dump toward any side.

lOOF

(f)

Multi-purpose

bucket

The bottom of the multi-purpose


opened.

This bucket

by closing the bottom,


and closing the bottom,

bucket can be

can by used for loading


for scraping by opening
and for dozer work by

opening the bottom.

lOOF

WELDING

20-71
a

APPLIED

2)

BULLDOZERS

INSTRUCTION

Major materials of buckets (Example:

AND

DOZER SHOVELS

D75SI

* The materials and dimensions of products are subject


to

change without

improvements

notice

of technology

in order to incorporate
or for reasons of manu-

facture.

Metal group

SCMnMoH

KES symbol

High tensile strength rolled steel plates


for welded structure

20-72
a

SHTGO, SHT80,

Low alloy steel casting

SCMnMoH

Manganese steel for machine structure

SMnlH

Carbon steel for machine structural

s45c

SHTl IOA

WELDING

APPLIED

2.

INSTRUCTION

BULLDOZERS

REPAIR/REBUILDING
Various

PROCEDURE

DOZER .SHOVELS

BUCKETS

types of buckets are used according to the

model and type of work.


cedures of buckets differ
below

FOR

AND

describes

how

to

Therefore,

the repair pro-

in every case. The section


make

repairs which

are

often needed.

,I

Inspection of buckets

1)
.

It is very important
its condition

to inspect a bucket to find out

of wear before repairing or rebuilding

it.
Inspect the following

items to determine

how to
I OOP899

repair the bucket.


(a)

Wear or breakage of tooth (I)

lb) Wearofcorners

(2)

(c) Wear of tip of cutting edge (3)


(4

Wear of surface of edge (edge fitting face) (4)

(4

Wear

of

inside

surface

(5)

or reinforcement

plate (6)

(f) Wear of side blade (7)

(9)

Wear of side plate (8)

(h) Cracking

and deformation

of

upper

edge of

bucket (9)
Ii)

Play and wear of boss for bucket (10)

(i)

Wear of bottom

of bucket

(11)

100P900

or wear plate

(12)
(k)

Cracking and deformation

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)

If the edge between

the teeth

worn,

build-up

repair

it

by

is not so
welding

as

described below.
[Welding rods for building up]
JIS DF2B-B

* Hard facing welding rod:

AWS not applicable


* Select hard facing welding rods which will
be deposited

as martensitic

metal

that

strongly resists wear by soil and sand.


. Before using the welding rods, dry them
at 300 to 35OC

for 30 to 60 minutes.

Preheat the base metal at 2OOC.

(2)

Weld plates by matching them to the form


of the worn sections, then weld their surface with hard facing welding rods.
[Welding

rods for building

up/low

hydro-

gen type mild steel welding rods]


JIS DFZB-B

* Hard facing welding rod:

,AWS not applicable

* Select hard facing welding rods which will


be deposited

as martensitic

metal that

strongly resists wear by soil and sand.


* Low
rod:

hydrogen

type

JIS D4316,

mild

steel welding
* Preheat at 2OOC.

AWS E7016

* Before using the welding rods (hard fac-

(b)

*Weld the plates with low hydrogen type

ing and low hydrogen types), dry them at

welding

300 to 35OC for 30 to 60 minutes.

hard facing welding rods.

rods, then

build

them

up with

Replacing edges and corners


upport or turnbuckle

if the surface or tip of an edge or the corners


are worn extremely,
*

replace them.

Spare edges and corners are available.

(1) Cut

the

weld

lines

between

the

edges

corners, and body of the bucket to remove


them.

(2) Finish the cut surface with a grinder, then


install new corners and an edge.
(3)

Weld permanently,
l

Welding rod:

then install the teeth.

JIS D5816,

AWS E9016

* Preheat at 200 to 25OC.


Side plate
.
/
Corner

Section A-A

20-74
0

&+
Section B-B

of body

kcornar
Section C-C

WELDING

APPLIED

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

(cl Replacing the inside bottom plate


If the flat bottom

plate in the bucket is worn

excessively, replace it, too.

Since difficult

work

such as bending the plate are not required, this


plate is often replaced.

(1) Gas cut the bottom plate in the bucket at


the end of its fiat
round

section)

reinforcement

section

together

(beginning

of

with the bottom

Ed

plate.

Bottom reinforcement plate

a
/\

(2)

Cut the reinforcement


the bottom

plate shorter from

side to remove the worn secCut the reinforcement plate here.

tion.
(3)

Prepare the replacement


inforcement

plate,

bottom

bottom

plate, re-

wear

plate,

corners and edge.


(4)

Finish the cut surface with a grinder, tack


weld

bottom

plate

(1).

corners

(2)

and

edge (3), then weld them permanently.


An example of D75S is shown on the next page.
(5)

Install bottom

reinforcement

plate (4) and

wear plate (5) by tack welding, then weld


them permanently.

For tack welding and


nent welding, use a
rt or turnbuckle.

WELDING

20-75
0

APPLIED

INSTRUCTION

BULLDOZERS

AND

DOZER SHOVELS

For step (4)


Example:

D75S

einforcement plate

. Material

Section A-A

Cutting edge:
Bottom plate:
Reinforcement

KES SMnl H
KES SHT80
plate:

KES SHT60

Fig. 1

Welding rod:

JIS D.5816, AWS E9016

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.

- Preheat at 200 to 25OC. and keep the


temperature
or above.

of the base metal at 15OC


After

welding,

cool the weld

zones gradually.

i)

Bevel the edge of the bottom


35

plate to

(leave 2 mm of lower section) as

shown

in

Fig.

1,

then

finish

the

beveled edge smoothly with a grinder.


ii)

Install the cutting edge to the bottom


plate by tack welding.

iii)

To prevent the strain caused by welding, temporarily

weld

plate@to

the

bottom plate and cutting edge.


iv)

Build

up section @ and @ shown in

Fig. 1 by welding.
v)
vi)

Weld the reinforcement


Remove plate@

plate @

and finish the welded

surfaces with a grinder.

20-76
0

WELDING

APPLIED

(d)

BULLDOZERS

INSTRUCTION

Replacing the round section of a bottom

AND

DOZER

SHOVELS

plate

If the inside of the bucket is worn extremely

up

to its round section, the round section must be


repaired,

Since this repair requires high

too.

technique,

have a skilled worker do it.

Especially,

care must be used in finishing the

cut surface, determining


welding

method

the weld lines, and the

for the ribs so that stress will

not be concentrated.
.
IS

(1) Gas lcut the inside bottom


bucket
section.

Cut th,erib

plates on the rear side

along the weld line< of the


but

plate of the

by the proper point of the round

keep them

bottom

installed ,to the

plate

bottom

plate.

(2)

Prepare
plate,

the

replacement

reinforcement,

bent

plate,

plate, corners and edges.

bottom

bottom

wear

Finish the cut surface with a grinder, and

(3)

install

bottom plate

(I),

corners

(2) and

edge (3) by tack welding, then weld them


permanently.
Install bottom

(4)

reinforcement

plate (4) and

wear plate (5) by tack welding, then weld


them permanently.
Finish the welded surfaces with a grinder,

(5)

then install the teeth.

Replacement
edge

Replacement corner

WELDING

20-77
0

APPLIED

BULLDOZERS

INSTRUCTION

(e) Replacing the inside reinforcement

AND

DOZER

SHOVELS

plates (wear

plates)

(1) If the inside reinforcement


plates)

of the

bucket

plates (wear

are worn,

remove

them with gas to install new plates.


[Reference]
Wear plate of D75S
Material:

KES SHTGO or KES SS41P

Thickness:

9 mm

Welding rod:

JIS D5016

(2) To make the reinforcement

(AWS E7016)

plates, bend a

plate with a bending roll, then cut it to the


proper width.
for

When bending with a press

sheet metal

proper

width,

work,
then

cut the plate to a

bend it changing

its

position little by little.

(f)

Replacing side plates and side blades


If the side plates and side blades of the bucket
are worn,

cut the worn

plates along the weld

line with gas to replace with new plates.


(1)

Remove

the side plates by cutting

along the weld

lines with

gussets of

corners

the

gas.
installed

them

Keep the
to

the

bottom plate.

SUPPOK

or
turnbuckle

(2)

Prepare

the

replacement

side plates and

side blades.
(3)

Finish the cut surfaces with a grinder, and


install side plates (1) and side blades (2) by

(1) Replacement side plate

(2) Replacement side blade

tack welding, then weld them permanently.


(4)

Finish the welded surface with a grinder.

[Reference]

D75S
(1)

Material

Side plate

KES SHTGO

Thickness

9mm

(2)

Side blade

KES SHTI 10A


19mm

- Welding rod: JIS D5816, AWS E9016


- Preheating temperature: 200C

20-78
0

WELDING

APPLIED

(g)

BULLDOZERS

INSTRUCTION

Preventing the deformation


While

AND

DOZER

SHOVELS

of the budtet

replacing the inside plate or side plates

of the

bucket,

the opening

often

made wider.

port

or turnbuckle.

of the

Generally,

the bucket is ready to open.


little

narrow

bucket

is

To prevent this, use a sup-

with

the center of

Therefore,

a support

set it a

or turnbuckle

when replacing the plates.


If the bucket whose center is projected
opening
will

is widened)

wear

rapidly

(whose

is used, its central section

and the

life of the

rebuilt

bucket will be shortened significantly.


* Example of turnbuckle
Trapezoidal thread

(h)

Replacing

the edge of the upper plate of the

budtet
The

edge of the upper plate of the bucket

often

cracked

or deformed

Since the deformation


from the appearance

line

is

because of rocks.

of this section detracts


the bucket,

it should be

replaced if possible.
(1)

Remove the edge of the upper plate with


gas.

(2)

install

the

replacement

plate

by

tack

welding.
[Reference]

Edge of upper plate of D75S

Material

Thickness:

KES SHT80

9 mm

Welding rod:
(3)

or SS41 P

JIS D5816,

Install the reinforcement

AWS E9916
plates to the out-

ermost edges from the rear side, and install


several rib plates vertically
(4)

Weld

them

by tack welding.

permanently,

then

finish

the

welded edges with a grinder.

I ooP907

WELDING

20-79
0

APPLIED

(i)

INSTRUCTION

Replacement

BULLDOZERS

AND

DOZER

SHOVELS

of boss of pad

If the boss is worn and there is play on it, cut


it along the weld line to replace it.
[Reference]

D75S

Material of boss: KES S43C


Welding rod:

JIS D4316,

AWS E7016

Preheating and postheating

(j)

Preheating temperature:

150 to 2OOC

Postheating temperature:

590 to 66OC

Repair of other cradted or deformed sections


Check each section for cracking and deformation, and repair it by welding if necessary.

20-80
0

WELDING

APPLIED

3.
1)

BULLDOZERS

INSTRUCTION

REPLACEMENT

PROCEDURE

FOR

BUCKET

EDGE

AND

DOZER SHOVELS

D155S-

Remove the edge and corners by cutting them along


the

weld lines on the bucket,

then finish the cut

surface with a grinder.

2)

Weld the new corners and edges to the bucket according to the following

- Welding rod:

procedure.

JIS D5816
AWS E9016

Before using the welding rods, dry them at 300


to 35OC for 30 to 60 minutes.

* When welding (including tack welding), preheat


at 200 to 250C,

and keep the temperature

the base metal at 150C

of

or above while welding.

After welding, gradually cool the base metal.


For the first layer and back run, use welding rods
KES SHSC-2

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

Bevel the edge of the bucket


50

smoothly

b)

to be welded to

(leave 2 mm of lower section),

Install

and finish

with a grinder.

the edge to the bucket

tack welding.

in position

by

Install the corners by tack weld-

ing, too.

(cl

Temporarily

weld plates @

to the bucket and

edge as shown in Fig. 4 to prevent weld strain.

(d) Weld sections @


*

and @

as shown in Fig. 3.

Weld them taking care not to leave strain on


the bucket and edge.

Fig. 4

WELDING

20-81
0

APPLIED

BULLDOZERS

INSTRUCTION

(el Weld the corners permanently

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

Weld the wear plates and edge (Fig. 3).


Remove

plates @

(Fig.

41,

and

finish

the

welded surfaces with a grinder.

20-82
0

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

RIPPER ADAPTER

SHANK

When a ripper shank on D80, 85-12,


D355-1,

1.

3 or D455-1

TYPES

18, D150,

is worn out or deformed,

AND

DOZER SHOVELS

(D80A through D455-I)


155-1,

shank adapter for the ripper is available.

a spare

This section

describes how to weld a ripper shank adapter.

OF ADAPTERS
Model

Part No. of adapter

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

The shanks marked *can

Material

be used for the fixed type multishank

ripper on D355-3.

Detailed dimensions of shank

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

Fixed type multishank


Variable multishank

175-78-21613

ripper

ripper
T 8651175-78-21693
6843-

D150,

175-78-21614

(Chromium-

175-79-31131

nolybdenum-

155-1

6859 - 7189

Fixed type giant ripper


sr

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

Variable giant ripper

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)

Shank type (1)


(a)

AND

BULLDOZERS

DIMENSIONS

AND

DOZER SHOVELS

OF SHANKS

Draw the first line according to dimensions A


and B which are the distances from the top of
the shank shown in Fig. 1.

(b)

Draw

the second line (auxiliary

cutting

10 mm below and in parallel to the first


according to dimension

2)

line)
line

E.

Shank type (II)


(a)

Draw the first line (final cutting line) according


to dimensions A and B which are the distances
from the top of the shank shown in Fig. 2.

(b)

Draw

the second line (auxiliary

cutting

line)

IO mm below and in parallel to the first line


according to dimension

E.

(c) After welding the adapter, build up the hatched


section.

3)

Shanktype
(a)

(Ill)

Second line

Draw the first line (final cutting line) according


to dimensions A and B which are the distances
from the top of the shank shown in Fig. 3.

(b)

Draw the second line (final cutting line) from


the

point

at distance

C from

shank to the intersection

the top of the

of the first line with

the vertical line at distance D from the rear of


the shank.
(c)

Draw the third and fourth

lines (auxiliary

cut-

ting lines) 10 mm below and in parallel with the


first and second lines according to dimension E.

WELDING

20-85
0

APPLIED

INSTRUCTION

BULLDOZERS

4)

AND

DOZER

SHOVELS

.I/

Shank type (IV)


(a)

Draw the first line (final cutting line) according


Second line

to dimensions A and B which are the distances


from the top of the shank shown in Fig. 4.
(b)

Draw the second line (final cutting line) from


the

point

at distance

C from

shank to the intersection


the

vertical

the top of the

of the first line with

line at distance

D from

the rear

surface of shank.
(c)

Draw the third and fourth

lines (auxiliary

cut-

ting lines) 10 mm below and in parallel to the


first and second lines according to dimension E.
(d)

After

Fourth line

welding the adapter, build up the hatched

section.
l

How to read Table 2

Fig. 4

For variable giant ripper (Serial No.7123


From marks *on

for D155-1)

Table 2,
175-79-32130

Part No. of shank:


Type of shank:

I I I (Fig. 3 in Section 3))

Dimensions of shank:

A = 1481 mm,.B = 1582 mm, C = 1352 mm, D = 77 mm (Fig. 3 in Section 3)

4.

HOW TO CUT THE

I)

Preparation for cutting the shank


Remove

SHANK

the shank and support

it horizontally

by

the points shown in the figure at right.

Mark off

the shank in this condition.

place the

Alternatively,

.
,/I/

AA

Float 50 mm
or so.

shank on one end of a stand so that the section to


If the shank is placed so, be care-

be cut off floats.

ful when the cut section drops.

Fig. 5
2)

Cutter
Use a cutting torch.

An automatic

gas cutter should

Guide plate

be used, but if it is not available, cut with a hand


torch along a guide plate so that the shank will be
cut evenly and smoothly.

Fig. 6

3)

prevent hair cracks.

Cutting procedure
Preheat
15OC
auxiliary

the auxiliary
(over a width
cutting

line.

cutting

of 20 mm).

Cut along the

With this cutting work, the

center of the final cutting

20436
Cc

line of the shank at

line will be preheated to

The final cutting line must be

cut just after the auxiliary

line is cut.

Cut along the

final cutting line.


Remove all the scale from

around the cut surface,

and finish smoothly with a grinder.

WELDING

APPLIED

5.

1)

INSTRUCTION

PREPARATION

BULLDOZERS

AND

DOZER SHOVELS

FOR WELDING

Prepare an AC arc welder (500 A), COz gas shielded

For the second and after layers, use welding rods 5

arc welder,

mm or 6 mm in diameter

and arc air gouging device, if possible.

of the 80 kg/mm*

tensile

If an arc air gouging device is not available, bevel the

strength dass (JIS D8016).

When building up with

edges to be welded (see the figure below).

a COz gas shielded welder,

use cores 1.6 mm or 1.2

Use covered welding rods 4 mm, 5 mm and 6 mm in

mm in diameter,

diameter.

welder.

For the first layer, use welding

mm in diameter

of the 60 kg/mm*

class (JIS 05016

or D5816).

rods 4

tensile strength

depending on the capacity of the

JIS D5016

(AWS E7016)

JIS D5816

(AWS E9016)

JIS D8016

(AWS E11016)

Preparation for welding


(a)

Preparation of edges
If a gouging device is not available, URANAMI
welding

must be performed

on the root.

welding rods 4 mm in diameter.

Use

To make good

welds, build up the center of the straight cut


surface so that URANAMI
formed

properly.

welding can be per-

At this time, the edges must

be preheated as if they were being welded.


(If a gouging device is available, the edges can
be prepared

by laying two layers and chipping

the back side, and therefore

the above work is


-+-1to2mm

not required.)

Fig. 7
(b)

Preparation for welding


To prevent

the diffusion

of welding

heat, do

not place the parts to be welded directly


floor or surface plate.

on a

Instead float them with

jacks or blocks as described in Section 4.


Before

fixing

the shank and adapter,

place a

stretch on them to set them in parallel by adjusting the height of the jacks or blocks.
Stretch

Check this gap.

Fig. 8
(c)

Other precautions
To make good and efficient
flat position

welds, weld in the

on both sides alternately.

(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

edges and beads.

Securely

connect the grounding cable to the hook of the


shank.

WELDING

20-87
0

APPLIED

6.
I)

BULLDOZERS

INSTRUCTION

WELDING

THE

AND

DOZER SHOVELS

ADAPTER

Fit the edges of the adapter and shank on a surface


plate, and adjust the root opening to 3 mm (Fig. 9).
Fix them at two

places by welding approximately

30 mm as shown in Fig. 9.
IOO-mm

At this time,

Plates to prevent metal from dripping


(for CO, gasshielded welding only)

preheat a

radius around the points to be welded at

2o0c.

2)

When permanently
preheat
line

welding the shank and adapter,

at least 100 mm on both sides of the weld


(The

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

of the weld line ex-

be cooled

surface

before

welding

temperature

with

Use a welding rod 4


mm in diameter.

or thermocouple.
Fig. 9

3)

Since the first

and second layers on the root (of

both sides) shrink a lot and crack easily, they must


be deposited
welding
E7016)
4)

manually.

Use low hydrogen

rods 4 mm in diameter
or D5816

JIS D5016

type
(AWS

(AWS E9016).

For the first layer of the root, start welding from


the prepared
weld

line.

edge and stop at the center on the

Then, start welding

from the opposite

side again, and stop at the center (Fig. 10).


5)

Before starting to deposit the second layer, check


the first weld zone for slag inclusion,
cracks.

If any defect

is found,

craters, and

remove it with

grinder or by arc air gouging.


6)

For the second and after layers, weld continuously.

Fig. IO

If it is necessary to change the welding rods, start


again by the

backward

start

method

(Fig.

11).

The first arc must also be started by this method to


Shank

prevent blow holes.


7)

Turn

over the shank,

remove

gouging (back chipping),

the root by arc air

then start to deposit the

second layer in the same way as on the first side.


8)

Turn

over the shank again, and deposit the third

layer.

For the third

rods 5 to

6 mm

and after

in diameter

layers, use welding


JIS

D8016

(AWS

El 1016).
Fig. 11
9)

Turn over the shank every two layers until the root
is built

up to about the half the thickness of the

shank, and every three layers after that.

20-88
0

WELDING

APPLIED

BULLDOZERS

INSTRUCTION

build up the lower face.

10) The distance between the edges is wide near the surface of the shank and adapter.

condition

If welded by weav-

Therefore,

DOZER SHOVELS

(Build it under the same

as for the third and after layers described

in Section 6.)

ing the whole width, too much heat will be given to


the base metals.

AND

weld by weaving with a

2)

narrow width near the surface of the base metals.

After

all the weld zones are cooled, remove the ex-

cessively deposited metal with a grinder.


[When performing

grinder

COs gas shielded welded]

in the lengthwise direction

that the grinding stone will


Before welding

the shank and adapter, weld plates

Move the

of the shank so

rotate

across the weld

line and notches on the weld line can be removed.

to both sides of the adapter to prevent melted metal


from dripping (Fig. 9).
Since the first

3)

and second layers on the root

(of

be deposited

Use low hydrogen

manually.

rods 4 mm in diameter

E7016)

or D5816

JIS D5016

a grinder,

on the finished

surface, re-

repair it by welding,

and

The base metal must also

be preheated for this repair.

type
(AWS
*

(AWS E9016).

For CO* gas shielded welding,

is found

finish it with the grinder.

both sides) shrink a lot and crack easily, they must


welding

If any defect
move it with

Precautions

use high tensile wire


Just after the welding, cover approximately

of the 70 kg/mm2 tensile strength class.

150 mm

on both sides of the weld line with asbestos to gradWhen

using a semi-automatic

positing

welder,

several layers to prevent

too

from being applied to the base metals.


time must be controlled
the

periphery

of the

weld by demuch

heat

The welding

so that the temperature


weld

line will

not

of

exceed

23OC.
*

Precautions
Before welding,
to 4OOC

for

dry the welding


one hour.

rods at 35OC

Do not strike an arc

when starting welding.


While welding,
their

check the shank and adapter for

horizontality.

If they are not horizontal,

weld the surface which is opened more than 180


to remove the strain.
Use Flux

Backing (Mold

flux)

a plate to prevent the melted

by Unionmelt
metal from

as

drip-

ping. If this is not available, mild steel plate 6mm


thick

may be used.

If covered welding rods are

used, these plates are not necessary.

7.

FINISHING

AFTER

1)

After

both sides of the shank, remove the

welding

WELDING

plates which were welded to both ends of the adapter to prevent the melted metal from dripping.

On

the place where the plates have been welded, gouge


to a depth of 15 mm, then weld to build up.

The

front side of the shank must be welded by an expert


worker

to prevent weld defects.

On this side, set

the shank upright, and weld it in the flat position.


If the levels of the end faces of the adapter
shank are different

WELDING

[Fig.

2 (B) and

and

Fig. 4 (D)l,

ually cool the weld zone.

If a tempering

furnace is

available,

at

about

keep the

shank

2OOC

minutes to gradually cool the shank.

for

30

APPLIED

8.

INSTRUCTION

ASSEMBLY

BULLDOZERS

OF SHANK

AFTER

See Table 3 for the protectors

ADAPTER

AND

DOZER SHOVELS

IS WELDED

and points that are

applicable to the shanks.

No. of adapter
Model/Part
~~~
~~
D80-12
D85-12
D80-18
D85-18
D150-1

154-78-l

5690

154-78-l

5691

I Part No. of protector

Part No. of long point

Part No. of standard point

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

Assembly of shank after the adapter is welded.

to install the point


D355,

198-79-l

and

and pin (198-79-

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

MAIN FRAME (Examples of HD320-2


1.

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

for welded structure

SC46

Carbon steel casting


Carbon steel tubes for machine
structural

purposes

Rolled steel for general structures

sS41 P

The materials and dimensions of products are subject to


change without

notice in order to incorporate

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

soil, sand, oil and grease from the main

frame with a high-pressure washer or steam cleaner.

2)

Check the main frame for cracks by means of the


dye penetrant check.
*

Check sections
frames shown

to

of the R.H. and L.H.

in Fig. 2 especially

carefully

for

cracks.

Fig. 2

3.

SELECTION

OF WELDING

RODS

To repair the main frame, use the following

welding

rods.
E7016/BS

E5133

B 26(H)

Used for

overlaps or undercuts.
-Take

Diameter of welding rods


the

1st to 3rd

layers on

beveled edges (gouged sections).


4.0 mm -

Welding precautions

* Take care not to make welding defects such as

JIS D5016/AWS

3.2 mm -

Used for the 4th and after layers on


beveled edges (gouged sections) and

care not to damage the corners of the

upper and lower plates of the frame while welding them.

-Cover the wiring and vinyl piping to protect


them from spatters.

for build up welding.


*

Before using low hydrogen type welding rods, be


sure to dry them at 350 to 4OOC for about one
hour.

WELDING

30-3
E

APPLIED

INSTRUCTION

DUMP

4.

REPAIR

1)

Repair of cracks at Section

OF CRACKED

TRUCKS

SECTIONS
A

Weld zones of upper, lower and side plates of a side


member
Remove the hydraulic

(a)

tank, hydraulic oil filter,

fuel tank, and transmission from the body.


Clean

(b)

the

cracked

surface,

and

confirm

the

crack by means of the dye penetrant check.


(1)

Bead cracks

- Make holes 6 mm diameter and 9 mm deep


at 10 mm from both ends of the crack (to
prevent the crack from extending).

- Gouge the cracked section 30 mm beyond


the actual crack to a depth of 9 mm.

* After

gouging,

finish the gouged surface

with a grinder, then recheck it for cracks


by means of the dye penetrant check.

(If a

crack is found, extend the gouge longer.)

Gouging length

Front
Top surface

kX46

Fig. 3
*

Clean

the

gouged

surface,

remove

the

Section A-A
*

If a bead crack is found,

check the other

chemicals used in the dye penetrant check,

beads for cracks by means of the dye pene-

and weld

trant check (upper and lower beads on the

again until the weld penetrates

into the backing strip.

inside and outside of both side frames).

* To remove the residual stress, peen the


weld zone sufficiently

after depositing each

layer.

30-4
0

WELDING

APPLIED

DUMP

INSTRUCTION

TRUCKS

(2) When a crack extends to the upper and side


plates but not to the base metal.

$6 - 7 (depth) x 2 (places)
Detail

0A

Fig. 4
-

- Clean

Make holes 6 mm diameter and 7 mm deep

gouged

surface,

remove

and weld

the actual crack.

stress, peen the weld zone sufficiently

gouging,

with

a grinder,

finish

again.

after

depositing each layer.

the gouged surface

- After

then recheck it for cracks

welding,

finish

smoothly with a grinder.

by means of the dye penetrant check.

When a crack extends to the upper and side


plates and the base metal.

View Z

Fig. 5

WELDING

the

To remove the residual

Gouge the cracked section 30 mm beyond

- After

(3)

the

chemicals used in the dye penetrant check,

at 10 mm from both ends of the crack.

the

weld

surface

DUMP TRUCKS

APPLIED INSTRUCTION

Gas cut the cracked section of the upper

Tack weld a wire to the backing strip.

plate as shown in Fig. 5.

* Finish the cut surface smoothly

with

grinder.
-

Install a backing strip and tack weld it.

Insert the backing strip.

Pull up the wire, fix the backing strip by


tack welding, and cut the wire.

Fix by tack welding

Gouge the cracked section of the side plate


15 mm beyond the end of the crack.

Remove all the slag from the gouged surface with a grinder or chipping hammer.

* Fill the cut section of the upper plate by


welding.

To

remove the

residual stress,

peen the weld zone after depositing

each

layer.

* Weld the gouged section of the side plate.


*

On the first layer, defects such as residual

stress

(which

lowers

the

fatigue

strength) can be made easily. Therefore,


deposit the first layer carefully.

SectionA-A

Fig. 6

30-6
0

WELDING

APPLIED

DUMP

INSTRUCTION

TRUCKS

When the root opening is less than


3 mm (Fig. 7):

Weld until the root

is melted sufficiently.

-4-P max.
Fig. 7

When

the root

mm (Fig. 8):

opening

is 3 to 6

Fill the root opening

in two passes.

_)

1 _3to6mm

Fig. 8

Do not fill the root opening with a


welding rod or piece of steel.

After

welding,

finish

the

weld

Bad !

Welding rod

zone

smoothly with a grinder.


2)

Repair

procedure

for

section @

of the transmis-

sion mount bracket


(a)

Remove the transmission

and the pipes, tubes

and hoses which may intetfere with the work.


(b)

Clean

the

cracked

section,

and

confirm

the

crack by means of a dye penetrant check.


[Repair procedure]
Repair
Steps

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

(b) Make parts @


Material:

KES

, @
SS41P.

and

ASTM

TRUCKS

_
A283Gr.D

or

equivalent
Thickness:
Plate (iiJ

9 mm
Plate

x 2 pieces

x 1 piece

To be used for the front side of the transmission

To be used for the right rear side of the

bracket (common to both sides).

transmission bracket.

120

285

Plate @

x 1 piece

To be used for the left rear side of the


transmission bracket.
128

30-8
0

_/

WELDING

APPLIED

(c)

DUMP

INSTRUCTION

Reinforcement

TRUCKS

drawing for R.H. bracket

Secure a distance of 5 to 7 mm between the top of the frame and


the bead. When welding, take care not to damage the corners at
the top of the frame.

mTopof

frame

Front of machine

---Lx

Bottom of frame

60

-f 8

Fill with bead

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)

to damage the corners at the top of the frame.

Fig. 9

WELDING

30-9
0

APPLIED

(d)

INSTRUCTION

Reinforcement

DUMP

TRUCKS

drawing for L.H. bracket

Secure a distance of 5 to 7 mm between the top of the frame and


the bead. When welding, take care not to damage the corners at
the top of the frame.

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)

Secure a distance of 5 to 7 mm between the bottom of


the frame and the bead. When welding, take care not
to damage the corners at the top of the frame.

Fig. 10

30-10
a

WELDING

APPLIED

DUMP

INSTRUCTION

TRUCKS

If the area between the transmission mount brackets


is cracked, reinforce it by welding.

* Weld plate (566-99-97650)

for the reinforcement

Reinforcement

as shown in Fig. 11.


(a)

Material

Plate (566-99-97650)

may be made in the field

plate

KES SS41 P, ASTM

A283Gr.D

or

equivalent

as shown below (common to both sides).

Thickness:

9 mm

665

(b)

Reinforcement

drawing

for the area between

the transmission mount brackets

Dump body stopper bracket


/
To be finished with a grinder.

,To be finished with a grinder.


This shows the right side.
On the left side, fill the
area between here and the
seat by welding.

Upper plate

Front of vehicle

This drawing shows the right inside.

Extend the bead smoothly, and finish


with a grinder.

Fig. 11

WELDING

30-11
cc

APPLIED

3)

INSTRUCTION

Repair

procedure

for

DUMP

cracked

section @

TRUCKS

of the

hoist bracket
(a)

(d)

Remove the pipes, tube and hoses which may

Make plate

shown below.

interfere with the work.


Plate @

(b)

Clean

the

cracked

surface,

and

confirm

crack by means of the dye penetrant check.

(cl

Repair

cracked

section

0
C

according

Material:

KES SS41 P, ASTM

A283Gr.D.

or equivalent

to Step

(2) and (3) of the Repair procedure for cracks

Thickness:

0.

on Section

x 1 piece

the

16 mm

Fig. 12

(4

Reinforcement

drawing for the hoist bracket

Finish the bead smoothly with a grinder.


\

/.

KES SS41 P (9 t)

Top of frame

finish smoothly with

Extend the bead.


Fig. 13

30-l 2
a

WELDING

APPLIED

4)

DUMP

INSTRUCTION

Repair

procedure

for cracked section @

TRUCKS

of seats

of hydraulic tank and hydraulic oil filter


(a)

Remove the hydraulic

tank, hydraulic oil filter,

and tubes and hoses which may interfere

with

the work.

b)

Clean

the

cracked

surface,

and

confirm

the

crack by means of the dye penetrant check.

(cl

Make holes 6 mm in diameter

at both ends of

the crack.

(4

Gouge the cracked section 30 mm beyond the


actual crack (until the crack is eliminated).

(4

After

gouging, finish the gouged surface with a

grinder, then check the surface for cracking by


means of the dye penetrant check.

(f) Clean the gouged surface, remove the chemicals


used in the dye penetrant

check, and weld it

again.

(9)

To

remove the

zone sufficiently

h)

After

residual stress, peen the weld


after depositing each layer.

welding,

finish

the

welded

surface

smoothly with a grinder.


6)

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,

NEWS NO. RELATED

TO WELDING

DOZER SHOVEL 1966lMAY

No.

Service News No.

Date of
Issued

to 1983lMAY

Subject

GN-163

JUL 76

Welding of replacement cutting edges to the trimming dozer

GN-026

APR 72

Bucket spill guard for machine models D55S-2.3

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

Ripper shank adapters for the D80,85-12,


welding practice

GN-124

MAY 76

Reinforcing the blade moldboard on models D80,85-12,

GN-163

JUL 76

Welding of replacement cutting edges to the trimming dozer

GN-189

APR 79

Repair of radiator core

GN-142

NOV 79

Ripper shank adapters for models D80,85-12,

D20-70906

OCT 80

Introducing bucket with reinforced spill guard and the method of reinforced the spill guard

10

D30-30-001

OCT 66

In-field reinforcement of D30S roller guard

11

D30-70426

DEC 77

Reinforcing the C-frame for D31P-16 swamp angledozer

12

D30-21903

JUN 79

Repair of cracked main frame cross bar support on D31-16

13

030~54-007

FEB 83

Repair of cracked engine hood on D31-17

14

D40-30-001

AUG 80

Repairing a cracked track frame on D45S machine

15

D40-21-001

JAN 83

Repair of oil leakage from bottom surface of steering case on D40,41-3

16

D40-30-092

APR 83

Repair of cracks in track frame D45S1

17

D50-70-018

DEC 65

Procedures of renewing rock bucket edges in field

18

D50-70919

FEB 66

Reinforcing the joint in D50-11 trimming frame

D150,155-1

and D355-1 machines and their


D150, D155-1 and D355-1

18, D150, 155-1, D355-3 and D455

19

D50-27-003

MAY 66

Replacement sprocket repair D50-8,10

20

D50-27-004

SEP 66

Introduction of replacement sprocket repair rims for D50-8.10

21

D50-70-036

NOV 67

Reinforcement of back hoe main boom

22

D50-70638

FEB 68

installation of additional bucket reference level

23

D50-70-044

JUL 68

Repair of crack in side frame

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

Welding of tip for repair of bucket tooth

27

D50-54913

MAY 78

Reinforcement of main frame on D57S1

28

D50-54-014

JUN 78

Repair of field engine bypass filter mounting on D57S1

29

D50-30-014

DEC 78

Reinforcement of track frame of D57S-1

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

Replacing multi-purpose bucket brackets on D57S-1 machine

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.

Service News 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

Protecting engine side cover of D50P-16 and D53P-16 from deformation

36

D50-78-016

APR 83

Repair of ripper holder on D50,53A-16,

37

D55-70-003

JUL 68

Repair of crack in side frame welding

38

D55-70-016

FEB 77

Welding of tip for repair of bucket tooth

39

D60-30-003

JUL 65

Methods of repairing and reinforcing D6OS-3 track frames

40

D60-70-008

OCT 65

Method of repairing reinforcing and setting D60S3

41

D6078605

DEC 65

Method of effecting modification in field on hydraulic ripper to improve ripper efficiency

42

D60-50-001

MAR 66

In-field reinforcement of D60S-3 equalizer bar

43

D60:70-009

MAR 66

Reinforcement in field of D60A-3 angle-rake blade

44

D60-27-001

MAY 66

Replacement sprocket repair rim D6OA.S1

45

D60-30608

MAY 66

Method of repairing and replacing D60S-3 track frame guards

46

D60-78-009

JUN 66

Reinforcement on hydraulic ripper link

47

D60-70-018

NOV 66

In-field reinforcement of D60S3

48

D60-70-025

OCT 67

Correction of cracked lift-arm connector in D60S3

49

D60-70627

NOV 67

Reinforcement of back hoe main boom

50

D60-70628

JAN 68

Recommendation for use of reinforced blade under severe job applications

51

D60-78-014

MAY 68

Repair of cracked ripper beams

52

D60-30-013

JAN 73

Repairing cracked track frames on D60.65-6 crawler tractors

53

D60-78-018

JAN 73

Repairing cracked ripper link on D60.65AS16

54

D60-22609

NOV 73

Repair of the oil-leaking or cracked steering case on the D6OS-6 machine

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

Repair of muffler on D60 and D65A,S,P,E-6

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

Repair of bent and cracked track frames on D60.65E-6

60

D60-70-048

FEB 77

Welding of tip for repair of bucket tooth

61

D60-70-047

APR 77

Reinforcing the power tiltdozer blade side for D60.65A,E-6

62

D60-70-050

JUN 77

Reinforcing the tiltdozer blade in D60.65P-6

63

D60-78622

JAN 78

In-field reinforcement of lower link of hydraulic ripper (DRP060-3)

64

D60-30-018

JUN 78

Repairing of D65P-6 track frame

65

D60-03-015

JUN 78

Repair of cracked weld on radiator upper tank on D60P-6 machine

66

D60-54-017

FE8 79

Prevention of dashboard cracking on D60.65A,P,E-6

67

D60-70058

FEB 81

Repairing cracked angle blade side plate for D60.65A-6

68

D60-70-057

FEB 81

Installing lining blades on machines in the field

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

Repair of cracked track frame in D6OP and D65P-6

D50,53S-16

and D57S1

bucket

and -3

bucket tilt lever

machines

machines

machines

for D60.65A.S-6

No.

Service News 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

Repair of cracked bell crank on D75S2

76

D75-70-007

JUL 72

Reinforcing the lift arm of D75S2

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

Welding of repair of bucket tooth

79

D75-70-012

MAY 78

Repair of cracked dump stopper weld on a bucket tilt lever in D75S3

80

D75-70-015

MAY 79

Modification procedure for cracked lift arm on D75S3

81

D75-21-001

JUL 79

Repair cracked steering case in D75S-3 machines equipped with hydraulic ripper

82

D75-78-006

JUL 79

Repair of hydraulic ripper on D75S3

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

Reinforcing the under-guards on D75S3

85

D75-21-002

DEC 79

Repair of detective final drive 2nd pinion and steering case on D75S3

86

D75-04-001

MAY 81

Reconditioning a cracked fuel tank on a D75.S3 machine

87

D75-70-017

DEC 81

Repair of tilt lever cracked at dump stopper in D75S3

88

D75-70-019

APR 83

Repair of cracked bottom of bucket on D75S3

89

D80-70-016

MAR 66

Method of reinforcing C-frame of D80-7, 8 models in field

90

D80-70-017

MAY 66

Reinforcing hydraulic stay with ribs

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

Reinforcing brace (under)

93

D80-70-020

MAY 66

Reinforcing brace (upper)

94

D80-70-021

MAY 66

Reinforcing blade

95

D80-70-022

JUN 66

Repairing of D80A-8 blade bracket

96

D80-54-006

JUL 66

Repair for the main frame of D80-8

97

D80-70-024

SEP 66

Method of reworking hydraulic cylinder bracket on D80-8 C-frame

83

Reinforcement of reinforced type rear under cover on D65E-6


Repair of lift arm on D75S-2
kevention of cracking of side frame on D75S2

machine

dozer shovel (with pin in upper most shank hole)

machine

98

D80-54-007

NOV 66

Repair method for main frame of D80-7

99

D80-54-008

NOV 66

Repair and reinforcement for bevel gear case

machine

100

D80-54-009

DEC 66

Reinforcement of undercover in D8OA-8

101

D80-70-025

DEC 66

Reinforcing method of D80A-8 straight-dozer blade (P/N. 150-71-I 11 IO)

102

D80-70-027

DEC 66

Reinforcing method of D80A-8 straight-dozer frame (?/N. 150-93-I 1210)

103

D80-70928

DEC 66

Re-work of blade in preparation for push work of scraper, etc.

104

D80-70-029

JAN 67

Reinforcing the blade tougher job applications

105

D80-21-004

FEB 68

Repair of final drive housing rib in D80-8

106

D80-70-034

MAR 68

Reinforcing the moldboard of D8OA-8 straightdozer

107

D80-78-012

MAY 68

Repair of cracked beam of parallelogram ripper

108

D80-70-039

DEC 68

Reinforcing the blade moldboard for pushing operation on D80.85-12

machines

Date of
,ssued

No.

Service News 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

angle dozer or straight (tilt) dozer

APR 69

Reinforcing the dozer equipment on D80.85A-12

straight-tiltdozer

MAY 69

Introducing the sprocket rim for use on D120,125

D80-70943

MAR 72

Reinforcing the braces of dozer equipment in D80. 85-12 machines

113

D80-30-014

JUL 72

Repair of cracked track frame on D80.8512

114

080-70-044

SEP 74

Reinforcing the blade for the D80.85A-12

115

D80-70947

JUL 77

Reinforcement of C-frame for D80.85-12

116

D80-70-050

AUG 79

Reinforcement of yoke, apron lift arm and rod for RS13H-1

117

D80-54-020

JAN 80

Field repair of chassis component (of D80, D85A,E-18


ing specification)

118

080-70-051

MAR 80

Repairing blade equipment on D80.85-18

119

D80-78-022

OCT 80

Replacing broken or cracked ripper beam shank holder on D80.85A,E-18

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

Protecting the blade with guards on D8OA, 85A-18 angledozer

122

080-70-054

JUL 81

Repair procedure for D80 and D85A-18 angledozer

123

D80-70-055

JUL 82

Modification of tilt piping protector in D80.85P-18

124

D80-70-056

DEC 82

Reinforcement of front plate of blade of D80.85A-18

125

D80-70-057

FE8 83

Spare trunnion ball stud for work equipment for D80A to D455 machines

126

D80-54-024

MAY 83

Replacement of equalizer bar bracket in main frame on D80.85A,E.P-18

127

D80-30-014

JUL 72

Repair of cracked track frame on D80,85-12

128

D95-70901

MAY 75

Repair of cracked lift arm on the D95S1

129

D95-70-002

JUN 75

Repair of the side frame on the D95S-1

130

095-70-003

JUN 76

Repair of cracked bucket on the D95S-1

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

machines equipped for forest operat-

or D155-1 land cleating dozer shipped to Indonesia


machines

angledozer

132

D95-70-004

JAN 83

Repair of cracked lift arm on D95S2

133

D150-21-001

JAN 73

Repairing cracked steering clutch cases in D150-1 and D155-1

134

D 150-60-002

JAN 73

Cracked hydraulic tank legs on the D150, D155A-1

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

Reinforcing (Repair) of main frame on D150A-1

137

Dl50-54-007

JUN 79

Repair of radiator guard crack for 0150,

138

D150-21-002

JUN 80

Replacing equalizer bar bracket on main frame of D15OA-1 and D155A-1

139

D150-54-010

MAY 81

Reinforcing a radiator guard on D155S1

140

D150-70-012

MAY 81

Reinforcing the U-dozer blade for D15OA-1 and D155A-1

and D155A-1

D155A-1
machines

machine
machines

141

D150-70913

MAY 81

Reinforcing the blade on D155A-1

142

D150-54-007

MAR 82

Repair of radiator guard crack for D150, D155A-1

machine in the field (for Jordan)

143

D150-70014

NOV 82

Reinforcing the shear blade on D155

144

D355-60-001

JAN 73

Repairing cracked hydraulic tank legs on the D355A

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

Repair of detective equalizer bar and its related parts on D355A-1

147

D355-70907

SEP 80

Repair of leaking tilt piping on D355A machines

machines

No.

Service News No.

148

D355-54-005

Date of
Issued

Subject

OCT 80

Reinforcing radiator guard on D355A-3

machine in the field

149

D355-70-008

MAY 81

Reinforcing the U-dozer blade for D355A-3

machines

150

D355-70-009

JUL 81

Installation procedure for the fabricated pusher plate on D355A-3

151

D355-70-010

MAY 82

Repairing broken tilt piping on D355A-3

152

D355-78-013

NOV 82

Repair of holder for multi-ripper of D355A-3

machines

153

D455-03-002

DEC 77

Reinforcing supports for radiator core on D455A-1

154

D455-30-001

DEC 77

Repair of track frames on D455-1 machine

155

D455-30-002

JAN 78

Repair of a cracked diagonal brace in D455 machine

156

D455-50-001

JAN 78

Repair of cracked equalizer bar in D455A-1

157

D455-30-003

MAY 81

Reconditioning a cracked diagonal brace on the track frame of D455A-1

158

D455-70002

MAY 81

Reinforcing the Udozer blade for D455A-1

159

D455-54-005

JUL 82

Repair of cracked floor frame on D455-1

160

D455-03-021

AUG 82

Repair of water leak from radiator of D455-1

161

D455-91-005

OCT 82

Repair of cracked cab of D455A-1

machine

machine

machine

machine

162

D455-30-003

DEC 82

Reconditioning a cracked diagonal brace on the track frame of D455A-1

163

D455-50603

FE6 83

Repair of cracked equalizer bar on D455A-1

164

D45530603

APR 83

Repair of cracked main frame of D455A-1

165

D455-30-005

APR 83

Field repairs of cracks in track frame of D455A-1

166

D455-54-006

APR 83

Repairing cracks in radiator guards of D455A-1

- DUMP TRUCK -

GN-189

APR 79

Repair of radiator core

HD180-04-001

MAR 75

Reinforcing the fenders for the HD180-4 dump truck

HD180-54-002

AUG 75

Reinforcement of the fender on the HD180-4 dump truck

HD180-54-004

NOV 77

Repair of a cracked cab on HD180-4 dump truck

HD180-70-001

JAN 80

Repair of cracked dump body on HD180-4 dump truck

HD180-03-001

SEP 81

Preventing water leakage from radiator on HD180-4 dump truck

HD180-03-002

FEB 82

Field modification of the radiator on HD180-4 dump truck

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

Repair of cracked rear transmission mount brackets in HD320-2 dump truck

10

H D320-46-002

SEP 79

Reinforcing the main frame of the HD320-2dump

11

HD320-46-003

MAR 82

Reinforcing main frame (transmission bracket section) of HD320-2, HD325-2

12

H D320-46-004

JUL 82

Repair of cracked main frame in HD320-2 and HD325-2

13

HD320-70-002

DEC 82

Repair of cracked dump body hinge pin bracket in HD320,

14

H D320-46-005

MAR 83

Reconditioning main frame in HD320-3,

15

HD320-70-003

APR 83

Repair of cracked dump body mount bracket on HD320, HD325-2

16

H D460-46-001

NOV 79

Repair and reinforcement of cracked main frame on HD460-1 dump truck

truck

HD325-2

HD325-3

No.

Service News No.

Date of
Issued

Subject

17

HD460-46-002

OCT 82

Repair of cracked main frame on HD460-1 dump truck

18

HD680-46-002

APR 71

Reconditioning and reinforcing a cracked main frame on HD680-2 dump truck

19

HD680-50-001

MAR 76

Repair of welding cracks in suspension covers on HD680-2 dump truck

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

Repair of a cracked cab rear support weld on HD680 dump truck

22

H D680-46-001

FEB 77

Repair of broken battery support brackets on HD6BO dump truck

23

HD680-22-001

NOV 78

Repair of rear axle housing on HD680

24

H D780-46-001

MAY 83

Repair of cracked main frame on HD780-1

25

HDI 200-27-001

OCT 82

Reinforcement of ribs around front wheel hub in HD1200M-1

-HYDRAULIC

EXCAVATOR

PC-70-019

JUN 81

Reinforcing the boom on PC200 or PC220 hydraulic excavator

PC-70-025

SEP 81

Reconditioning a cracked boom on PC04 hydraulic excavator

PC-70626

APR 82

Reinforcement procedure for arms of PC200-1 or PC220-1

PC-70-028

APR 82

Repair procedure of cracked boom on PC300-1

PC-70-030

MAY 82

Repair of cracked boom and on PClOO, PClOOL and PC120

PC-70-01 9

MAY 82

Repairing a cracked boom on PC200-1 or PC220-1 hydraulic excavator

PC-70-027

MAY 82

Repair of cracked arm on PC300-1 hydraulic excavator

PC-54-006

MAY 82

Cracked operators cab door on PC300-1

PC-70632

JUL 82

Repair of cracked arm on PC400

10

PC-70938

AUG 82

Repairing a cracked boom on PC200-1 hydraulic excavators

11

PC-70-037

AUG 82

Reinforcement of standard bucket on PC300-1

12

PC-70-034

AUG 82

Repair of cracked boom on PC200-1, PC220-1 hydraulic excavator

13

PC-70635

AUG 82

Reinforcement of boom (top) on PC200-1, PC220-1

14

PC-46601

AUG 82

Repair of cracked revolving frame on PC300-1

15

PC-30-004

AUG 82

Repair of cracked truck frame on PC300-1

16

PC-70039

OCT 82

Repair procedure for cracked boom and arm of PClOO, PCIOOL, PC120

17

PC-46-003

NOV 82

Reinforcement of boom foot of revolving frame in PC200-2, PC220-1

18

PC-46-002

NOV 82

Repair of cracked boom foot on revolving frame of PC200-1 and PC220-1

19

PC-70-040

NOV 82

Repair of cracked boom on PC400 hydraulic excavator

20

PC-70641

DEC 82

Reinforcing the boom of PC200-1 or PC220-1

21

PC-46004

DEC 82

Reconditioning the boom mount of revolving frame in PC220-2

22

PC-70-042

DEC 82

Repair of short arm on PC200-1 and long arm on PC220-1

23

PC-70946

MAR 83

Repair of cracks in boom tip on PC200-2 and PC220-2

24

PC-70947

MAR 83

Repair of cracked boom and arm on PCXOO-1

25

PC-30-007

APR

Repair of cracks in track frame of PC300

-WHEEL

No.

LOADER

Service NewsNo.

Date of
Issued
APR 79

GN189

Subject
Repair of radiator core

W120-46-001

AUG 81

Reconditioning a cracked axle pad in front frame of W120 wheel loader

w170-54-004

SEP 81

How to repair front frame center hinge plate in W170 wheel loader

W120-46-082

OCT 81

Reconditioning a cracked front frame boom mount on W120

-MOTOR

GRADER

1 GN189

APR 79

Repair of radiator core

GD30-46-001

AUG 66

Repair procedure for motor grader frame

GD31-46-001

AUG 66

Repair procedure for motor grader frame

GD37-46-001

AUG 66

Repair procedure for motor grader frame

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

Reconditioning cracked tandem cases in GD605R-1

GD500-70-002

MAY 81

Reinforcing a drawbar on GD310RC3A

GD500-46-001

JUN 81

Reconditionings cracked main frame in GD310RC-3A

10

GD40-70-008

SEP 81

How to repair a cracked lifter bracket on GD705 or GD40 motor grader

11

GD700-70-003

SEP 81

How to repair a cracked lifter bracket on GD705 or GD40 motor grader

12

GD600-22-004

JUL 82

Repair of reinforcing pipe of tandem case on GD600

13

GD500-70-004

JUL 82

Reinforcing a circle support in GD310RC3A

14

GD600-70-005

JUL 82

Repair of cracked blade lift bracket on GD600-1

15

GD500-46-001

AUG 82

Reconditioning a cracked main frame in GD310RC3A.

16

G D600-46-00 1

SEP 82

Repair of cracked front frame on GD605A

motor graders

or GD5OOR-1 motor graders


or GD500R-1

motor graders

or GD500R-1

GD500R-1

and GD655A-1

motor grader

17

GD40-70-008

SEP 82

Repair of cracked blade lift bracket on GD705, GD40 motor grader

18

G D700-79003

SEP 82

Repair of cracked blade lift bracket on GD705, GD40 motor grader

19

GD600-46-002

NOV 82

Repair of cracked frame on GD600 series motor grader

20

G D700-04-001

FEB 83

Repair of cracked fuel tank bracket on GD705R-1

21

GD600-46-003

MAR 83

Repair of frame pipe on plate side of GD600R-1,

22

GD600-91-005

MAR 83

Repair of ROPS frame on GD600R-1,605R-1,650R-1,655R-1

23

GD600-70-007

MAR 83

Repair of cracked circle support on GD605R-1

and GD705R-2
605R-1, 650R-1

- MOTOR SCRAPER -

No.

Service News No.

y::,,

GN189

APR 79

Repair of radiator core

WSI 646-001

DEC 75

Reinforcing the hitch frame on the WSl6-2

motor scraper

WS16-70903

JUN 78

Replacement of bowl class-member on WSl6-2

WS23-70903

APR 82

Repairing a cracked yoke on a WS23S motor scraper

motor scraper

WS23-46-001

MAY 82

Repair of tractor frame on WS23S1

WS23-46-004

FEB 83

Repair of cracked tractor frame on WS23S1

WS23-46-005

FEB 83

Repair of cracked hitch frame on WS23S1

motor scraper

- SOIL COMPACTOR -

WF22-30-001

JUL 82

Repair of cracked drum wheel on WF22A-2soil

WF22-54-002

DEC 82

Repair of cracks in WF22A-2

soil compactor

compactor

Komatsu America international Company


440 North Fairwav Drive
I
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186

PROPOSAL

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR


2

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PHONE NO:

:
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DEPARTMENT:

E
R

NAME:

MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
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PFMRl 081696

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