STOW IMTA\INTOWAN Ls KOMATSU WELDING I SEBF14001The affected pages are indicated by the use of the following marks It ws requested that necessary actions bbe taken to these pages according to the table below Mark Incieston [Acton rquved oO Page to be newly added Add e Page to be replaced Replace (—_)[ Pace robe aetetoa Dicas | Pages having no marks are those previously revised or made additions LIST OF REVISED PAGES Mark Page REVO" ator Page POMS" latory page REO amare page REVO park page Revnon ¢ 01 @ 20 9 108 née @ © 002 @ 31 70 109 u7 @ © 0021 @ 32 n 110 18 oO © 03 @ 2 n m ns @ (COVER (01}) 34 3 N2 N10 @ or ® 35 m 13 nn @ ‘CONTENTS 1 36 8 14 1120 «@ CONTENTS 2 37 76 115 n° @ CONTENTS 3 38 W 6 nua @ CONTENTS 4 38 7B 7 nis © 1 40 9 18 nw © 2 41 80, 19 nuw7 @ 3 a2 at 120 nwe © 4 43, 82 121 nw @ 5 44 a 122 na © 8 45 a 123 ua O 7 46 as 124 nz ® 8 a7 86 125 11230 «@ 9 48 87 126 ua © 10 49 88 127 12 @ " 50 89 128 1125 © 12 51 90 129 uz © 13 82 3 130 na © 14 53 2 131 a1 O 18 54 3 132 16 55 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@ 2025 @ 2078 «© | ° 124 @ 2025 @ 2079 © | o 1248 @ 227 © 2080 © | o 1245 © 2028 @ 2081 @ o 1246 @ 2029 @ 2082 © | o 1247 @ 2030 © 2083 © o 1248 @ 2031 @ 2084 © o 1249 @ 2032 @ 28 © o 1250 @ 2033 © 2086 «@ o 1251 @ 2034 © 2087 «@ © 1252 @© 2035 2088 © o 1283 © 2036 © 2089 «© | o 1254 @ 2037 © 2090 «@ } o 125 @ 2038 © o 1256 @ 2038 © 301 oO o 1267 © 2040 © 302 ® o 126 © 24 © 303 ® | o 1259 @ 2042 © (304 ® | 2043 © 305 ® | oo 131 @ 2044 © 306 oO o 132 © 2045 © 307 ® o 133° © 2046 © 308 ® o 134 @ 2047 © 309 ® o 135 © 2048 © 3010 © o 136 © 2049 © 3011 @ o 137° @ 2050 © 3012 @ WELDING tatCONTENTS (Sections marked * are in preparation) GENERAL INSTRUCTIONS No of page: 01 GENERAL INSTRUCTIONS. o1- 4 APPLIED INSTRUCTIONS 11 BASIC WELDING W-4 12 HARD-FACING OF WEAR PARTS 121 13 REPAIR OF RADIATOR AND OIL COOLER 1301 20 REPAIR OF BULLDOZERS AND DOZER SHOVELS BY WELDING 20-1 Main frame 20- 2 Track frame 20- 8 Blade 20-16 Bucket 20-70 Ripper adapter shank 20-83 30 REPAIR OF DUMP TRUCKS BY WELDING 30-1 Main frame 30- 2 Dump body 40 REPAIR OF HYDRAULIC EXCAVATORS BY WELDING Revolving frame Track frame Bucket Boom Arm 50 REPAIR OF WHEEL LOADERS BY WELDING Main frame Bucket Boom 60 REPAIR OF MOTOR GRADERS BY WELDING Main frame Blade 70 REPAIR OF MOTOR SCRAPER BY WELDING Hitch frame Bowl 80 REPAIR OF SOIL COMPACTOR BY WELDING Foot LIST OF SERVICE NEWS NO RELATED TO WELDING % The list of Service News No related to welding 1s attached Refer to the Service News until the Applied Instruction Section of the Shop Manual 1s completed * tte eee HEE EEE EE EEE WELDING. 00-3 2OI GENERAL INSTRUCTIONS WELDING, General descnption of welding techniques Features of welding methods Selecting welding methods Preparations for welding Welding techniques Weld defects and countermeasures How to distinguish materials and how to check welded areas, How to read welding symbols How to handle gas (oxyacetylene) welding and cutters Preventing accidents Cost of welding consumables: Examples of troubles in welded structures and countermeasures List of standards of welding rods by countries, List of standards of metal matenals by countries Melting temperature of various base metals, and alloys Conversion table Names of standards n various countries ‘A guide to welding terms 58 62 70 a4 87 92 99 104 108 109 4 15 01-1 @QCONTENTS GENERAL DESCRIPTION OF WELDING TECHNIQUES 11 Preface 1 2 Hint on safety in operation 1) Introduction 2) Safety im gas cutting 3) Safety 1n welding 4) Safety in sheet metal work 5) Preventing electric shocks 6) Cautions during welding and cutting 1.3 Types of welding methods FEATURES OF WELDING METHODS 21 Gas welding 2 2 Arowelding 1) Are welding with covered electrodes 2) Submerged are welding '3) CO, gas shielded are welding SELECTING WELDING METHODS PREPARATIONS FOR WELDING 4-1 Types of joints 4. 2 Standard edge preparation 4.3 Types of steels end weldability 1) Rolled steel for general structures 2) Rolled steel for welded structures 3} Cold rolled steet 4) Carbon steel for machine structural use 8) 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 WELDING TECHNIQUES - 5 1 Types of welding rods and how to select them 1) Classification of welding rods 2) Types and features of covered welding rods ‘Types and features of covered welding rods for muld steel “Types of covered welding rods for mild steel ‘Types of covered welding rods for high tensule steel 3) Types of wires for CO, gas shielded arc welding 4) Types of gas welding rods for mild steel 5) How to select welding rods 8 2 Types of arc wolders for arc welding with covered welding rods and how to select them 5 3 Welding positions 5 4 Methods of deposition 1) Forehand welding 2) Backhand welding 3) Symmetric welding 4) Stap welding 5) Prestrain welding 6) Restrain welding 7) Heat induction welding 8) Water cooling welding 9) Multi layer welding 10 10 " 12 12 2 13 13 13 4 4 6 16 16 "7 7 a 18 19 2 2 23 2 26 275. Welding conditions 1) Are voltage 2) Are current 5 6 Deposition rate 1) Welding conditions for V shape butt joints in flat posttion 2) Welding conditions for fillet welded joints in horizontal position Welding conditions for pipes Back run and backing Tack welding 1) dust after tack welding 2) Butt tack welding 3) Examples of tack welding igs 510 Regular welding 1) Examples of treatment of starting/ending positions for various kinds of welding 511 Brazing 1) Brazing and its features 2) Flux 3) Brazed joints 4) How to braze 512 Arc air gouging 1) Power soures 2) Cartoon electrodes 3) Gouging torches 4) How to gouge WELD DEFECTS AND COUNTERMEASURES 6 1 Welding strains 1) Symmetric welding 2) Backhand welding 3) Skip welding 4) Prestram welding 5) Restrain welding 6) Peening 6 2 Defective shapes of beads 1) Too thick or too thin throat depth 2) Overlaps 3) Undercuts 4) Defective treatment of eraters 6 3 Cracks 1) Bead cracks 2) Cracking in heat affected zones 3) Hot cracking 4) Cold cracking 5) Unusual cracking 6) Countermeasures against cracking 6 4 Internal defects 1) Countermeasures against blow holes and pts (manual welding and CO; gas shielded welding) HOW TO DISTINGUISH MATERIALS AND HOW TO CHECK WELDED AREAS 71 Simple methods of distinguishing materials 1) Spark test 2} Spectroanalysis 7 2 How to check welded areas 1) Visual checks 2) Magnafiux inspection 3) Detecting supersonic flaws 4) Penetration inspection (Color check) 55) Magnetic analysts inspection 28ssssessaa10 " 12 HOW TO READ WELDING SYMBOLS 8 1 Welding symbots 8 2 Howto enter weld symbols 8 3 Exemple of entnes HOW TO HANDLE GAS (OXYACETYLENE) WELDERS AND CUTTERS 9 1 Basie factors of oxyacetylene welders 9 2 Structure and use of wolding torches 1) Low pressure type (Invector 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 type) 2) Medium pressure type 3) Cutting method 9 4 Pressure regulator 1) Types of pressure regulators 2) Structure of pressure regulators 9 5 How to handle oxyacetylene welders 1) General cautions 2) How to handle torches 3) How to handle regulators 9 6 Other tools for welding and cutting 1) Hoses and connectors 2) Collecting devices 97 Assembly of equipment 9 8 Removal of equipment @ 9 Safety rules PREVENTING ACCIDENTS 10 1. Preventing accidents n welding work 1) Accidents caused by electrical shocks 2) Ailments caused by harmful radiation 3) Ailments caused by the smoke produced in welding 4) Countermeasures against ailments caused by the smoke produced in welding 10 2 Preventing accidents caused by gas, 1) Cautions in work operation 2) Cautions when handling tanks COST OF WELDING CONSUMABLES 111 Cost of preparation 11.2 Expenditures on welding 1) Consumption of weld metal 2) Consumption of covered are welding rods 3) Time required for arc welding with covered welding rods, 4) Power consumption for arc welding EXAMPLES OF TROUBLES IN WELDED STRUCTURES AND COUNTERMEASURES 121. Box type welded structures 12.2. Butt welding of box type welded structures 123 Welded structures with added substances 124 Connection of welded structures with connectors 125 Connection of box type welded structures to planes Sa2ess13 4 16 16 7 8 126 How to place reinforcement patches 127 Welding between cast or forged matenals or to sheet metal frame 128 Materials on which stress 1s concentrated because of difference of rigidity 129 Box type welded structure with bosses LIST OF STANDARDS OF WELDING RODS BY COUNTRIES 18 1. Classification of covered are 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 LIST OF STANDARDS OF METAL MATERIALS BY COUNTRIES 1) Rolled steel for general structures 2) Rolled steel for welded structures 3} Cold rolled steet 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) MELTING TEMPERATURE OF VARIOUS BASE METALS AND ALLOYS CONVERSION TABLE 161 Strength 162 Tomperature 163 Pressure 164 Length 165 Werght NAMES OF STANDARDS IN VARIOUS COUNTRIES A GUIDE TO WELDING TERMS 99 100 100 101 102 103, 104 104 104 105 105 105 106 108 107 108 109 109 110 TT 112 113 14 1181 1 1 ” 2 GENERAL DESCRIPTION OF WELDING TECHNIQUES 1 PREFACE ‘Welding 1s a technique used widely 1n many indus ‘tries and st 8 common knowledge that welding 1s used to connect metals. Many welding techniques are luted in the manufacture and maintenance of con struction machinery Welding s often used to built up the structure of construction machinery and its im portant parts and thus the quality of the weld wall ‘greatly affect the overall quality of the machinery This means that welding techniques play an essential role in the service department This manual will describe how to do welding work properly This book uses the symbols approved by JIS (apa nese Industrial Standard) Some tables however also indicate the symbols approved by AWS/ASTM For the relation of JIS and AWS/ASTM and standards of ‘other major coutries (BS or DIN) refer to Section 13 Lust of Standards of Welding Rods by Countries and Section 14 List of Standards of Metal Materials by Countries 2 HINTS ON SAFETY IN OPERATION Introduction Safety means protecting yourself end others from inyury Sheet metal working 1s especially dangerous because the shape and weight of the workpieces change as ‘they pass from one process to another (making the work operations in each process different) and be cause workers often need to handle heavy materials ‘The workers must always arrange their surroundings properly and strictly observe the standard work operations The safety tps on material handling and transportation slinging work and hoisting work must always be observed to prevent accidents and to create a bright working environment Safety in gas cutting (1) Never leave your work position without good (2) Before and after gas cutting make sure there 1s rho gas leakage then close the main valve (Use soapy water to check for gas leakage | (8) Never bring your face near the nozzle of an tgnition lighter If ignition fails close the gas cack once and check for abnormalities Then try to ignite again {4) Unauthorized persons must not handle the gas ‘cutting machines (8) Asa rule do not pile products or materials more ‘than one meter high (6) Observe the safety tips for transportation sting ng work hoisting work etc 3) Safety in welding (1) When working 1n a small place or on a positioner stand take care so that the holder does not come into contact with your body (2) Always use specified protectors (leg covers arm ‘covers apron safety mask etc) (3) Nevor use damaged holders or cabtyre cables (4) Never wear oly or torn clothes when welding (5) Use a noncombustible screen When gouging set the sereen in the area whare the sparks fly 4) Safety 1n sheet metal work (1) Always remove gloves when using @ sledge hammer Use earplugs if very norsy (2) Check j»gs and tools for breakage before using them Use only the specified sigs and tools (3) When turning matenal over vith a crane never stand on the side on which the products will be ‘turned over (4) When working with 2 grinder place screens around the work place and wear safety goggles (5) Always weer the specified protectors. (6) When working with shngs always observe the standard work procedure 5) Proventing electric shocks (1) Always maintain welders in good condition (2) Always make sure that the housing of the welder and the matenals to be welded are grounded securely {3) Always make sure electrode holders are well insulated (4) Always make sure welding cables are completely insulated (5) Always wear dry welding gloves. The gloves must bbe in good condition16) Nover expose your body to the welding flame Do not let a sweaty shirt dangle Alvays weer 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 @ container which contained an inflammable or poisonous substance make sure that all residues of the dangerous substance have been removed completely If a drum wash out the inside completely before cutting Remember that some substances which are not poisonous at normal temperatures may produce a poisonous ‘gas when heated When working on a container ‘which has contained an inflammable substance first fill rt with water as shown in the figure and make sure there 1s an opening to allow any remaining gas to mox with external air (3) When heating welding or gas cutting an enclosed ‘container or material which has a cavity always It make sure that there 1s an opening for there 1s not an air passage drill a hole to mal ‘one After finishing the welding fill the hole (4) When cutting materials with gas protect the containers hoses legs ete from sparks (5) When heating a cast iron product remove bear ings ete which have a different thermal expan sion coefficient If not removed they may pop ‘out while being heated and may cause an ac ‘excont1 3 TYPES OF WELDING METHODS. ‘The welding methods used in various fields are shown below The methods shown in boxes [are often used in the construction machinery field Are weld ing with a covered electrode 1 widely used in the service department to repair structures and provide reinforcement [— Spot welding Lap welding Seam welding L— Projection wataing Renstance welding Flos mains | Gat pressure wolding Butt welding Upset welding L- percuton welding |— Frcton weiding Forge wlaing [— erating soda | sot searing [| submerand as wrldine Welding metiods }4 Consumebe tecrode —| [= ta wena "Are wang et cuban Non consuable electrode — Tig welding Got welding Onacine natna | | Thermt weing Fusonwaléma]-t— etactrosiag welding | etectrogs welding L_ etecron bua welding Pane are wang Pressure welding Joining metals by heating them Fuson welding Jung metals by fusing thom wath until they become soft and then lapping them ‘the heat of gas or en ace Brazing Joining metals by depositing a molten alloy with a much lower melting point (solder hard solder etc } between the metals to be joined2 FEATURES OF WELDING METHODS 2 a 2) 3) 4) 5) 6) 1 GAS WELDING Gas welding 1s a method of joining metals by melting parts of them with a high temperature flame pro duced by gas and oxygen and adding filler metal {welding rod) Generally acetylene gas s used as the ges Since temperatures of 3 000°C and above can be ‘obtained if the gas 1s burnt in oxygen most common metals can be melted ‘This 1s called oxyacetylene gas welding the outline of ‘which 1s shown at right Since the temperature pro duced by gas welding 1s much lower than by arc weld. ing and the concentration of heat isnot high that 1s ot efficient 1 1s not used so widely nowadays However since the heat can be adjusted manually by changing the distance between the torch and metals a8 welding 1s suitable for joining metals that crack easily because of sensitivity to heat sheet metals (less the 1mm thick) pipes and nonferrous metals Another merit of the gas welding is that it can be per formed in places where electric equipment 1s not available by carrying the simple welding devices Gas welding Advantages Wide range of application Heat can be adjusted freely Devices can be transported easily Equipment cost 1s low Metals that are highly sensitive to heat and that are likely to crack ean be welded Surtable for welding sheet metals pipes nonferrous metals and especially metals with @ low fusion point » 2 3) 4) 5) 6) n Winn TT ‘Acetylene is dissolved in acetone and absorbed by ‘porous substance inside the pressurized tank Disadvantages ‘Atea heated 1s wider than in are welding Heating time 1s long ‘The mechanical strength of welded metals is lower ed in some cases Welded metals may be carbonized or oxidized Depositing rate 1s low There 5 8 large possiblity of explosion Cost of consumables is high2 2 ARC WELDING In are welding an arc 1s produced between the base ‘metal and electrode and the resulting heat 1s used as the heat souree for welding The temperature of the arc is very high When ste! 18 used as the electrode the temperature can excoed 6 000°C ‘The temperature of the metal melted in this hot arc 18 also high and the melted metal absorbs a lot of oxygen and nitrogen from the aw and becomes brittle To prevent this phenomenon various methods are used to prevent the air from contacting the metal 1) Ate welding with covered electrodes In this widely used method the flux covering the core wire provents the ar from contacting the melted metals that is the decomposed flux covers the melted metals ‘The flux not only improves the chemical and mechan teal properties of the weld metal but also improves Nts workability This method has the following advantages (1) The arc is stabilized by the decomposed flux (2) The gas or slag protects the melted matals from being exposed to the air which would oxidize and nutrify them (3) Impurities such as oxides phosphorus and sul phur do not get muxed in the melted metals (4) Elements of the alloy are added to the melted metals (5) The slag protects the melted metals from cooling rapidly AC and DC current are used as the power source for are welding In the early stage of arc welding devel lopment 4 DC current was widely used because of its stable of are However the stability has been increased by improving the electrodes and thus the more economical AC welders are more widely used at present Welder (ac) “Transformer (AC) FRocufer (AC) Generator (AC) Eloctrod, Wielding dicction ae (covering fax Gas Rlamoved afterwards Core wire A Stag E Hoatettected zone 8 Reinforcement of weld F Base meta not afected by heat © Penetration 6 Base mete! D Weld metal2) Submerged are 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 it from contacting the melted metals The arc 1s generated under the flux This 1s called submerged arc welding because the wre ‘arc 1s generated under the powder flux and the blue spark cannot be seen ‘Since the core wire wound on a wire reel is sent out continuously instead of using covered electrodes \ ‘the machines are automated or semiautomated Bate metal csiigd oe taded tlm ules om AN ‘over are welding with covered electrodes (1) Since a targe current can be used. the depositing rate and penetration are extremely high and relatively thick steel plates can be welded m a single pass {2) The welding conditions can be held constant ‘Therefore differences in welders skills are rmunimized and relrabitty improves (3) Since the amount of bevel and leg length of the fillet weld can be decreased the welding mate tals can also be decreased Submerged arc welding 1s mainly used to join mate tials im ship building tanks steel pipes bridges and other structures in build up welding for under carriages of construction machinery and in wear portions of machines used in cil engineering It 1s most suitable for welding thick materials con ‘tnuously over a long weld line3) CO, gas shielded are welding In this method COs gas or CO, gas and other gates are sent around the weld metal to shut off the air while welding Before it was confirmed that CO, gas can be used as a shield gas the inert gases that 1s argon helium ‘ete were used However inert gas shielded arc welding 1s limited to high alloy steels and nonferrous metals and carbon steel and low alloy steels are usually welded by CO, gas shielded welding CO, gas shielded welding is roughly divided into three methods (1) Bare steel wire CO; method CO, gas 15 used as the shield gas and bare steel wire containing deoxidizing elements (manga ‘nese silicon titantum etc) is used as the core wire (2) Bare steel wire COs — 03 method ‘A mixture of COz gas and O gas 1s used as the shield gas and bare steel wire containing a relatively large quantity of deoxidizing elements ‘8 used as the core wire (3) Various flux methods CO; gas core wire and flux (containing manga ‘nese silicon titamtum etc) are added in various ways Method using a flux cored wire electrode Method where magnetic powder flux 1s stuck 10 steel core (Union are welding) CO, ~ 03 are welding Bare ste! ware containing ddeoxidizng elements (081) Power source for welding (Dey @eotanty Grounding Grounding power source Deposited Melted Bate toc)" botany metal metal metal Union arc welding Stee! ware electrode (Fed automaticaly ‘nd contiauousiy) Fluxand get Fux stuck to steel wore lectrode Arcosare wire Fuse are wire Flux cored wire OOO® gee‘Since the core wire 1s supplied continously in the CO, gas shielded are welding in the same way as in the submerged arc welding described before the machine 1s automated or semiautomated and 1s easy rouse Welding with the bare steel wire 1s mainly used for highly efficient welding of thin plates and medium thick plates On the other hand as welding with steet ‘wire and flux has good workability and produces a ‘good bead it 1s used for fillet welding and in places ‘where good appearance 1s requited In addition since alloy elements can be muxed into the flux tt 1s also used for case hardening ouild up welding ‘The advantages common to various CO, gas shielded ‘welding are shown below (1) Weld metals can be obtained which contain little oxygen nitrogen_and hydrogen (2) Since cheap CO; gas (sometimes with a little oxygen) 1s used es the shield gas high speed Welding with thin wire can be done so the cost ‘of welding 1s lower than other welding methods (3) Because of the density of the welding currents the peneration 1s deep and the depositing rate 1s high3 > SELECTING WELDING METHODS ‘There are many welding methods. To select the most appropriate method such factors as the properties shape and size of the materials to be welded the welding position and economy must be considered The following table shows the appropriateness of the main welding methods by thickness of materials, types of joints types of structures and cost Appropriateness of main welding methods © Nos approprate © Approprate A Acceptable X Insppro “Twekses m ] Type of ont “ype of structure con Avoroprateness T : ‘ang method gee| 2/2) 3) 2|¢ ed aallfes| sf] } Aja tl alll Oxyacetyione welding @/A)x]elojalalo}ala;x f | Aeration ont 0/0] 0] 0]0/4) 0] 0] oO) O] 0] O/ 0 Jrow! tow J | svomisesarewonina — | a | cfofalolojololelolo tli Ro hee oe o[efolofofa ©| 8/8] 6] e] G| o [Me | Low ‘Arc welding 1s the most widely used method especial ly are welding with covered electrodes COz gas shielded arc welding and submerged are welding With the recent innovations in technology manual welding methods (oxyacetylene welding and arc welding with covered olectrodes) in which the ‘quality of the weld depends on the welder s skill are gradually being phased out At present. the use of the oxyacetylene welding is limited to joining sheet metals and pipes to thin walls On the other hand the use of COs gas shielded welding which does not require special skill and which can generally be controlled to obtain high efficiency 1s rapidly becoming more widespread However arc welding with covered electrodes 1s the main method used by Komatsu service shops to weld general structures because of the peculiarrty Of the work and the cost of equipment ‘As mentioned above the quality of are welding with covered electrodes depends greatly on the welder s skill 0 the welders need training and experience4 PREPARATIONS FOR WELDING ‘To achieve good welds you must not only choose the best welding method for the properties of the mate nial to be welded but also prepare the edges appro 4-1 TYPES OF JOINTS nately for the thickness of the materials and the type of joints to be used Barious types of joints are shown below Butt ont Lap jot ‘Gornerjornt Tee ome Edge ort ‘Singlestrepped yunt Doublestrapped unt Four welding methods are shown below ‘Butt wolding| Fillet welding Plug welding The welding made continuously on @ weld line is called continuous welding ed intermittent welding ‘one made in stages is eal When fillet welding on both sides of a plate the weld can be classified as erthe er parallel welding or staggered intermittent fillet welding according to the positions of the weld zone ‘Continuous welding Tatermttont welding Paralll welding ered ntermtent ft welding LP Sha HE —10—